Knitted Wire Mesh Catalyst Retention in Chemical Reactors
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Solution Overview
Problem
Chemical reactors for heterogeneously catalyzed conversions face issues with catalyst loss due to thermal stress, especially under adiabatic conditions, leading to uneven gas flow and equipment damage, and existing solutions like inert particle layers are complex and inefficient.
Innovation Solution
A chemical reactor using a wire mesh knitted fabric as a holding device for catalyst and inert particles, where the average clear mesh size is smaller than the particle size, providing elasticity and preventing particle passage while allowing for thermal expansion without damage, and eliminating the need for inert material layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If slotted screens are used to support catalyst particles, then catalyst support function is achieved, but thermal stress causes wire deformation and breakage leading to catalyst loss
Solution Approach 1:
The patent replaces rigid slotted screens with flexible knitted wire mesh fabric. The knitted structure allows the material to deform elastically under thermal stress without breaking, while maintaining its function as a support for catalyst particles. The flexibility of the knitted fabric absorbs thermal expansion and contraction forces that would otherwise cause wire deformation and breakage in rigid screens.
Solution Approach 2:
The patent changes the structural parameters of the support material from rigid slotted screens to flexible knitted fabric with specific mesh sizes. By selecting appropriate wire diameters and mesh dimensions, the support structure can accommodate thermal stress while maintaining catalyst retention capability. The parameter optimization includes choosing mesh sizes smaller than catalyst particles and wire diameters that provide sufficient flexibility and strength.
2Reliability
If inert particle layers are added to prevent catalyst passage, then catalyst loss is reduced, but reactor complexity and filling difficulty increase
Solution Approach 1:
The patent removes the complex multi-layer inert particle support structure and replaces it with a simple knitted wire mesh fabric. The knitted fabric itself provides the catalyst retention function through its mesh structure, eliminating the need for additional inert particle layers. This extraction of the unnecessary inert layer simplifies the overall support structure while maintaining catalyst retention reliability.
Solution Approach 2:
The knitted wire mesh fabric performs multiple functions simultaneously: it supports the catalyst bed, prevents catalyst particle passage, and accommodates thermal stress. This single universal component replaces the previous multi-component system consisting of slotted screens and inert particle layers, thereby reducing device complexity and simplifying the filling process.
3Productivity
If smaller catalyst particles are used to increase efficiency, then reaction efficiency improves, but catalyst loss through defects increases
Solution Approach 1:
The patent optimizes the mesh size parameter of the knitted fabric to be appropriately smaller than the catalyst particle size. This parameter matching ensures that even small, efficient catalyst particles are retained by the support structure. The wire diameter and knit density are also optimized to provide sufficient mechanical strength while maintaining appropriate mesh openings for particle retention.
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 effectively prevents catalyst loss, maintains reactor integrity under thermal stress, and simplifies maintenance and filling processes, allowing for longer operation without regeneration and increased catalyst loading.
Implementation Method 1
the average clear mesh size of the wire mesh is smaller than the average particle size of the particles which are intended for inclusion in the holding device
Implementation Method 2
the wire mesh knitted fabric ensures that it is not damaged during periodic operation at different temperatures
Data Source
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AI summary
The invention relates to a chemical reactor for heterogeneously catalyzed conversion of a fluid, comprising a retaining device for catalyst and/or inert particles (80, 100), through which the fluid flows, wherein the upstream side of the retaining device as seen in the flow direction of the fluid comprises a woven wire mesh product (50), and the average mesh opening size of the woven wire (50) is smaller than the average particle size x50,3 of the particles (80, 100). The invention further relates to a method for converting a fluid, wherein the conversion takes place in a reactor according to the invention in the presence of heterogeneous catalyst particles (80) and the catalyst particles (80) are disposed in the retaining device for catalyst particles (80). A further object of the invention is the use of woven wire mesh product (50) as a retaining device for catalyst and/or inert particles (80, 100) in chemical reactors.