Moving Bed Reactor Feed Distribution Apparatus
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Solution Overview
Problem
Conventional moving bed reactors face difficulties in transferring and managing three-phase co-current flows due to uneven distribution of flow phases, leading to reduced activity, temperature spikes, and catalyst deactivation, and lack control over independent flow rates of each phase.
Innovation Solution
A distribution apparatus for moving bed reactors with solids inlet conduits and a distributor plate featuring concave volumes and angled exit surfaces for even liquid distribution, allowing separate control of solid and liquid introduction with a lateral velocity component, facilitating uniform mixing and phase separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods are used to transfer three-phase flow, then the transfer can be achieved, but uneven distribution of flow phases occurs leading to reduced activity and temperature spikes
Solution Approach 1:
The distributor plate is segmented into multiple concave volumes, each receiving a specific phase (gas, liquid, or solid) and distributing it to a designated region of the catalyst bed. This segmentation ensures that each phase is delivered to the appropriate location, preventing uneven distribution and maintaining reliable reactor performance.
Solution Approach 2:
Different regions of the catalyst bed are assigned different qualities based on the phase being introduced. The concave volumes are positioned to deliver gas, liquid, or solid phases to specific zones, creating local quality variations that optimize the reaction process and prevent maldistribution.
2Ease of operation
If conventional transfer methods are used, then three-phase flow can be transferred, but independent control of flow rates for each phase is limited
Solution Approach 1:
The distributor plate is divided into multiple concave volumes, with each volume receiving fluid from a separate inlet conduit. This segmentation allows independent control of flow rates for gas, liquid, and solid phases through separate control mechanisms, while the modular design keeps the overall system complexity manageable.
Solution Approach 2:
The concave volumes act as intermediaries between the inlet conduits and the catalyst bed. Each concave volume receives fluid from its dedicated inlet and distributes it to the appropriate region, providing a simple intermediary mechanism that enables independent flow rate control without requiring complex distribution systems.
3Reliability
If counter-current flow reactor is used, then three-phase flow can be handled, but residence time for contact between liquid and catalyst particles is relatively high
Solution Approach 1:
Instead of using a counter-current flow configuration where liquid and gas move in opposite directions to the solid particles, this invention employs a co-current flow approach where all phases move in the same direction through the catalyst bed. This inversion of the flow configuration allows for shorter contact times while maintaining reliable flow management capability.
Solution Approach 2:
The distributor plate creates local quality variations by delivering different phases to specific regions of the catalyst bed. This localized distribution optimizes the contact between phases and catalyst, achieving effective mass transfer and reaction in shorter residence times compared to conventional counter-current systems.
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
Enables efficient and uniform distribution of three-phase flows, reducing catalyst deactivation and temperature issues, and allowing for precise control of contact time and flow rates, thereby enhancing reactor performance and product yield.
Implementation Method 1
introducing a liquid feed into a plurality of concave volumes in at least one distributor plate... passing the liquid feed through the one or more orifices into the solids volume
Implementation Method 2
At least a portion of the liquid feed can have a lateral velocity component as it passes through the one or more orifices
Implementation Method 3
passing solid particles into a solids volume of a moving bed reactor through one or more solids inlet conduits. The solid particles can form a cone at an angle of repose for the solid particles within the solids volume
Implementation Method 4
each concave volume can include one or more orifices providing fluid communication, through an exit surface, between the concave volume and the solids volume
Data Source
AI summary
A feed distribution apparatus and method of using such an apparatus are provided for introducing a three-phase flow into a moving bed reactor that is operated under co-current flow conditions. The feed distribution apparatus can allow for separate introduction of liquid and solids in a manner that allows for even distribution of liquid within the solids. The gas portion of the flow can be introduced in any of a variety of convenient manners for distributing gas into a liquid or solid flow.