Reactive Monomer Feed Nozzle Layout to Prevent Column Channeling
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Solution Overview
Problem
Dual flow trays in reactive monomer separation devices suffer from channeling phenomena due to uneven feed distribution, leading to reduced efficiency, decreased gas-liquid contact area, and increased energy consumption.
Innovation Solution
A reactive monomer separation device with a feed supply unit design that includes a circular feed transfer pipe, inner pipes, and spray nozzles, where the spray angle is optimized to ensure uniform feed distribution, preventing channeling and maximizing gas-liquid contact area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If dual flow trays are used to increase allowable flow rate and respond to polymer fouling, then the column can handle higher flow rates and resist fouling, but channeling phenomenon occurs due to uneven feed distribution, reducing column efficiency
Solution Approach 1:
The feed supply system is segmented into multiple spray nozzles distributed across the column cross-section, with each nozzle serving a specific radial zone. This segmentation of the feed distribution function prevents channeling by ensuring uniform feed introduction across different regions, while maintaining the high flow rate capability of dual flow trays
Solution Approach 2:
Different regions of the column are provided with locally optimized feed spray characteristics. The spray nozzles are positioned and angled to create locally uniform feed distribution in each radial zone, with spray parameters (angle, position, flow rate) tailored to local hydrodynamic conditions. This local quality approach ensures efficient gas-liquid contact throughout the column cross-section
2Object-affected harmful factors
If dual flow trays are used without downcomers to prevent polymer fouling, then resistance to fouling is improved, but liquid redistribution cannot occur, causing channeling and decreased overall efficiency
Solution Approach 1:
Feed is introduced preliminarily and uniformly across the column cross-section through multiple spray nozzles before the gas-liquid contact process begins. This preliminary uniform distribution prevents the formation of channeling patterns that would otherwise develop during operation, eliminating the need for downcomer-based liquid redistribution while maintaining high efficiency
Solution Approach 2:
The spray nozzles act as intermediaries between the feed supply line and the gas-liquid contact zone. They transform the feed stream into fine sprays that distribute uniformly across the column, mediating the interaction between feed introduction and gas-liquid contact to prevent channeling without requiring downcomers
3Device complexity
If feed is not uniformly distributed in the column, then the dual flow tray structure can be maintained, but channeling phenomenon reduces gas-liquid contact area and decreases product quality
Solution Approach 1:
The feed distribution problem is solved by transitioning from a single-point or single-line feed introduction to a multi-dimensional spray distribution system. Spray nozzles are positioned at different radial locations and angles, creating a three-dimensional feed distribution pattern that ensures uniform coverage across the entire column cross-section, thereby maintaining simple tray structure while achieving high product quality
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 optimized feed supply unit design enhances column efficiency by uniformly distributing feed, preventing channeling and improving product quality while reducing energy consumption.
Implementation Method 1
a spray nozzle provided at each end of each of the one or more inner pipes. A spray angle (θ) of the spray nozzle may be equal to or less than a maximum spray angle defined by the following Equation (1)
Data Source
AI summary
A reactive monomer separation device in which a structure of a feed supply unit is designed so that feed can be uniformly distributed inside a column, thereby improving column efficiency. The feed supply unit includes a circular feed transfer pipe provided along an inner wall of a cylindrical column; one or more inner pipes extending in a direction of a central axis from the circular feed transfer pipe; and a spray nozzle provided at each end of the one or more inner pipes, and a spray angle (θ) of the spray nozzle is ≤a maximum spray angle defined by the following equation:maximum spray angle=2×tan-1(l/h)Equation (1)where l is a length of the inner pipe, and h is a height from a lower dual flow tray of the stage equipped with the feed supply unit to the feed supply unit.