Modular Catalyst Support Grid for Reactor Pressure Drop Reduction
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Solution Overview
Problem
Existing catalytic reactors face challenges with catalyst migration downstream and high pressure drops, requiring improved support systems that can be easily installed through limited openings without welding, while minimizing empty spaces and allowing increased catalyst loading without using degrading inert support materials.
Innovation Solution
A modular catalyst support grid with a robust design, comprising a center support, radial arms, and radial wedges, which can be assembled within the reactor vessel without welding, allowing for efficient catalyst bed support and reduced pressure drop, and enabling increased catalyst loading without inert support particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional small support devices are used, then catalyst migration is prevented, but pressure drop increases significantly
Solution Approach 1:
The support system is divided into multiple functional layers: a lower support grid for structural stability and catalyst retention, and an upper distribution grid for fluid distribution. This segmentation allows each layer to be optimized independently - the lower grid can have smaller openings for retention while the upper grid provides larger flow paths, resolving the contradiction between prevention and pressure drop.
2Loss of energy
If larger support devices are used, then pressure drop is reduced, but installation through limited opening becomes difficult
Solution Approach 1:
The large support system is segmented into modular components that can be assembled in situ through the limited opening. The lower support grid and upper distribution grid are separate assemblies that can be installed sequentially, allowing the overall large structure to be built through small openings without requiring the entire assembly to pass through at once.
Solution Approach 2:
The modular components are designed to be nested or stacked during installation, with smaller elements fitting within or alongside larger structural components. This nesting approach allows the large support system to be constructed through the limited opening by progressively assembling components rather than inserting the complete structure at once.
3Quantity of substance
If inert catalyst support particle beds are used, then catalyst loading is increased, but operating costs increase due to degradation over time
Solution Approach 1:
The inert support particles are completely removed from the system. Instead of using particle beds as support, the invention employs structured grid supports that provide mechanical support without requiring inert filling materials. This extraction of the inert support function eliminates the associated degradation and replacement costs while maintaining high catalyst loading capacity through the grid structure itself.
4Device complexity
If support systems with empty or dead spaces are used, then catalyst bed support is simplified, but reactor volume is wasted
Solution Approach 1:
The support function and volume utilization function are merged into a single integrated grid structure. The grids are designed with optimized spacing and geometry that provides adequate support while minimizing void spaces. The structure combines mechanical support capabilities with efficient space utilization, eliminating the need for separate support elements that would create dead spaces.
Data Source
Figure 1
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Figure 4
AI summary
A support grid (100) for a chemical reactor fixed bed catalyst. The support grid (100) is formed of (i) a center support cylinder (10), made in areas of a vertical cylinder, that is assembled within the vessel on the bottom closure head; (ii) a peripheral support skirt (30) located at the outer circumference of the grid, assembled in sections inside the reactor pressure vessel, that sets without welding to bottom closure head of the reactor vessel; (iii) a set of radial support arms (50) that extend from the center support structure (10) to the support skirt (30) to tie these sections into a rigid frame to support the catalyst bed support grid wedges; and (iv) a grid or disc (60) formed of a plurality of catalyst bed support grid wedges or sections (60a) that are radial in orientation and are assembled inside the reactor pressure vessel to form a disc that is about 80% of the reactor vessel in outside diameter.