Planar Catalyst Filling With Staggered Plate Edges
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Solution Overview
Problem
In larger reactors, the formation of flow passages between abutting catalyst plates reduces dwell time and catalyst efficiency due to non-ideal abutment edge alignment, leading to suboptimal catalytic conversions and product output.
Innovation Solution
A catalyst filling system with layers of planar catalyst material where each layer's plates are configured to avoid congruent abutment edges, ensuring that no two abutment edges from different layers intersect, thereby preventing flow passages and optimizing dwell time and catalyst efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If multiple catalyst plates are used in each layer to fill large reactors, then the reactor volume utilization increases, but flow passages form between abutting plates that reduce dwell time and catalyst efficiency
Solution Approach 1:
The invention applies asymmetry by arranging plates in adjacent layers with different orientations and configurations. Specifically, plates in one layer are positioned at angles relative to plates in adjacent layers, ensuring that abutment edges do not align vertically. This asymmetric arrangement prevents the formation of continuous flow passages through the catalyst bed while maintaining high reactor volume utilization.
Solution Approach 2:
The invention transitions from a two-dimensional plate arrangement to a three-dimensional configuration by stacking multiple layers with varying plate orientations. By introducing vertical dimensionality and varying the angular positions of plates across layers, the invention eliminates aligned abutment edges that would create flow passages, thereby optimizing both volume utilization and dwell time.
2Productivity
If continuous plates fully fill the reactor cross-section, then catalyst efficiency is maximized in small reactors, but the reactor dimensions exceed plate dimensions in large reactors requiring multiple plates per layer
Solution Approach 1:
The invention applies segmentation by dividing the catalyst filling into multiple discrete plates arranged in layers, rather than using a single continuous plate. Each plate is a separate element that can be independently positioned and oriented. This segmentation allows for flexible arrangement strategies that prevent flow passage formation while maintaining high catalyst efficiency through proper geometric configuration.
Data Source
AI summary
The invention relates to a catalyst filling, comprising a first layer of a planar catalyst material and a second layer of a planar catalyst material lying over said first layer, wherein the catalyst material of the first layer comprises at least two plates, which butt against each other to form an abutment edge in each case, wherein the catalyst material of the second layer comprises at least two plates, which butt against each other to form an abutment edge in each case, and wherein the plates of the second layer are designed and/or arranged relative to the plates of the first layer in such a way that the abutment edge or abutment edges of the second layer are not aligned with the abutment edge or abutment edges of the first layer.