Offset Reactor Support Plates for Tube Stability and Fluid Flow
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Solution Overview
Problem
Existing methanol synthesis reactors face issues with pressure drop due to long reactor tubes and the need for additional support plates, which cause bending, kinking, and vibration during transport and operation.
Innovation Solution
A reactor design featuring offset support plates with recesses that allow for fluid exchange, minimizing obstruction and supporting tubes without restricting fluid flow, while preventing buckling and bending.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If long reactor tubes are used, then the reactor can be transported in restricted external dimensions, but the pressure drop on the coolant side increases
Solution Approach 1:
The reactor vessel is divided into multiple sections by inserting support plates at intermediate positions along the long reactor tubes. This segmentation allows the tubes to be supported at multiple points, reducing the span between supports and thereby reducing pressure drop while maintaining the long tube configuration for restricted dimension transport.
Solution Approach 2:
Support plates are introduced as intermediary elements between the tube bundle and the reactor vessel walls. These support plates provide additional mechanical support and reduce pressure drop by creating intermediate flow paths, while not interfering with the overall long tube configuration needed for transport restrictions.
2Stability of the object's composition
If additional support plates are inserted to prevent sagging during transport, then tube stability is improved, but the tubes are subject to bending, kinking, and vibration during operation
Solution Approach 1:
The support plates are designed with differentiated local properties: they provide robust mechanical support at critical locations to prevent sagging during transport, while their geometry and positioning are optimized to minimize interference with tube movement and vibration characteristics during operation. The support plates have openings and recesses that allow fluid flow while providing localized structural support.
Solution Approach 2:
The support plates are designed to accommodate dynamic tube movement during operation while maintaining stability during transport. The plates provide rigid support when needed but allow sufficient freedom for thermal expansion and vibration, creating a dynamic balance between stability and flexibility.
3Ease of operation
If support plates are offset within the reactor vessel, then coolant flow path is created, but the obstructive effect of the support plates increases
Solution Approach 1:
The support plates are nested within the reactor vessel geometry, with multiple support plates arranged at different positions along the tube length. The plates are offset from each other to create coolant flow paths while minimizing overall obstruction. The recesses in the support plates are designed to accommodate tube bundles while maintaining flow channels.
Solution Approach 2:
The support plates are designed with multiple openings and recesses that create a porous-like structure, allowing coolant to flow through and around the plates. This porous design reduces the obstructive effect while maintaining the mechanical support function, enabling coolant flow in meandering patterns around the support plates.
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 design reduces pressure loss and mechanical stress on tubes, ensuring stable operation and efficient heat exchange during methanol synthesis.
Implementation Method 1
Cooling in a water-cooled reactor occurs through heat transfer into the water, which can generate steam.
Implementation Method 2
The steam-water mixture rises up the tubes.
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
Device (1.1; 1.2) comprising a reactor vessel (2), a tube bundle (3) with a plurality of tubes (4), a first support plate (5) and a second support plate (6), wherein the tube bundle (3) is arranged in the reactor vessel (2), wherein the tube bundle (3) comprises a plurality of first tube groups (7) and a plurality of second tube groups (8), wherein the first support plate (5) and the second support plate (6) are arranged transversely to a longitudinal axis (9) of the reactor vessel (2) in the reactor vessel (2), wherein the first support plate (5) is offset from the second support plate (6) along the longitudinal axis (9) of the reactor vessel (2), wherein each of the tubes (4) of the first tube groups (7) is guided through a respective tube opening (10.1) of the first support plate (5), and wherein the first support plate (5) has a plurality of recesses (11.1) for fluid exchange, wherein each of the second tube groups (8) is guided through a respective one of the recesses (11.1) is guided in the first support plate (5), wherein each of the tubes (4) of the second tube groups (8) is guided through a respective tube opening (10.2) of the second support plate (6), and wherein the second support plate (6) has a plurality of recesses (11.2) for fluid exchange, wherein each of the first tube groups (7) is guided through a respective one of the recesses (11.2) in the second support plate (6), wherein the first support plate (5) supports the tubes (4) of the first tube groups (7) in the tube openings (10.1) of the first support plate (5) transversely to the longitudinal direction of the tubes (4) and the second support plate (6) supports the tubes (4) of the second tube groups (8) in the tube openings (10.2) of the second support plate (6) transversely to the longitudinal direction of the tubes (4).