Multi-Phase Fluid Distributor Structure for Uniform Catalyst Bed Flow
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Solution Overview
Problem
Existing distribution units for hydro-processing reactors fail to provide uniform distribution of multi-phase fluid mixtures over catalyst beds, leading to inefficiencies, hot-spot formation, and catalyst degradation due to sensitivity to tray levelness and high pressure drops.
Innovation Solution
A distribution unit with a distribution body featuring first and second distal body portions, including slots and an aperture, which allows for the mixing and uniform dispersion of gas and liquid flows to form a multi-phase fluid mixture, reducing sensitivity to tray levelness and pressure drops.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional distribution units with minimal spray angle are used, then the structure is simple, but uniform distribution of reactants over the catalyst bed cannot be achieved
Solution Approach 1:
The distribution unit is divided into multiple functional segments: a spray section with multiple nozzles arranged in different patterns (radial, axial, tangential) to create segmented spray zones, and a distribution section with perforations. This segmentation allows each zone to contribute to overall uniform distribution, resolving the contradiction between achieving uniformity and maintaining structural simplicity.
Solution Approach 2:
The invention transitions from a single-point or single-plane spray approach to a multi-dimensional spray configuration. Nozzles are arranged in radial, axial, and tangential directions, creating a three-dimensional spray pattern that covers the catalyst bed more uniformly. This dimensional expansion enables better distribution without requiring complex mechanical systems.
2Manufacturing precision
If chimney type distributors with aperture restrictions are used, then liquid distribution is improved, but the system becomes very sensitive to tray levelness
Solution Approach 1:
The invention changes the flow control parameters from restrictive apertures dependent on tray levelness to a multi-nozzle system with varying spray angles and orientations. The nozzles are designed with specific spray patterns (radial, axial, tangential) that maintain consistent performance across different tray conditions, reducing sensitivity to levelness variations while preserving distribution uniformity.
3Manufacturing precision
If vapor lift distribution trays with inverted U-shaped devices are used, then vapor-liquid contact is enhanced, but only the catalyst portion directly below the tube is wetted
Solution Approach 1:
The distribution unit employs asymmetric nozzle arrangements with different spray directions (radial, axial, tangential) and orientations. This asymmetric configuration ensures that spray coverage extends to all regions of the catalyst bed, including areas not directly below the distribution unit, thereby achieving comprehensive wetting coverage without requiring multiple symmetric vapor lift tubes.
4Manufacturing precision
If distribution units with restricted flow paths are used, then spray angle control is improved, but pressure drop increases significantly
Solution Approach 1:
The distribution unit integrates multiple functions into a single structure: the spray section with multi-directional nozzles provides both spray angle control and flow distribution, while the distribution section with perforations handles additional flow regulation. This multi-functional design achieves precise spray angle control without requiring separate restrictive components that would increase pressure drop.
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 across the catalyst bed, reducing hot-spot formation and enhancing catalyst utilization and product quality while minimizing pressure drops and fouling.
Implementation Method 1
a vapor lift distribution tray fitted with an inverted 'U'-shaped device termed 'vapor lift tube'
Implementation Method 2
The plurality of first slots discharges the flow of the multi-phase fluid mixture
Data Source
AI summary
A distribution unit for distributing a multi-phase fluid mixture is disclosed. The distribution unit includes a distribution body defining a first passage, and a first distal body portion having a plurality of first slots. The distribution body includes a second distal body portion having a plurality of second slots distributed on a side wall of the second distal body portion. Each of the plurality of second slots is adapted to accommodate a baffle plate. The second distal body portion includes at least one aperture formed on a bottom wall of the second distal body portion. The plurality of first slots, the plurality of second slots, and the at least one aperture are in fluid communication with the first passage to discharge the flow of the multi-phase fluid.