Reactor Inlet Equalizer and Distributor for Vapor Flow
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Solution Overview
Problem
Existing reactor inlet designs often result in uneven distribution of reactant vapors due to higher velocities around bends, leading to hot spots and underutilization of catalyst, which reduces productivity and causes premature catalyst aging.
Innovation Solution
A reactor inlet system with an equalizer section that minimizes obstruction and balances vapor velocities using flange and ring plates, and a distributor section with deflector rings and nozzles to ensure uniform vapor distribution across the reactor vessel, supported by a perforated fixed valve tray for even gas flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If baffles and vanes are used to create back pressure on the inlet stream, then reactant distribution is improved, but pressure drop increases
Solution Approach 1:
The inlet system is segmented into multiple functional sections: an equalizer section with multiple equalizer plates (first, second, third equalizer plates) spaced at different heights, and a distributor section with distributor plates. Each segment performs a specific function in progressively equalizing and distributing the vapor flow, achieving uniform distribution without requiring high back pressure.
Solution Approach 2:
The invention introduces vertical dimensionality by spacing equalizer plates at different heights within the inlet system. This multi-level arrangement allows vapor to be equalized at multiple vertical levels simultaneously, creating uniform distribution across the reactor cross-section without relying on high pressure drops that would be needed with single-plane baffles.
2Manufacturing precision
If an inert support bed with thick layer is provided to create tortuous paths, then mixing and back pressure are improved, but reactor volume increases
Solution Approach 1:
The invention extracts the flow-distribution function from the catalyst bed region and places it in a dedicated inlet system. By taking out the distribution function to the inlet section, the catalyst bed can be thinner and more compact, reducing overall reactor volume while achieving the same distribution effect that would otherwise require a thick inert support bed.
Solution Approach 2:
The equalizer and distributor plates perform the mixing and distribution action preliminarily, before the vapor enters the catalyst bed. This preliminary distribution eliminates the need for a thick inert support bed to perform the same function downstream, thereby reducing the volume required for the catalyst bed and overall reactor.
3Ease of manufacture
If conventional inlet designs are used, then construction is simple, but vapor distribution becomes uneven causing hot spots and catalyst underutilization
Solution Approach 1:
The invention merges the equalization function and distribution function into a single integrated inlet system. The equalizer plates and distributor plates work together in sequence within one compact assembly, achieving both uniform vapor distribution and simple construction without requiring separate complex systems for each function.
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 solution achieves a balanced vapor distribution across the reactor vessel, optimizing catalyst usage, increasing productivity, and extending catalyst run time while maintaining low pressure drop.
Implementation Method 1
the equalizer section of the reactor inlet system dampens asymmetrically distributed velocities of vapor entering the reactor inlet system to provide the distributor section with a generally symmetrically balanced velocity profile across the generally cylindrical body
Implementation Method 2
the distributor section distributes the flow of vapor outwardly and downwardly from the outlet end of the inlet system such that vapor flow is generally uniform across the shell into which vapor is arranged to be delivered
Implementation Method 3
A catalyst bed is supported by a perforated fixed valve tray having opening arranged to distribute the flow of gases through the perforated fixed valve tray more evenly across the interior space within the shell
Data Source
AI summary
The invention relates to equalizing and distributing vapor more evenly across the interior space of a reactor vessel utilizing an equalizing section and distributor section at the inlet end and a fixed valve tray at the bottom of the reactor to equalize and distribute the flow.