Pressure-Controlled Reactor for Uniform Pyrolysis Feed Distribution
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Solution Overview
Problem
Existing chemical reactors face challenges in achieving homogeneous product formation during pyrolysis or thermolysis processes due to uneven introduction of starting materials, leading to variations in product quality and quantity, especially with short residence times and multiple reactors.
Innovation Solution
A tube bundle reactor system with pressure reduction units having different capillary diameters and lengths to ensure equal inflow of starting material into individual reactor tubes, maintaining a controlled negative pressure and uniform flow rate, which prevents excessive throughput or concentration differences that cause by-product formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional pressure control systems are used in multiple reactors, then the system can operate with short residence times, but uneven introduction of reactants occurs leading to varying product quality and quantity
Solution Approach 1:
The patent applies local quality by providing each reactor tube with individually tailored pressure reduction units having specific capillary dimensions. This ensures that each tube receives the precise flow rate needed for uniform reactant introduction, thereby maintaining high product quality while enabling short residence times and high throughput.
Solution Approach 2:
The patent changes the parameters of the pressure reduction units by varying capillary diameter and length for different reactor tubes. This parameter optimization allows precise control of flow distribution across multiple tubes, achieving both high productivity through short residence times and consistent product quality through uniform reactant introduction.
2Productivity
If feedstock is introduced at high flow rates to increase productivity, then throughput increases, but excessive throughput or high feedstock concentrations in some tubes lead to increased byproduct formation
Solution Approach 1:
The patent implements local quality by equipping different reactor tubes with pressure reduction units having specifically optimized capillary dimensions. This local optimization ensures that each tube operates at its optimal flow rate, preventing excessive throughput in any single tube and thereby minimizing byproduct formation while maintaining high overall throughput.
Solution Approach 2:
The patent replaces complex mechanical flow control systems with simple capillary-based pressure reduction units. These passive capillary structures inherently control flow rates through their dimensional properties, providing reliable flow distribution that prevents localized excessive throughput and the associated byproduct formation.
3Manufacturing precision
If pressure reduction units with different capillary dimensions are used to control uniform inflow, then manufacturing precision of feed distribution improves, but device complexity increases
Solution Approach 1:
The patent applies local quality by providing each reactor tube with individually optimized pressure reduction units. This approach achieves precise feed distribution uniformity across all tubes, with each unit's capillary dimensions specifically tailored to its location and flow requirements.
Solution Approach 2:
The patent employs simple, inexpensive capillary structures as pressure reduction units. These basic capillary components provide precise flow control through their inherent dimensional properties without requiring complex mechanisms, thereby achieving high feed distribution uniformity while minimizing device complexity.
4Stability of the object's composition
If all reactor tubes are fed uniformly to ensure homogeneous decomposition, then product homogeneity improves, but the system requires complex pressure regulation mechanisms
Solution Approach 1:
The patent implements local quality by equipping each reactor tube with pressure reduction units having specifically optimized capillary dimensions. This local optimization ensures uniform decomposition conditions in all tubes, producing homogeneous products while avoiding the need for complex centralized pressure control mechanisms.
Solution Approach 2:
The patent employs passive capillary-based pressure reduction units that automatically regulate flow distribution based on their inherent dimensional properties. These self-regulating components achieve uniform feed distribution and homogeneous product formation without requiring external control systems or complex pressure regulation mechanisms.
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 approach ensures even decomposition of starting materials across all reactor tubes, reducing by-product formation and enhancing the homogeneity and quality of pyrolysis or thermolysis products by maintaining precise control over flow and pressure parameters.
Implementation Method 1
capillaries with different pressure resistance due to different capillary diameters and/or capillary lengths
Implementation Method 2
the reactor tubes are heated in at least a first section to a decomposition temperature of the feedstock
Implementation Method 3
a corresponding underpressure inside the reactor tubes
Data Source
Figure 1~2
Figure 3~4
Figure 5A
AI summary
The present invention relates to a method and a device for the pyrolysis or thermolysis of a fluid or fluidized starting material under negative pressure in a multi-tube reactor comprising a plurality of heatable reactor tubes, wherein the starting material is fed to the multi-tube reactor at one end by means of at least one supply line, wherein the supply line has several pressure reduction units, which enable a positive pressure before the starting material is introduced into individual reactor tubes of the multi-tube reactor and a negative pressure related thereto inside the reactor tubes, wherein the pressure reduction units control a substantially equal inflow of the starting material into individual reactor tubes, and the reactor tubes are heated to a decomposition temperature of the starting material in at least one primary section, whereby the starting material is pyrolyzed or thermolyzed and a pyrolysis product or thermolysis product is obtained.