Fluidization Grid Plate Conical Depression Overlap
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Solution Overview
Problem
Existing catalyst activator vessels face challenges in scaling up while maintaining structural integrity and efficiency, particularly in achieving optimal fluidization for large diameters, as higher overlap percentages are required but result in excessive metal removal and potential catalyst attrition.
Innovation Solution
A catalyst activator vessel with a fluidisation grid plate featuring an array of conical depressions that overlap by less than 17%, allowing for a stronger and more efficient design with reduced metal usage, and a process for activating polymerization catalysts using a fluidisation grid with holes extending through the lower surface to ensure uniform fluidization and prevent catalyst attrition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conical depressions in the fluidisation grid plate overlap by at least 17% as taught in WO 2004/024312, then optimal fluidization is achieved for large diameter vessels, but excessive metal removal occurs and structural integrity deteriorates
Solution Approach 1:
The patent changes the overlap parameter from the previously taught minimum of 17% to a new range of 5-15%, specifically 7-12% in preferred embodiments. This parameter change optimizes the balance between fluidization performance and structural integrity, reducing metal removal while maintaining effective catalyst activation for large diameter vessels (≥50 inches or ≥1.27 meters).
Solution Approach 2:
Instead of requiring full overlap (≥17%) which causes excessive metal removal, the patent applies partial action by using reduced overlap (5-15%). This partial overlap is sufficient to achieve optimal fluidization and catalyst activation while preserving grid plate strength and reducing material consumption.
2Loss of substance
If conical depressions overlap by less than 17% as proposed in the invention, then metal usage is reduced and structural integrity is improved, but optimal fluidization for large diameters may be compromised
Solution Approach 1:
The patent establishes a new overlap parameter range (5-15%) that optimizes the trade-off between metal conservation and fluidization effectiveness. This parameter change demonstrates that less metal removal (compared to ≥17% overlap) does not compromise fluidization performance, but rather improves it by maintaining grid plate structural integrity while achieving effective catalyst activation.
Solution Approach 2:
The conical depressions are strategically positioned and sized to create local quality variations in the grid plate structure. Each depression is configured with specific dimensions and spacing to optimize local fluidization characteristics while maintaining overall structural integrity, enabling effective fluidization with reduced overlap.
3Productivity
If the fluidisation grid plate uses higher overlap percentages to achieve optimal fluidization, then catalyst activation efficiency improves, but catalyst attrition increases due to excessive metal removal
Solution Approach 1:
By changing the overlap parameter from high (≥17%) to optimized range (5-15%), the patent eliminates catalyst attrition caused by excessive metal removal while maintaining activation efficiency. The reduced overlap prevents grid plate degradation that would otherwise cause mechanical stress and catalyst particle breakage during fluidization.
Solution Approach 2:
The patent converts the potential harm of reduced overlap (which might be perceived as compromising fluidization) into a benefit by demonstrating that moderate overlap (5-15%) actually improves overall system performance. The moderate overlap maintains grid plate strength, preventing catalyst attrition, while still achieving effective fluidization and catalyst activation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables the activation of larger catalyst volumes with improved structural integrity and uniform fluidization, reducing metal waste and energy consumption while maintaining catalyst quality, even in deeper fluidized beds, by optimizing the overlap percentage and fluidization grid design.
Implementation Method 1
The catalyst is usually activated as a fluidised bed, the fluidisation being achieved by passing the activating gas through a grid, known as a fluidisation grid
Implementation Method 2
an array of generally conical depressions in the upper major surface that overlap by less than 17%
Data Source
AI summary
The invention relates generally to a catalyst activator, and in particular to a catalyst activator for heat conditioning a catalyst, comprising: a) a vessel for containing a catalyst charge having an internal diameter of at least 1.2 meters and/or an internal volume of at least 5 m3; b) a fluidization grid plate disposed in said vessel, said fluidization grid plate and having an upper major surface and a lower major surface; c) an array of generally conical depressions in said upper major surface that overlap by less than 17%; and d) an array of holes perforating said fluidization grid plate, said holes extending from at least some of said generally conical depressions through said lower surface.