Manifold Assemblies for Gas Phase Reactors
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Solution Overview
Problem
In gas phase reactors, the polymerization of olefins often results in catalyst fouling at the inlet, leading to system shutdowns for cleaning, which is undesirable and reduces profitability and productivity.
Innovation Solution
The design of manifold assemblies with minimal discontinuities and integrated cleaning apertures to reduce catalyst buildup and facilitate simplified cleaning, including a main channel that extends transverse to the catalyst and carrier gas inlets, and a flange portion with a smooth surface finish to minimize eddy flows and catalyst accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If liquid catalyst is passed into the reactor through conventional inlet assemblies, then catalyst delivery is achieved, but polymerizable olefin polymerizes and fouls at the inlet prior to entering the reaction vessel
Solution Approach 1:
The inlet assembly is segmented into distinct functional zones: a catalyst inlet channel separate from the main reactor inlet, with the catalyst introducer positioned to deliver catalyst directly into the reaction zone without contacting the polymerizable olefin at the main inlet. This segmentation prevents fouling at the main inlet while ensuring reliable catalyst delivery.
Solution Approach 2:
The catalyst introducer acts as an intermediary component that receives liquid catalyst through its own dedicated inlet channel and delivers it to the reaction zone. This intermediary pathway isolates the catalyst delivery function from the main olefin flow, preventing polymerization-induced fouling at the main inlet assembly.
2Productivity
If conventional inlet assemblies are used, then catalyst can be delivered to the reactor, but system shutdown for cleaning is required
Solution Approach 1:
The catalyst delivery function is extracted from the main inlet assembly through a separate catalyst inlet channel and catalyst introducer. This extraction ensures that the main inlet remains free of catalyst-related fouling, eliminating the need for system shutdown and cleaning, thereby maintaining continuous productivity.
Solution Approach 2:
The catalyst is delivered through a dedicated pathway that is designed from the outset to prevent fouling. By establishing this separate delivery route beforehand, the system avoids the need for subsequent cleaning operations, maintaining continuous operation and productivity.
3Reliability
If minimal discontinuities are used in manifold assembly, then eddy flows and catalyst buildup are reduced, but manufacturing complexity increases
Solution Approach 1:
The manifold assembly is designed as a merged, integrated structure where the catalyst inlet channel, carrier gas inlet channel, and main reactor inlet are combined into a single coordinated assembly. This merging eliminates discontinuities and gaps between separate components, ensuring smooth catalyst flow and reducing eddy flows without requiring multiple separate parts.
Solution Approach 2:
The manifold assembly incorporates localized smooth surface finishes and optimized channel geometries at critical locations where catalyst flow occurs. This local quality enhancement reduces eddy flows and prevents catalyst buildup in specific areas without requiring complex modifications throughout the entire assembly, balancing reliability with manufacturability.
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 solution reduces catalyst fouling and simplifies cleaning processes, minimizing downtime and maintaining reactor efficiency by preventing the buildup of catalyst within the manifold assembly.
Implementation Method 1
The catalyst material may be carried in a gas phase reactant, such as a polymerizable olefin
Implementation Method 2
combining the liquid catalyst and the carrier gas in the main channel of the manifold assembly forming a combination of the liquid catalyst and the carrier gas
Data Source
AI summary
Disclosed herein is a method for polymerizing a compound in a gas phase reactor. The method includes at least passing a liquid catalyst to a catalyst inlet of a manifold assembly, passing a carrier gas to a carrier gas inlet of the manifold assembly, combining the liquid catalyst and the carrier gas in the main channel of the manifold assembly, and passing the combination of the liquid catalyst and the carrier gas to the reaction chamber. The present disclosure is also directed to manifold assemblies for communication with reaction chambers.