Reaction Pump Seal Protection Chamber for Hydrocarbon Conversion
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Solution Overview
Problem
Existing methods for hydrocarbon conversion at low temperatures and pressures face challenges in durability and cost-effectiveness due to bearing wear and air leakage issues, particularly with high-speed mixer chambers and liquid ring vacuum pumps, which result in short operational lifetimes and increased maintenance costs.
Innovation Solution
A reaction pump design featuring a housing with a reaction chamber, a mixing element, and bearings located outside the chamber, utilizing a seal protection chamber with a liquid barrier to separate the reactant from the bearings, ensuring airtightness and protecting the bearings from abrasive catalysts and debris, while allowing for efficient heating and turbulence to promote hydrocarbon conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-speed mixer chambers are used for hydrocarbon conversion, then conversion efficiency is improved, but bearing service life deteriorates to only 30-250 hours due to abrasive wear from catalyst and debris
Solution Approach 1:
The invention divides the mixer chamber into two separate chambers: a first chamber that processes abrasive hydrocarbon feedstock with catalyst, and a second chamber that receives the processed material. This segmentation isolates the abrasive environment from the bearing system, allowing high-speed mixing to continue without compromising bearing longevity.
Solution Approach 2:
The invention extracts the bearing system from the abrasive reaction environment by positioning bearings outside the first mixer chamber. A shaft connects the impeller in the first chamber to the drive mechanism, allowing the bearings to operate in a clean, non-abrasive environment while the impeller continues to process abrasive materials at high speed.
2Reliability
If seals are used to maintain airtightness in the reaction chamber, then anaerobic conditions are maintained, but air leakage occurs due to thermal expansion and contraction at temperatures above 300°C
Solution Approach 1:
The invention applies different sealing strategies to different parts of the system. In the first chamber, a liquid seal or grease seal is used that can accommodate thermal expansion. In the second chamber, a mechanical seal or packing seal is used where the shaft passes through the chamber wall. This localized approach allows each seal to be optimized for its specific thermal and pressure conditions.
Solution Approach 2:
The invention changes the physical state of the sealing medium by using liquid seal or grease seal in the high-temperature first chamber, which remains effective despite thermal expansion and contraction. This liquid/grease barrier maintains airtightness under varying thermal conditions better than traditional mechanical seals would in this environment.
3Temperature
If bearings are positioned inside the reaction chamber for direct cooling, then thermal management is improved, but bearing durability deteriorates due to exposure to abrasive catalysts and debris
Solution Approach 1:
The invention introduces a shaft as an intermediary element that connects the impeller in the abrasive environment to the drive mechanism. The shaft transmits rotational force while allowing the bearings to be positioned outside the abrasive first chamber, thus protecting the bearings from catalyst and debris while maintaining the cooling benefit of external positioning.
Solution Approach 2:
The bearing system is extracted from the abrasive reaction environment in the first chamber and positioned in a protected area outside the chamber. This extraction allows the bearings to operate in a clean environment while the impeller continues to process abrasive materials at high speed, solving both the cooling and durability requirements.
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 design enhances the durability and airtightness of the reaction pump, extending operational lifetimes, reducing maintenance, and maintaining anaerobic conditions, thus achieving more efficient and cost-effective hydrocarbon conversion in the temperature range of 260°C to 360°C.
Implementation Method 1
The mixing element is disposed inside the reaction chamber and is rotated about the shaft in use to a speed which promotes turbulence in the reaction chamber
Implementation Method 2
The mixing element, which in use is disposed inside the reaction chamber for transferring energy to the fluid reactant
Implementation Method 3
a barrier means, disposed between the reaction chamber and the at least one bearing, for fluidically separating the reactant from the at least one bearing
Data Source
Figure 1a
Figure 1b
Figure 1c
AI summary
Reaction pumps and systems for hydrocarbon conversion are disclosed. A reaction pump for conversion of hydrocarbons has a housing, a reaction chamber enclosed by the housing, for containment of a hydrocarbon process fluid or liquid reactant, a mixing element disposed inside the reaction chamber, the mixing element coupled to a rotatable shaft, and a plurality of bearings receiving the shaft, each bearing being disposed outside the reaction chamber. At least one of the bearings is closest to the reaction chamber. A type of barrier is disposed between the reaction chamber and the closest bearing, for fluidically separating the reactant from the closest bearing. This barrier can take the form of a seal protection chamber. A system for hydrocarbon conversion includes the reaction pump and an additional circuit for cleaning and recycling process fluid or liquid.