Predistribution Filter Plate for Fixed-Bed Reactor Clogging
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Solution Overview
Problem
Chemical reactors with downward co-current gas and liquid flows face issues with clogging particles depositing on catalytic beds, leading to reduced interstitial volume, pressure loss, and heterogeneous flow distribution, necessitating frequent shutdowns and catalyst replacement.
Innovation Solution
A predistribution filter plate with a filtration bed and discharge tube is used to trap clogging particles and regulate liquid flow, integrating filtration and distribution functions to ensure homogeneous liquid supply and reduce pressure loss by attenuating flow variations at the downstream distributor plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a distributor plate is used to supply gas and liquid to the catalytic bed, then the distribution of phases is improved, but clogging particles still deposit on the catalytic bed reducing interstitial volume
Solution Approach 1:
The patent introduces a predistribution filter plate positioned upstream of the distributor plate to perform preliminary filtration of the liquid phase before it reaches the catalytic bed. This preliminary action removes clogging particles in advance, preventing them from depositing on the catalytic bed and reducing interstitial volume, while the distributor plate maintains its phase distribution function.
Solution Approach 2:
The predistribution filter plate acts as an intermediary component between the liquid feed and the distributor plate. It mediates the liquid flow by filtering out clogging particles through its filtration medium, allowing the downstream distributor plate to focus on distribution functions without being compromised by particle deposition.
2Quantity of substance
If clogging particles are present in the liquid feed, then the liquid flow rate is maintained, but pressure loss increases and reactor shutdown is forced
Solution Approach 1:
The predistribution filter plate performs preliminary filtration of the liquid phase before it enters the reactor, removing clogging particles that would otherwise accumulate in the catalytic bed and cause pressure loss. This advance action maintains pressure drop within acceptable limits by preventing progressive fouling.
Solution Approach 2:
The filtration medium of the predistribution filter plate extracts and removes clogging particles from the liquid phase through physical filtration. This extraction of harmful particles prevents them from entering the catalytic bed, thereby maintaining stable pressure loss characteristics throughout operation.
3Stress or pressure
If blockage occurs in the catalytic bed, then pressure loss increases, but catalyst replacement is required reducing process cycle time
Solution Approach 1:
The predistribution filter plate performs preliminary filtration to remove clogging particles before they can cause blockage in the catalytic bed. This advance prevention action extends the operating cycle time by delaying or preventing the need for catalyst replacement, as the filtration medium captures particles that would otherwise accumulate and force shutdowns.
Solution Approach 2:
The predistribution filter plate serves as an intermediary protective layer between the liquid feed and the catalytic bed. It mediates the interaction by filtering out particles, thereby protecting the catalyst from fouling and extending the operational cycle before catalyst replacement becomes necessary.
4Ease of operation
If deposition of clogging particles occurs randomly in the bed, then flow distribution becomes heterogeneous, but homogeneous distribution is disrupted
Solution Approach 1:
The predistribution filter plate performs preliminary filtration to remove clogging particles from the liquid phase before it enters the reactor. This advance action prevents random deposition of particles throughout the catalytic bed, thereby maintaining homogeneous flow distribution and stable empty fraction distribution by eliminating the source of heterogeneity.
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 extends the operating time of the reactor by reducing clogging occurrences, maintaining homogeneous flow and reaction progress, and minimizing pressure loss, allowing for longer cycle durations and reduced catalyst replacement frequency.
Implementation Method 1
a predistribution plate comprising a medium filtering
Data Source
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AI summary
The device described in the present invention is used to predistribute the gas/liquid feedstock feeding a reactor operating in descending gas/liquid co-current mode, by means of a predistribution plate comprising a filter medium and an overflow tube for regulating the flow rate of liquid arriving on a distributor plate located downstream of said device. The present device applies more particularly to the selective hydrogenation treatment of feedstocks containing acetylene and diene compounds.