Distributor Plate for Fixed Bed Reactor Clogging
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Solution Overview
Problem
Existing filtration and distribution plates for fixed bed catalytic reactors in trickle flow mode face issues with clogging, leading to imbalanced liquid flow and risk of damage during dismantling, particularly due to the integration of filtration and distribution functions, which complicates maintenance and operation.
Innovation Solution
A distributor plate with a separated filtration layer and distribution elements, where gas and liquid inlets are located outside the filtration layer, allowing for independent operation and easy maintenance, with a perforated support and protective sleeves to prevent clogging and facilitate disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the filtration function and distribution function are integrated in the same plate structure, then the device complexity is reduced, but the reliability decreases due to clogging risks and the ease of repair worsens because dismantling becomes difficult when chimneys are stuck to the catalytic bed
Solution Approach 1:
The invention divides the integrated plate into two separate components: a filtration plate with filtration layer and support, and a distribution plate with chimneys. This segmentation allows each component to perform its specific function independently, preventing clogging from affecting distribution and enabling separate maintenance of each element.
Solution Approach 2:
The filtration function is extracted from the distribution plate structure and implemented as a separate filtration plate positioned above the distribution plate. The filtration layer and support are taken out as independent elements that can be maintained separately from the distribution chimneys, resolving the clogging and dismantling issues.
2Device complexity
If the filtration layer is positioned directly above the distribution chimneys with inlets inside the filtration layer, then the device complexity is reduced, but the ease of operation deteriorates due to blockage risks and maintenance difficulties
Solution Approach 1:
The invention segments the plate configuration into distinct functional zones: the filtration plate with its support structure forms one segment, while the distribution plate with chimneys forms another. This spatial segmentation allows independent access and maintenance of each component without disrupting the other.
Solution Approach 2:
The filtration support acts as an intermediary element between the filtration layer and the distribution chimneys. It provides structural separation that prevents direct contact between the filtration layer and chimney inlets, allowing the filtration layer to be maintained or replaced without affecting the distribution system.
3Ease of repair
If multiple removable baskets containing filtration particles and catalyst particles are used on the distributor plate, then the ease of repair improves by facilitating fitting and dismantling, but the device complexity increases and productivity decreases due to large number of baskets requiring long fitting time
Solution Approach 1:
Instead of using multiple small baskets, the invention segments the filtration function into a single integrated filtration plate with a continuous filtration layer supported by a support structure. This reduces the number of separate components from many baskets to one unified assembly, significantly reducing fitting and dismantling time while maintaining ease of repair.
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
Ensures uniform gas-liquid distribution over the catalytic bed, maintains fluid flow balance, and simplifies fitting and dismantling by disconnecting filtration from distribution functions, reducing the risk of clogging and damage, while allowing for flexible liquid flow rate adjustments.
Implementation Method 1
a filtration layer (4) which is supported by said perforated support (3)... said filtration layer (4) being blocked by the various impurities recovered over time
Implementation Method 2
a perforated support (3) not covering the whole section of the reactor... said perforated support (3) being blocked by the various impurities recovered over time
Implementation Method 3
fixed bed reactor with a co-current downflow gas-liquid flow... liquid surface velocity in the range 0.1 cm/s to 1.5 cm/s
Data Source
AI summary
The present invention describes a distributor plate adapted to co-current downflow flows of gas and of liquid, more particularly in the “trickle” mode, said distributor plate integrating a filtration function separate from the distribution function.