Pneumatic Tank Transfer for Catalyst Loading and Unloading
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Solution Overview
Problem
The loading and unloading of catalysts and adsorbents in reactors is complex, risky, inefficient, and often requires manual labor in confined and hazardous environments, posing safety and operational challenges.
Innovation Solution
A pneumatic system comprising an intermediate tank, pump, and pneumatic conveyor is used to fluidically connect tanks for efficient loading and unloading of particulate solid materials, utilizing negative pressure to transfer particles between tanks without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual labor with human intervention inside the tank is used for loading and unloading catalysts, then flexibility and adaptability are maintained, but safety risks increase and productivity decreases due to slow and inefficient operations in confined hazardous spaces
Solution Approach 1:
The patent replaces manual mechanical operations with a pneumatic conveying system that uses gas flow to transport catalyst particles through pipes. The system includes a pneumatic conveyor, cyclone separator, and control valve assembly that automatically loads and unloads catalyst without human intervention in hazardous environments, thereby improving safety while maintaining productivity
Solution Approach 2:
The patent introduces an intermediate pneumatic conveying system as a mediator between the catalyst storage and the reactor tank. This intermediary system uses controlled gas flow and cyclone separation to transfer catalyst particles, eliminating the need for direct human contact with hazardous materials while efficiently managing the loading and unloading processes
2Productivity
If complex mechanical equipment is used at the top of tanks for loading and unloading, then productivity improves through automated operations, but device complexity increases and safety risks arise from equipment operations
Solution Approach 1:
The patent employs pneumatic principles to simplify the loading and unloading system. A pneumatic conveyor delivers catalyst particles through controlled gas flow, and a cyclone separator uses centrifugal force generated by rotating gas flow to separate particles from the gas stream. This pneumatic approach replaces complex mechanical equipment with simpler, more reliable gas-driven mechanisms, improving productivity while reducing device complexity
Solution Approach 2:
The patent extracts the complex mechanical operations from the tank top environment and relocates them to a remote pneumatic conveying system. The catalyst loading and unloading functions are separated from the reactor tank, with the pneumatic conveyor and cyclone separator positioned outside the hazardous zone, thereby reducing device complexity at the tank while maintaining high productivity
3Adaptability or versatility
If exhaustive manual labor is used for catalyst replacement, then adaptability to different catalyst types is maintained, but loss of time increases due to slow operations and frequent human intervention
Solution Approach 1:
The patent replaces manual catalyst handling with an automated pneumatic conveying system that can quickly transport different catalyst particles. The system's ability to adjust gas flow rates and cyclone separator parameters allows it to adapt to various catalyst types and sizes, eliminating the time-consuming nature of manual operations while maintaining versatility in catalyst handling
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
Enables safe, efficient, and automated loading and unloading of catalysts and adsorbents, reducing risks and labor intensity while maintaining a controlled environment.
Implementation Method 1
The pump is configured to generate negative pressure in the intermediate tank, the empty or partially empty solid material tank, and the tank containing saturated or degraded solid material particles to carry the saturated or degraded solid material particles from inside the tank to the inside of the empty or partially empty solid material tank
Implementation Method 2
a pneumatic system and method for loading and unloading solid material used to carry out a physical, chemical or biological process in a tank
Implementation Method 3
The pneumatic conveyor is positioned below the intermediate tank, and the intermediate tank is configured to carry the unsaturated or undegraded solid material particles received into the pneumatic conveyor. The pneumatic conveyor is fluidically connected to the tank to carry the unsaturated or undegraded solid material particles received into the tank
Data Source
AI summary
The present invention relates to a system for loading and unloading agents in the form of particulate solid material, used for carrying out a physical, chemical, and/or biological process in one or more tanks. The system includes: an intermediate tank, a pump, and a pneumatic conveyor. The intermediate tank and the pump are fluidically connected. For unloading a tank containing saturated or degraded solid material particles, an empty or partially empty solid material tank is fluidically connected to the intermediate tank and the tank containing saturated or degraded solid material particles. For loading a tank, a solid material tank containing unsaturated or undegraded solid material particles is fluidically connected to the intermediate tank.