Layered Honeycomb Ceramic Rectifier for Reactor Flow Distribution
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Solution Overview
Problem
Conventional rectifiers in petrochemical reactors experience uneven liquid-oil distribution due to radial resistant forces, leading to reduced reaction efficiency caused by turbulence and fluid drag differences at the reactor bottom.
Innovation Solution
A rectifier with a layered structure of bird nest honeycomb ceramic, featuring increasing honeycomb porosities from the central to the external layer, forming meshed honeycomb pores that enhance liquid oil distribution and reduce turbulence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional rectifier is used in the reactor, then the structure is simple, but the liquid-oil distribution is uneven due to radial resistant forces causing turbulence and reducing reaction efficiency
Solution Approach 1:
The rectifier is divided into multiple layers (first layer, second layer, third layer) with different honeycomb pore structures. Each layer segments the liquid oil flow path, creating staged distribution that eliminates turbulence and improves reaction efficiency.
Solution Approach 2:
Different layers of the rectifier have different honeycomb pore densities and orientations tailored to local flow requirements. The first layer has larger pores for initial distribution, while subsequent layers have progressively smaller pores for fine distribution, optimizing liquid-oil distribution at each location.
2Manufacturing precision
If honeycomb porosity is increased to improve liquid-oil distribution, then flow distribution improves, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The rectifier utilizes honeycomb ceramic materials with controlled pore structures. The porous nature of the material inherently provides flow distribution capabilities, eliminating the need for complex external flow control mechanisms while maintaining manufacturing feasibility.
Solution Approach 2:
The invention systematically varies key parameters including honeycomb pore size, pore density, and layer thickness across the different layers. This parameter optimization achieves uniform liquid-oil distribution while keeping manufacturing processes within standard industrial capabilities.
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 promotes a dense and homogeneous flow of liquid oil, significantly improving reactive performance and reactor efficiency by minimizing turbulence effects.
Implementation Method 1
a rectifier with a layered structure of bird nest honeycomb ceramic, featuring increasing honeycomb porosities from the central to the external layer, forming meshed honeycomb pores that enhance liquid oil distribution
Implementation Method 2
A dense and homogeneous distribution formed on the layer of the main agent by the liquid oil is capable of eliminating an effect of turbulence to the greatest extent
Data Source
AI summary
A rectifier mounted at a bottom of a reactor includes a central layer (1), at least one interlayer (2) and an external layer (3), which are made of bird nest honeycomb ceramic, wherein porosities of the central layer, the interlayer and the external layer increase in turn. The central layer, the interlayer and the external layer are respectively provided in a central-layer cone shaped body, an interlayer cone shaped body and an external-layer cone shaped body which are installed concentrically, so as to form meshed honeycomb pores with different porosities at the bottom of the rectifier. The rectifier is made of bird nest ceramic with high density honeycomb pores, and a minimum density thereof is over 200 meshes.