Three-Phase Reactor Distribution Device for Uniform Phase Mixing
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Solution Overview
Problem
Large industrial reactors face challenges in achieving uniform distribution of liquid and gaseous phases over a fixed catalyst bed, leading to unsatisfactory conversions and selectivities in three-phase reactions, particularly in reactors with diameters greater than 0.5 meters.
Innovation Solution
A reactor design featuring a mixing and distribution device with a trough distributor and a distributor plate equipped with vertical nozzles, where the outlet tubes of the trough distributor extend below the surface of the liquid on the distributor plate, ensuring uniform introduction of the liquid phase and controlled entry of the gaseous phase, maintaining optimal liquid distribution across varying feed rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional distributor devices are used in large industrial reactors, then the reactor can be operated, but uniform distribution of liquid and gaseous phases is not achieved, leading to unsatisfactory conversions and selectivities
Solution Approach 1:
The distributor device is segmented into multiple functional components: a distributor plate with numerous small openings (10-100 mm) for gas distribution, trough distributors for liquid distribution, and optional mixing elements. This segmentation allows each component to optimize its function, creating uniform phase distribution across the entire reactor cross-section even in large reactors with diameters greater than 0.5 meters
Solution Approach 2:
The distributor plate provides locally optimized gas distribution through its specific opening pattern and size, while trough distributors provide locally optimized liquid distribution. This local quality optimization ensures that both phases are uniformly distributed at every location across the reactor bed, achieving high conversion and selectivity throughout the entire reactor volume
2Productivity
If the reactor diameter is increased for industrial application, then production capacity is improved, but uniform distribution of phases becomes more difficult to achieve
Solution Approach 1:
The distributor device is designed as a universal system that can be effectively applied to reactors of various sizes, including large industrial reactors with diameters greater than 0.5 meters. The combination of distributor plate, trough distributors, and mixing elements creates a multi-functional system that maintains uniform phase distribution regardless of reactor scale, enabling both high production capacity and uniform phase distribution
3Device complexity
If adiabatic operation is used to simplify the reactor design, then the structure is simpler, but temperature homogeneity deteriorates due to heat of reaction effects
Solution Approach 1:
The distributor device with its optimized opening patterns and mixing elements creates self-service conditions for temperature homogeneity. The uniform distribution of both phases ensures even heat generation throughout the catalyst bed, and the mixing elements promote local circulation that prevents hotspot formation, maintaining temperature homogeneity without requiring complex external cooling systems
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 configuration ensures uniform distribution of both phases, enhancing conversion and selectivity in large reactors, with improved temperature homogeneity and extended catalyst life, as demonstrated by increased conversion and selectivity in selective hydrogenation processes.
Implementation Method 1
a mixing and distribution device with a trough distributor for the liquid phase having trough-shaped channels and outlet tubes in the trough-shaped channels for the liquid phase and a distributor plate which is arranged with a spacing below the trough distributor and in which vertical nozzles having one or more openings for entry of the gaseous phase and one or more openings, which are arranged below the openings for entry of the gaseous phase, for entry of the liquid phase into the nozzles are installed
Implementation Method 2
the number and size of the openings for entry of the liquid phase being designed so that, at a predetermined liquid feed rate, the surface of the liquid on the distributor plate is established below the openings for entry of the gaseous phase and above the openings for entry of the liquid phase
Data Source
AI summary
A reactor for carrying out a three-phase reaction of a liquid phase, a gaseous phase, and a catalyst over a fixed catalyst bed is disclosed. The liquid and gaseous phases are passed through the reactor via a mixing and distribution device positioned over the fixed catalyst bed. The mixing and distribution device includes a trough distributor for the liquid phase, having trough-shaped channels, outlet tubes in the trough-shaped channels for the liquid phase, a distributor plate below the trough distributor, and vertical nozzles, having one or more openings for the gaseous phase and one or more openings, arranged below the openings for the gaseous phase. For entry of the liquid phase, the nozzles are installed so that, at a predetermined liquid feed rate, the surface of the liquid on the distributor plate is below the openings for the gaseous phase and above the openings for the liquid phase.