Distribution Tray with Deflector Cone for Reactor Charge
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Solution Overview
Problem
Existing devices for distributing mixed liquid and gaseous phases in descending-flow reactors face challenges in maintaining uniform distribution and preventing phase separation, leading to inefficient exothermic reactions and catalyst deactivation due to preferential flows and hot spots.
Innovation Solution
A device comprising a flat tray with drainage tubes and a metal rod connected to a deflector cone, which directs the mixed charge to the periphery of the tray, ensuring even distribution by allowing gas to flow laterally and liquid to drain through orifices, promoting prolonged contact and uniform distribution onto the catalyst beds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If simple perforated plates are used as distribution trays, then the device complexity is low, but the distribution uniformity and phase mixing efficiency are insufficient
Solution Approach 1:
The distribution tray is segmented into multiple functional zones: a perforated plate section for initial liquid distribution, a baffle wall system for flow direction control, and a lower distribution plate for final charge allocation. This segmentation allows each zone to perform a specific function, improving overall distribution uniformity while maintaining reasonable structural complexity.
Solution Approach 2:
Baffle walls are introduced as intermediary elements between the upper and lower distribution plates. These baffles mediate the flow path of the liquid-gas mixture, forcing it to change direction and distribute more uniformly across the catalyst bed, thereby enhancing charge distribution without requiring complex mechanical components.
2Device complexity
If the charge is injected directly onto the catalyst bed, then the device complexity is minimal, but preferential flows and hot spots form causing catalyst deactivation
Solution Approach 1:
The charge injection system is divided into multiple distribution plates positioned at different heights, with the first plate located 0.5-2.0 meters above the catalyst bed and the second plate closer to the bed surface. This vertical segmentation allows progressive distribution of the charge, preventing direct impact and preferential flow formation, thereby protecting catalyst activity stability.
Solution Approach 2:
The upper distribution plate performs preliminary distribution of the liquid-gas charge before it reaches the catalyst bed. By pre-distributing the charge at a higher position, the system prevents concentrated flow paths and hot spot formation, ensuring more uniform catalyst utilization and extending catalyst life.
3Speed
If the liquid phase is allowed to flow directly down the reactor, then the fluid flow efficiency is high, but uniform distribution onto the catalyst surface cannot be achieved
Solution Approach 1:
The distribution system utilizes the vertical dimension by positioning distribution plates at different heights (0.5-2.0 meters above the catalyst bed). This vertical arrangement transforms the flow path from a simple vertical drop into a multi-level distribution system, allowing the liquid to gain velocity while still achieving uniform surface distribution through gravitational spreading between plates.
Solution Approach 2:
The multi-level plate system ensures continuous distribution action throughout the vertical flow path. The liquid-gas mixture is continuously redistributed as it passes between plates, maintaining distribution uniformity throughout the reactor height rather than only at a single point, thereby sustaining effective catalyst contact along the entire flow path.
4Stability of the object's composition
If the gaseous phase and liquid phase are not well-mixed, then the phase separation occurs naturally, but the stoichiometric ratio of reagents cannot be maintained
Solution Approach 1:
Baffle walls serve as intermediary structures that force intimate contact between the liquid and gaseous phases during flow. By directing the phases through restricted pathways between baffles, the system promotes continuous mixing and mass transfer, maintaining the required stoichiometric ratio despite the natural tendency toward phase separation.
Solution Approach 2:
The system utilizes the hydraulic flow characteristics of the liquid-gas mixture to promote phase mixing. The flow regime is controlled to maintain a dispersed phase distribution, where gas bubbles are carried through the liquid phase and vice versa, ensuring continuous contact and stoichiometric ratio maintenance throughout the reactor.
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 enhances the homogeneity of the charge and improves the distribution uniformity, reducing catalyst deactivation and maintaining the stoichiometric ratio of reagents, resulting in more efficient exothermic reactions and prolonged catalyst life.
Implementation Method 1
allowing gas to flow laterally and liquid to drain through orifices
Implementation Method 2
directs the mixed charge to the periphery of the tray, ensuring even distribution
Implementation Method 3
promoting prolonged contact and uniform distribution onto the catalyst beds
Data Source
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AI summary
The present invention relates to a device and respective process for distribution of mixed charges comprising a flat tray in the form of a disc drained by a series of drainage tubes located above the surface cf fixed beds of catalysts, capable of promoting the homogenisation and distribution of charges by means of said device. Such drainage tubes mounted in said manner have the objective of restricting and reorienting the flow of mixed charges, multiplying the points whereon they fall, principally of the liquid phase, onto said beds of catalysts. For the purpose of doing so said drainage ducts, being segments of tubes, distributed on the entire surface of said tray possess caps affixed at the upper extremity thereof impeding the direct flow of charge onto the bed of catalyst, creating a reservoir of liquid on the tray, subsequently being drained down such device in a more controlled manner.