Multi-bed Catalytic Reactor Mixing Device for Phase Separation
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Solution Overview
Problem
Current multi-bed hydroprocessing reactors face challenges in achieving effective mixing and reducing reactor volume, especially in situations where the fluid comprises both liquid and gas phases, which complicates mixing due to centrifugal and gravitational forces.
Innovation Solution
A new multi-bed reactor design with a cylindrical shape incorporates a mixing device mounted between two catalyst beds, featuring a support beam, support grid, divider plate, and pipe segments that form a circular or spiral shape for efficient fluid flow and mixing, while occupying minimal reactor space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mixing devices are installed in the quench section, then mixing effectiveness is improved, but the reactor volume occupied increases
Solution Approach 1:
The mixing device is divided into multiple sections (inlet section, mixing section, discharging section) with distinct functions. The inlet section collects fluid from the upper bed, the mixing section performs the mixing function with reduced volume, and the discharging section redistributes fluid to the lower bed. This segmentation allows each section to be optimized for its specific function while minimizing overall volume occupation.
Solution Approach 2:
The mixing device is nested within the existing quench section structure, utilizing the vertical space between catalyst beds. The support beams and grids are integrated into the reactor's structural framework, allowing the mixing device to occupy minimal additional volume while maintaining mixing effectiveness through the concentric circular flow path.
2Volume of stationary object
If the quench section height is reduced to save reactor volume, then reactor volume decreases, but mixing effectiveness may be compromised
Solution Approach 1:
The mixing device utilizes the radial dimension of the reactor by creating concentric circular flow paths. The inlet section receives fluid from the upper bed, the mixing section creates a high-velocity circular flow pattern that enhances mixing, and the discharging section redirects fluid to the lower bed. This dimensional approach allows effective mixing within a compact vertical height.
3Manufacturing precision
If distributor trays are designed to operate within narrow liquid depth limits, then distribution quality is improved, but flow parameter control becomes more difficult
Solution Approach 1:
The mixing section performs preliminary mixing and flow conditioning before the fluid reaches the distributor trays. By creating a controlled circular flow pattern and ensuring uniform liquid depth in the mixing section, the system prepares the fluid flow in advance, making it easier to control and distribute evenly across the distributor trays within their operational limits.
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 proposed solution achieves high-efficiency mixing and redistribution with minimal pressure loss and reduced reactor volume, allowing for easier installation, maintenance, and integration with other reactor internals.
Implementation Method 1
mixing of liquid and gas phases which challenges the mixing due to the influence of centrifugal and gravitational forces
Implementation Method 2
mixing of liquid and gas phases which challenges the mixing due to the influence of centrifugal and gravitational forces
Data Source
AI summary
The present invention relates to multi-bed catalytic reactor with a cylindrical shape comprising a mixing device mounted between two catalyst beds in the reactor, said mixing device comprises connected pipe segments forming mixing section and discharging section.