Multistage Reactor with Parallel Planes for Methanol Synthesis
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Solution Overview
Problem
Existing multistage reactors for exothermic equilibrium reactions, such as methanol production, face challenges with inefficient spatial arrangement leading to unfavorable dimensions, mechanical instability, complex gas handling, and suboptimal temperature control, resulting in increased costs and product yield losses.
Innovation Solution
A reactor design with series-connected and fluid-connected reactor cells within a common shell, featuring separate reaction, cooling, and phase separation apparatuses arranged in parallel planes, allowing for a compact and modular structure that avoids direct placement of reaction and phase separation apparatuses alongside each other, enabling a homogenized temperature profile and reduced material stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If reactor cells are arranged in successive vertical or horizontal configuration, then the reactor can perform exothermic equilibrium reactions with intermediate condensation, but the reactor shell dimensions become unfavorable with excessive length
Solution Approach 1:
The patent transitions from one-dimensional successive arrangement to two-dimensional planar arrangement of reactor cells. Multiple reactor cells are organized in parallel planes with series connection within planes and parallel connection between planes, achieving compact spatial utilization and reducing overall reactor length while maintaining reaction capacity.
Solution Approach 2:
The patent implements nested arrangement where cooling-down apparatus and phase separation apparatus are positioned within or adjacent to reactor cell structures. This nested configuration allows efficient space utilization and reduces the overall reactor shell dimensions.
2Device complexity
If reactor cells are arranged in successive configuration, then the reactor structure is simplified, but mechanical stability becomes problematic requiring additional steel framework
Solution Approach 1:
The patent merges multiple functional apparatus (reaction, cooling-down, phase separation) into integrated reactor cell structures. This consolidation creates a more compact and mechanically stable configuration that inherently provides structural support without requiring additional external steel framework.
Solution Approach 2:
By arranging apparatus in parallel planes rather than successive linear configuration, the patent creates a more distributed structural load pattern that improves mechanical stability while maintaining structural simplicity.
3Volume of stationary object
If reaction apparatus and phase separation apparatus are placed alongside each other, then the reactor design is compact, but temperature control becomes suboptimal with direct thermal influence
Solution Approach 1:
The patent segments the reactor into distinct parallel planes: reaction apparatus in one plane, cooling-down apparatus in a second plane, and phase separation apparatus in a third plane. This spatial segmentation prevents direct thermal influence between hot reaction zones and cold separation zones while maintaining compact overall design.
Solution Approach 2:
The cooling-down apparatus positioned in an intermediate plane acts as a thermal mediator between the hot reaction apparatus and the cold phase separation apparatus, facilitating temperature control and preventing direct thermal coupling.
4Use of energy by moving object
If thermoplates are used as heat exchanger structure, then heat transfer efficiency is improved, but production costs increase due to individual assembly manufacturing and installation
Solution Approach 1:
The patent integrates heat exchanger structures directly into the reactor cell design rather than using separate thermoplate assemblies. This merging approach allows heat exchanger surfaces to be manufactured as integral parts of the reactor cells, reducing production costs while maintaining heat transfer efficiency.
5Length of moving object
If reactor cells are arranged horizontally in recumbent configuration, then total length is reduced, but process gas regime becomes more complicated
Solution Approach 1:
The patent uses parallel plane arrangement with vertical or inclined positioning of apparatus within planes, combining the space-saving benefits of horizontal configuration with simplified gas flow patterns through proper orientation and gravity-assisted flow management.
6Area of stationary object
If horizontal flow toward reactor bed is used, then shell diameter can be reduced, but bypass flow control becomes difficult and maldistribution increases over catalyst lifetime
Solution Approach 1:
The patent employs vertical or upward flow configurations within reactor cells rather than horizontal flow toward the bed. This dimensional change in flow direction improves flow distribution uniformity and reduces bypass flow issues while maintaining compact shell dimensions through parallel plane arrangement.
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
This design achieves a more compact and stable reactor with improved temperature control, reduced material stresses, and lower production costs, while maintaining efficient gas handling and product yield.
Implementation Method 1
a cooling apparatus which is in a heat-exchanging relationship with the solid catalyst and through which a cooling medium can flow
Implementation Method 2
a condensation apparatus configured for condensing the liquid reaction product from the product gas mixture
Implementation Method 3
a separation apparatus configured for separating the condensed liquid reaction product from the residual gas mixture
Data Source
AI summary
The invention relates to a reactor for performing exothermic equilibrium reactions, especially for producing methanol from synthesis gas in a multistage synthesis with intermediate condensation of the reaction product. The reactor according to the invention has a reactor shell and a multitude of series-connected and mutually fluid-connected reactor cells disposed within the reactor shell, where each of the reactor cells includes a reaction apparatus, a cooling-down apparatus and a phase separation apparatus as reactor cell elements. The reactor has a multitude of reactor planes disposed in a mutually parallel arrangement within the reactor shell, where reactor cell elements of the same kind are disposed in the same reactor plane. The inventive arrangement of the reactor cell elements enables the building of a compact reactor and reduces material stresses within the reactor by the avoidance of large temperature differences within the reactor shell.