Pellet Loading Funnel with Hanging Cord Measurement
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Solution Overview
Problem
The existing methods for loading catalyst or inert pellets into chemical reactor tubes are cumbersome, time-consuming, and often result in damage to the pellets and increased pressure drop due to the need for frequent insertion and removal of rods to check levels, leading to inefficient and inaccurate loading processes.
Innovation Solution
A device featuring a cord with a weight and a loading funnel that allows for quick and precise measurement of pellet levels, combined with a vacuum-assisted system for gentle handling and controlled release of pellets, enabling efficient and accurate loading of pellets to specific heights within reactor tubes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the operator uses a tape or rod to check pellet level in the tube, then the pellet level can be determined, but the process becomes time-consuming and the catalyst pellets are damaged
Solution Approach 1:
The patent introduces a cord as an intermediary measurement tool that can be left hanging in the tube during the entire loading process. The cord with weight at its end serves as a continuous reference marker, allowing the operator to check pellet levels by observing the cord's position relative to the pellet surface, eliminating the need to repeatedly insert and remove rods or tapes.
Solution Approach 2:
The cord is positioned in advance at the desired final pellet level before loading begins. This preliminary positioning establishes a visual reference point that guides the loading process, allowing the operator to stop loading when the pellets reach the cord's position, thereby eliminating the need for multiple measurement cycles.
2Productivity
If the operator adds many pellets at once to reach desired height, then loading time is reduced, but the pellet level becomes inaccurate and excess pellets must be removed
Solution Approach 1:
The cord serves as a visual intermediary guide that allows the operator to monitor pellet level in real-time during loading. This enables the operator to add pellets in controlled amounts while continuously observing when the pellet surface reaches the desired level marked by the cord, achieving both speed and accuracy.
Solution Approach 2:
The hanging cord provides continuous visual feedback to the operator during the loading process. As pellets are added, the operator can immediately see when the pellet level reaches the cord's position, allowing for real-time adjustment of loading rate and preventing overfilling, thus eliminating the need to remove excess pellets.
3Measurement precision
If the operator repeatedly inserts and removes rods to check pellet level, then the measurement can be taken, but the catalyst pellets are smashed and dust is generated
Solution Approach 1:
The cord acts as a non-intrusive intermediary measurement tool that remains stationary in the tube throughout the loading process. It provides measurement capability without requiring repeated physical insertion and removal of tools, thereby preventing mechanical disturbance and damage to the catalyst pellets.
Solution Approach 2:
The cord is left in place to continuously indicate the desired level, serving itself as the measurement reference throughout the entire loading operation. This eliminates the need for the operator to repeatedly introduce external measurement tools that could disturb or damage the pellets.
4Manufacturing precision
If the operator removes excess pellets from the tube after overfilling, then the correct pellet level can be achieved, but the process becomes time-consuming and difficult
Solution Approach 1:
The hanging cord provides continuous visual feedback during the loading process, allowing the operator to stop loading exactly when the pellet level reaches the desired height. This real-time feedback mechanism prevents overfilling from occurring in the first place, eliminating the need for time-consuming pellet removal operations.
Solution Approach 2:
By positioning the cord at the desired final level before loading begins, the system establishes a preventive measure that stops the operator from adding excess pellets. This preliminary anti-action approach prevents the problem of overfilling before it can occur, rather than requiring corrective action afterward.
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 solution streamlines the loading process, reduces pellet damage, and ensures precise control over the loading height, improving the efficiency and accuracy of catalyst distribution while minimizing dust generation and pressure drop issues.
Implementation Method 1
A vacuum-assisted device is used to pick up a measured quantity (or load) of pellets to deliver to the aforementioned funnel for loading into the tube
Implementation Method 2
A cord with a weight at its distal, free end is reeled into the tube through a special loading funnel. The cord and weight remain hanging from the funnel as the pellets are loaded into the tube, with the weight slightly above the desired pellet level in the tube
Data Source
AI summary
A device and method for loading pellets. A funnel includes a means for loading pellets into a reactor tube, and a means for quickly and easily measuring the elevation of pellets in the reactor tube while the reactor tube is being loaded. A vacuum-assist device may be used to pick up and transfer a desired volume of porous pellets while removing dust from the porous pellets.