Hydrocarbon Synthesis Apparatus Catalyst Discharge
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Solution Overview
Problem
In hydrocarbon synthesis reaction apparatuses, the settlement and clogging of catalyst particles lead to reduced productivity and flow issues due to uneven dispersion and oxidation, causing filter clogging and decreased catalytic activity.
Innovation Solution
A hydrocarbon synthesis reaction apparatus with a powdered catalyst particles-discharging device that separates and removes fine and agglomerated catalyst particles using classifiers and separators, preventing filter clogging and maintaining catalyst dispersion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the particle diameter of catalyst particles is made large to facilitate separation, then the settling velocity increases and separation becomes easier, but the reaction with synthesis gas cannot be reliably performed due to insufficient dispersion
Solution Approach 1:
The patent changes the physical parameter of catalyst particles by controlling particle size distribution and introducing hydrophobic coating. This modifies the settling characteristics while maintaining reaction activity, resolving the contradiction between easy separation and reliable reaction performance
Solution Approach 2:
The patent applies hydrophobic coating specifically to the surface of catalyst particles, creating local quality differences. The core maintains catalytic activity while the coated surface modifies settling behavior, allowing simultaneous achievement of good dispersion and easy separation
2Reliability
If the particle diameter of catalyst particles is made small to improve dispersion and reaction, then the settling velocity decreases for better mixing, but the filter becomes clogged by fine particles
Solution Approach 1:
The patent modifies particle properties through hydrophobic coating, which changes the effective density and surface characteristics of fine particles. This allows small particles to maintain good dispersion for reaction while reducing their adhesion to filter surfaces, preventing clogging
Solution Approach 2:
The patent converts the harmful effect of fine particle generation (which causes filter clogging) into a benefit by using hydrophobic coating to make these fine particles easier to separate. The coating transforms the problem of fine particle management into an advantage for separation efficiency
3Productivity
If the filter is operated continuously without maintenance, then productivity is maintained, but the filtering differential pressure increases and clogging occurs
Solution Approach 1:
The patent enables continuous operation of the filter by implementing a particle removal system that operates concurrently with filtration. This maintains the filtering function without interruption while preventing pressure buildup, resolving the contradiction between continuous productivity and pressure control
4Quantity of substance
If powdered catalyst particles are not removed, then catalyst quantity is maintained, but the particles are entrained in off-gas and scatter to the top gas system reducing efficiency
Solution Approach 1:
The patent extracts powdered catalyst particles from the slurry using a dedicated removal device. This separates the harmful fine particles from the functional catalyst population, maintaining adequate catalyst quantity while preventing loss through gas entrainment and improving overall reaction efficiency
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
Stable delivery of liquid hydrocarbons is ensured by preventing filter clogging and maintaining catalyst dispersion, reducing catalyst settling and oxidation, thus enhancing productivity and flowability.
Implementation Method 1
a first classifier configured to separate the powdered catalyst particles from the solid catalyst in the slurry, using a settling velocity difference of the particles in a liquid
Implementation Method 2
a powdered catalyst particles separator that is provided in the outflow passage and is configured to trap the powdered catalyst particles
Implementation Method 3
a filter that installed inside the reaction vessel and is configured to separate the liquid hydrocarbon compound from the catalyst
Data Source
AI summary
The hydrocarbon synthesis reaction apparatus according to the present invention includes a reaction vessel that brings a synthesis gas having carbon monoxide gas and hydrogen gas as main components into contact with a slurry having a solid catalyst suspended in a liquid hydrocarbon compound to synthesize a liquid hydrocarbon compound using a Fischer-Tropsch reaction; a filter that is provided within the reaction vessel and is configured to separate the liquid hydrocarbon compound from the catalyst; and a powdered catalyst particles-discharging device configured to discharge powdered catalyst particles in the solid catalyst in the slurry to the outside of the reaction vessel.