Adiabatic Reactor Collector Distributor for Inter-bed Heat Exchange
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Solution Overview
Problem
Adiabatic multi-bed catalytic reactors face challenges in efficiently and cost-effectively performing gas collection and distribution between catalytic beds for inter-bed heat exchange, particularly in axial reactors, which limits their adoption due to difficulties in achieving uniform gas distribution and heat recovery.
Innovation Solution
A reactor design featuring a stack of axially aligned catalytic beds with a sideways located indirect heat exchanger and a combined collector/distributor member with parallel channels, allowing for efficient gas collection and distribution, and supporting the structural requirements of the reactor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional gas collection and distribution components are used between catalytic beds, then gas collection and distribution function is achieved, but device complexity and cost increase
Solution Approach 1:
The patent combines multiple functions (gas collection, heat exchange, gas distribution, and structural support) into a single integrated component called a 'combined collector/distributor member'. This eliminates the need for separate gas collection and distribution components, reducing device complexity and manufacturing cost while maintaining all necessary functions between catalytic beds.
Solution Approach 2:
The combined collector/distributor member performs multiple functions simultaneously: it collects gas from the first catalytic bed, conveys it to the heat exchanger, distributes the cooled gas to the second catalytic bed, and provides structural support. This multi-functionality reduces the number of components needed and simplifies the overall reactor design.
2Volume of moving object
If multiple separate components are used for gas collection and distribution, then functional requirements are met, but reactor space is reduced
Solution Approach 1:
By merging gas collection, heat exchange, distribution, and support functions into a single integrated component, the patent eliminates the space that would be required for multiple separate components. The combined collector/distributor member occupies only the space needed for its primary function while performing all necessary operations.
3Stability of the object's composition
If complex gas distribution systems are installed, then uniform gas distribution is achieved, but pressure drop increases
Solution Approach 1:
The combined collector/distributor member incorporates local quality features such as strategically positioned gas-permeable walls and optimized channel configurations. These localized design elements ensure uniform gas distribution to different regions of the catalytic bed while minimizing flow path length and pressure drop.
4Loss of energy
If heat exchanger is integrated inside reactor, then heat recovery is improved, but device complexity increases
Solution Approach 1:
The heat exchanger is integrated into the combined collector/distributor member, merging heat recovery functionality with the gas collection and distribution system. This integration allows heat exchange to occur within the existing reactor structure without requiring separate heat exchanger components, thereby improving heat recovery efficiency while minimizing additional complexity.
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 design enables efficient inter-cooling and heat recovery in axial reactors, maintaining uniform gas distribution and catalyst utilization, while being compact, low-cost, and facilitating revamping of existing reactors.
Implementation Method 1
at least one heat exchanger between the two beds. A gaseous flow exiting the first catalytic bed is heated or cooled in the heat exchanger
Implementation Method 2
catalytic beds including at least one first catalytic bed and a second catalytic bed operating in series with axial flow
Implementation Method 3
the chemical reactions involved are exothermic, which means that the gaseous flow heats up significantly when passing through each catalytic bed
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Axial reactor for exothermic or endothermic chemical reactions, comprising at least a first catalytic bed (3) and a second catalytic bed (4) operating in series and at least one heat exchanger (5) between the two catalytic beds, wherein the first catalytic bed has a collector bottom(6) having a box-like structure with flat and parallel walls,which are gas-permeable,and a plurality of parallel channels (15, 16) defined between the walls, wherein a first series of said channels collects the gaseousflow exitingthe catalytic bed and passing through the first wall, said gaseous flow is directed towards the heat exchanger, and the flow exitingthe exchanger is directed towards the second catalytic bed via a second series of said channels of the collector bottom.