Reactor Nozzle Cleaning Fluid Flow Distribution
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Solution Overview
Problem
Current batch-wise heterogeneous processing systems face challenges with uncontrolled wear of solid reaction members, complex cleaning processes, and inefficient loading and unloading, particularly in reactors with soft and compressible gels, leading to reduced reactor life and increased operational costs.
Innovation Solution
A reactor design featuring a cylindrical flow distributor with a top, bottom, and peripheral wall, allowing for controlled vortex creation to trap and release solid reaction members, along with a nozzle system for efficient cleaning, enabling speedy and thorough cleaning and repeated batch processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If solid reaction members are freely suspended and agitated in the fluid medium, then mixing and contact between phases is improved, but the solid reaction members are subjected to uncontrolled wear resulting in reduced life time
Solution Approach 1:
The reactor is divided into distinct functional zones: a suspension zone at the bottom for mixing and a separation zone above for settling. This segmentation allows intensive mixing only where necessary while providing a calm environment for the majority of the reaction volume, reducing unnecessary wear on solid reaction members.
Solution Approach 2:
The system uses periodic agitation cycles rather than continuous mixing. The agitator operates intermittently to achieve phase contact, then stops to allow settling. This periodic action reduces cumulative wear on solid reaction members while maintaining effective mass transfer during active mixing periods.
2Ease of operation
If filtration or sedimentation steps are added to separate phases after batch processing, then phase separation is improved, but the overall process complexity and time consumption increase
Solution Approach 1:
The reaction and separation functions are merged into a single reactor vessel. The reactor design incorporates both a suspension zone for reaction and a separation zone for settling, eliminating the need for separate filtration or sedimentation equipment. Phase separation occurs in-situ within the reactor through density-driven settling.
Solution Approach 2:
The system uses the inherent density difference between the fluid medium and solid reaction members to achieve automatic phase separation. The design requires no additional separation aids, filters, or complex separation mechanisms - the phases separate themselves through gravity settling in the designated separation zone.
3Productivity
If the concentration of solid reaction members is increased to improve reaction efficiency, then transformation rate is improved, but the risk of solid member destruction during agitation increases
Solution Approach 1:
Different regions of the reactor provide different hydrodynamic conditions: the suspension zone at the bottom provides gentle mixing suitable for high concentrations of soft gel members, while the upper separation zone provides a calm environment. This local differentiation of flow conditions allows high solid member concentrations without excessive mechanical stress.
Solution Approach 2:
The system dynamically adjusts the intensity and duration of agitation cycles based on the concentration of solid reaction members. For higher concentrations, the agitation is more gentle and shorter in duration, optimizing the balance between achieving adequate mixing for transformation and minimizing mechanical stress on the solid members.
4Ease of operation
If cleaning nozzle is inserted via man hatch and cleaning process is performed as GMP-process, then cleaning thoroughness is improved, but the cleaning time and operational costs increase significantly
Solution Approach 1:
The manual mechanical cleaning process is replaced with an automated fluid-based cleaning system. Cleaning fluid is pumped through distribution manifolds and sprayed onto internal surfaces using controlled spray patterns. This automated fluid cleaning achieves thorough GMP-compliant cleaning much faster than manual methods while maintaining documentation and consistency.
Solution Approach 2:
The cleaning system operates continuously with fluid circulation and recirculation. Cleaning fluid is pumped, sprayed, collected, filtered, and recirculated through the system in a continuous cycle, maximizing cleaning efficiency and minimizing the time required to achieve thorough cleaning compared to intermittent manual cleaning operations.
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 design facilitates faster and more efficient loading and unloading, reduces wear on solid reaction members, and simplifies the cleaning process, significantly saving time and costs compared to prior art systems.
Implementation Method 1
a flow distributor (1) rotating about a longitudinal centre axis (L1) of the flow distributor (1) thereby creating a vortex (V)
Implementation Method 2
at least one nozzle (15) arranged to direct a flow of a cleaning fluid in a direction towards a longitudinal centre axis (L2) of the flow distributor (1)
Data Source
AI summary
The invention refers to a reactor and a method respectively for performing, by means of solid reaction members, a biological or chemical transformation, or physical or chemical trapping from, or release of agents to, a fluidic media, and a subsequent cleaning of the reactor, said reactor comprising a vessel (11) in which a transformation device (100) has been mounted. The invention also refers to a reactor kit comprising such reactor. The reactor comprises at least one nozzle (15) arranged on the longitudinal inner wall of the vessel (11). The at least one nozzle (15) is arranged to direct a flow of a cleaning fluid (CF) in a direction towards a longitudinal centre axis (L1) of a flow distributor (1) arranged in the vessel (11).