Horizontal Catalytic Reactor Sliding Container for Catalyst Maintenance
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Solution Overview
Problem
Horizontal plate-type catalytic reactors face challenges with poor accessibility to the interior, leading to increased downtimes and costs for catalyst replacement and maintenance due to their design, which affects heat exchange efficiency and catalyst handling, especially in exothermic reactions.
Innovation Solution
A horizontal-axis reactor design featuring a cylindrical shell with a container for the catalytic bed and heat exchange plates that can be slidably extracted and inclined, allowing for easier access and maintenance, with a system of guides and wheels enabling the container to be rotated or overturned for improved accessibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If parallel cooling plates are used in horizontal reactors, then heat exchange efficiency is improved and local overheating is avoided, but accessibility to the interior and ease of catalyst loading/unloading deteriorate
Solution Approach 1:
The reactor is divided into a stationary outer shell and a movable inner container that holds the catalytic bed and cooling plates. This segmentation allows the inner container to be independently extracted and tilted, providing accessibility for catalyst replacement while maintaining the parallel plate configuration for efficient heat exchange during operation.
Solution Approach 2:
The inner container is designed with movable degrees of freedom, allowing it to be extracted linearly and tilted dynamically. This transforms the static, inaccessible plate arrangement into a dynamic structure that can be positioned for maintenance while preserving its functional configuration during operation.
2Temperature
If the reactor is designed as a fixed horizontal structure, then heat exchange plates can be arranged parallel for uniform cooling, but downtime for maintenance and catalyst replacement increases
Solution Approach 1:
By separating the cooling plate assembly into a distinct movable container, the system enables rapid removal and replacement of the catalytic bed without disassembling the entire reactor or disturbing the parallel plate configuration, significantly reducing maintenance downtime.
Solution Approach 2:
The container is pre-equipped with extraction and tilting mechanisms that are activated only during maintenance operations. During normal operation, the container remains in its optimal position for uniform cooling, and the preliminary preparation of extraction guides and tilting guides ensures rapid maintenance access when needed.
3Device complexity
If radial arrangement of plates is used in vertical reactors, then structure is simplified, but heat exchange becomes non-uniform and less efficient towards the periphery
Solution Approach 1:
The patent adopts an asymmetric configuration where parallel cooling plates are positioned specifically to address the heat exchange needs of exothermic reactions, with plates arranged to provide uniform cooling across the catalytic bed rather than using a symmetric radial pattern.
Solution Approach 2:
The parallel plate configuration serves multiple functions: it provides uniform heat exchange for exothermic reactions, maintains structural integrity during catalyst loading, and allows for the integrated extraction and tilting mechanisms that enable maintenance access.
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
This design reduces downtimes and maintenance costs by facilitating easier loading, unloading, and replacement of catalysts, while maintaining efficient heat exchange and preventing local overheating, making it suitable for exothermic reactions like formaldehyde synthesis.
Implementation Method 1
a plurality of heat exchange plates (6) immersed in said catalytic bed (5), said plates being parallel to each other and passed through internally by a heat exchange fluid
Implementation Method 2
said plates being parallel to each other and passed through internally by a heat exchange fluid
Implementation Method 3
a container (7) for said catalytic bed and said plates, which can be extracted slidably on at least a first guide with respect to said shell
Implementation Method 4
said shell comprising at least one second guide for inclining the container starting from said extracted position
Data Source
Figure 1~3
Figure 4~5
Figure 6~7
AI summary
Horizontal reactor (1) for catalytic reactions, comprising an outer cylindrical shell (2), a catalytic bed (5) and heat exchange plates (6) immersed in said catalytic bed, parallel to each other and supplied with a heat exchange fluid; said reactor comprises a container (7) for said catalytic bed (5) and said plates (6), said container is extractable slidably from said shell, by means of at least one linear guide (31, 32, 45) extended longitudinally with respect to said shell (2).