Percussion Suction Hose for Granular Catalyst Removal
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Solution Overview
Problem
Existing methods for emptying granular catalyst material from reactors, particularly in industrial chemistry, face challenges with catalyst compaction and adhesion, making it difficult to remove the material efficiently, especially when it forms a cohesive mass or is still free-flowing, due to the limitations of existing devices in handling varying states of catalyst material.
Innovation Solution
A device combining suction and pulsed beating mechanisms, where a percussion tool with articulated chain links is used to loosen and dislodge the granular material, allowing it to be sucked out, and a manipulation device for positioning the suction hose and percussion machine from outside the reactor, ensuring effective loosening and removal of the catalyst material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a suction hose is used to remove granular catalyst material from the reactor, then the material can be transported out, but the suction device cannot handle cohesive masses of grains effectively
Solution Approach 1:
The invention combines a suction device with a percussion device into a single integrated system. The percussion device generates vibrations that are transmitted through the suction hose to loosen cohesive catalyst grains, while the suction device simultaneously removes the loosened material. This merging of functions allows the system to handle both free-flowing and cohesive material states effectively.
Solution Approach 2:
The percussion device generates mechanical vibrations that are transmitted through the suction hose to the cohesive catalyst material inside the reactor. These vibrations loosen the cohesive masses of grains, converting them into a more free-flowing state that can be easily suctioned out. This principle directly addresses the problem of handling cohesive material by using vibration to break up aggregates.
2Ease of operation
If manual tools are used to loosen cohesive grains, then the material can be freed, but the process becomes time-consuming and labor-intensive
Solution Approach 1:
The invention replaces manual mechanical tools with an automated percussion device that generates vibrations through the suction hose. This substitution eliminates the need for manual intervention to loosen cohesive grains, significantly reducing both the time required and the labor intensity while maintaining effective material loosening.
Solution Approach 2:
The suction hose serves a dual function: it not only transports the catalyst material out of the reactor but also acts as a transmission medium for the percussion vibrations. The system uses itself (the suction hose) to deliver the loosening action directly to the material, eliminating the need for separate manual loosening operations.
3Productivity
If high-pressure air is blown into the grain mass to flush material, then removal is accelerated, but the device complexity increases
Solution Approach 1:
The suction hose is designed to perform multiple functions simultaneously: it transports catalyst material, transmits percussion vibrations, and serves as the structural framework for the entire emptying system. This multi-functionality eliminates the need for separate air blowing equipment or additional complex mechanisms, maintaining simplicity while achieving effective material removal.
4Ease of operation
If a percussion machine with rigid arms is used to break up cohesive material, then loosening effectiveness increases, but the device jams easily in cohesive masses
Solution Approach 1:
The invention replaces rigid arms with a flexible hose that can dynamically adapt to the catalyst material's state. The flexible hose transmits vibrations while being able to bend and flex without jamming, providing both effective loosening through vibration transmission and resistance to jamming through its flexible nature. This dynamic flexibility allows the system to handle varying material conditions reliably.
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 simplifies the emptying process by maintaining a constant load on the suction side, reducing sudden changes in grain flow, and effectively loosening and removing both free-flowing and cohesive catalyst materials, improving efficiency and ease of operation for a wide range of reactor conditions.
Implementation Method 1
a suction device (34, 36) which is responsible for sucking in and transporting away grains
Implementation Method 2
a percussion machine (42) arranged directly in front of the end of the suction, responsible for loosening any coherent mass of grains
Implementation Method 3
The suction device has a cyclone (34) and a vacuum pump (36)
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to a device for emptying granular catalyst material from a reactor (20), having a suction hose (28), which has a lower, open suction end (30) that is located in the reactor (20), and which has an upper outlet end (32) that is connected to a suction device, and is located outside of the reactor (20), and a percussion machine (42), which is connected to the suction hose (28) in the vicinity of the suction end (30), which has a motor (44), which has an output shaft (46), and a percussion tool (48) that is rotatable about the output shaft. The percussion tool (48) has a central part (50) connected to the output shaft (46), which has receiving openings (54), and at least two arms (52) arranged on said central part (50). Each arm (52) has at least one chain link (56), which is arranged freely jointed in one of the receiving openings (54). In a state of rest, the arms (52) hang freely down from the central part (50). In an operating state of the device, the arms (52) are located crosswise to the shaft axis. The arms (52) are always located under the suction end (30). In the operating state, the arms (52), during movement thereof, sweep over the surface of the suction end (30) at least in part, but without contacting the suction end (30).