Multiphase Fluid Distributor Tray for Uniform Catalyst Bed Flow
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Solution Overview
Problem
Current distribution units for hydro-processing reactors fail to provide uniform distribution of multi-phase fluid mixtures over the catalyst bed, leading to inefficiencies, hot-spot formation, and catalyst degradation due to non-uniform reactant distribution.
Innovation Solution
A distribution unit with a distribution body featuring first and second distal body portions, including slots and an aperture, designed to accommodate baffle plates, which mixes and disperses gas and liquid flows to form a multi-phase fluid mixture and distribute it uniformly across the catalyst bed, reducing sensitivity to tray levelness and pressure drop.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional distribution units with minimal spray angle are used, then the device complexity is reduced, but the uniformity of reactant distribution deteriorates
Solution Approach 1:
The distribution unit is divided into multiple nozzles arranged in a circular pattern, each nozzle independently directing fluid at a specific angle. This segmentation allows the system to achieve wide overall coverage while maintaining simple individual nozzle structures, resolving the contradiction between device complexity and distribution uniformity.
Solution Approach 2:
The invention introduces a vertical dimension to the spray pattern by angling nozzles downward at 45 degrees from a horizontal plane. This dimensional change allows the distribution unit to achieve wide radial coverage and deep penetration into the catalyst bed simultaneously, improving uniformity without requiring complex multi-axis mechanisms.
2Stress or pressure
If conventional distribution units are used, then the pressure drop is reduced, but hot-spot formation increases due to non-uniform distribution
Solution Approach 1:
Each nozzle is specifically designed with a 45-degree downward angle to target specific regions of the catalyst bed. This local optimization ensures that reactants are delivered precisely where needed, preventing stagnant zones and hot-spots while maintaining reasonable pressure drop characteristics through efficient fluid delivery.
Solution Approach 2:
The circular arrangement of nozzles creates a dynamic spray pattern that covers the entire catalyst bed surface. The multiple angled jets work together to create uniform distribution across varying flow rates, preventing the formation of hot-spots without requiring active pressure regulation mechanisms.
3Device complexity
If minimal spray angle distribution is used, then the device complexity is minimized, but catalyst utilization efficiency deteriorates
Solution Approach 1:
The distribution unit employs multiple segmented nozzles arranged circularly, each contributing to the overall coverage. This segmentation allows simple individual nozzle designs to collectively achieve wide coverage and deep penetration, maximizing catalyst utilization without complex mechanisms.
Solution Approach 2:
By introducing a downward vertical component to the spray angle, the system delivers reactants deeper into the catalyst bed in addition to radial coverage. This dimensional enhancement improves catalyst utilization efficiency by ensuring thorough penetration while keeping each nozzle structurally simple.
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 ensures uniform distribution of reactants, reduces hot-spot formation, enhances catalyst utilization, and improves the quality and stability of the final product by effectively distributing the multi-phase fluid mixture across the catalyst bed, even at varying flow rates.
Implementation Method 1
The distributor tray is effective for distributing liquid and vapor flows across a catalyst bed in a hydro-processing reactor using vapor lift principle
Implementation Method 2
The distribution unit allows an improved mixing of a flow of gas and a flow of liquid to form a flow of a multi-phase fluid mixture
Data Source
Figure 1
Figure 2a~2b
Figure 3a
AI summary
A distribution unit (204-1) for distributing a multi-phase fluid mixture is disclosed. The distribution unit (204-1) includes a distribution body (302) defining a first passage (304), and a first distal body portion (326) having a plurality of first slots (330). The distribution body (302) includes a second distal body portion (328) having a plurality of second slots (336) distributed on a side wall of the second distal body portion (328). Each of the plurality of second slots (336) is adapted to accommodate a baffle plate (338). The second distal body portion (328) includes at least one aperture (402) formed on a bottom wall (334) of the second distal body portion (328). The plurality of first slots (330), the plurality of second slots (336), and the at least one aperture (402) are in fluid communication with the first passage (304) to discharge the flow of the multi-phase fluid.