Fluid Catalytic Reactor Transition Portion Scaling
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Solution Overview
Problem
Scaling up fluid catalytic reactors is challenging due to changes in reaction parameters that affect product output, particularly due to alterations in the transition portion's height and shape, which impact fluid velocity profiles.
Innovation Solution
A method for scaling up fluid catalytic reactors involves maintaining the height of the transition portion at least 70% of the riser's width and modifying its shape to match the template reactor's velocity profile, ensuring similar performance by maintaining the ratio of cross-sectional areas and adjusting the scale-up factor to maintain consistent fluid dynamics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the cross-sectional area of the reactor is increased by a scale-up factor to scale up the fluid catalytic reactor, then the reactor capacity is improved, but the transition portion height increases which changes the velocity profile and affects product output
Solution Approach 1:
The patent applies parameter changes by modifying the transition portion geometry parameters. Specifically, it controls the transition portion height to be within 0.5 to 1.5 times the riser diameter, and sets the taper angle between 15-45 degrees. These parameter adjustments allow the reactor to be scaled up while maintaining similar velocity profiles and fluid dynamics characteristics, thus preserving product output despite increased reactor capacity
Solution Approach 2:
The patent applies local quality by focusing on the specific geometry of the transition portion rather than uniformly scaling all dimensions. By locally optimizing the transition portion height and taper angle independently from other reactor dimensions, the patent maintains favorable fluid flow characteristics in this critical region while still achieving overall reactor capacity increase through scale-up
2Stability of the object's composition
If the transition portion height is increased to maintain its general shape during scaling up, then the structural consistency is improved, but the velocity profile changes leading to altered product output
Solution Approach 1:
The patent resolves this contradiction by changing the interpretation of shape consistency from maintaining absolute dimensions to maintaining dimensionless geometric parameters. By controlling the height-to-diameter ratio and taper angle within specific ranges, the patent achieves shape consistency that preserves velocity profiles while allowing the transition portion to scale appropriately with reactor size
Solution Approach 2:
The patent transitions from thinking about transition portion geometry in absolute terms to dimensionless terms. By expressing the height as a multiple of riser diameter (0.5-1.5 times) and the taper angle in degrees (15-45), the patent creates a scalable geometric framework that maintains dynamic similarity across different reactor sizes
3Productivity
If the scale-up factor is applied to increase reactor size, then the production capacity is improved, but the reaction parameters change affecting fluid dynamics and product output
Solution Approach 1:
The patent applies parameter changes by establishing specific geometric parameter ranges for the transition portion (height: 0.5-1.5 times riser diameter, taper angle: 15-45 degrees) that remain consistent during scale-up. These parameter constraints ensure that fluid dynamics characteristics are preserved across different reactor sizes, maintaining reaction reliability while increasing production capacity
Solution Approach 2:
The patent uses the template reactor's successful geometric configuration as a model to be copied and scaled. By replicating the transition portion geometry principles (height-to-diameter ratio and taper angle) from the template reactor and applying them to the scaled-up reactor, the patent ensures that the larger reactor reproduces the fluid dynamics and reaction performance of the smaller successful design
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 approach allows for successful scaling of fluid catalytic reactors while maintaining similar product output and fluid velocity profiles, avoiding the pitfalls of increased transition portion height or reduced width, thus ensuring consistent reactor performance.
Implementation Method 1
the transition portion may taper inward from the lower reactor portion to the riser such that the fluid path from the lower reaction portion to the riser is narrowed over the height of the transition portion
Implementation Method 2
A fluid catalytic reactor may convert a feedstock chemical into the product chemical by contact with a fluidized particulate catalyst
Implementation Method 3
the spent catalyst may be transferred to the regeneration unit to be regenerated, thus increasing its activity from its spent state
Data Source
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AI summary
According to one or more embodiments of the present disclosure, a fluid catalytic reactor may be scaled-up by a method that includes one or more of constructing, operating, observing, or obtaining data related to a template fluid catalytic reactor comprising a template riser, a template lower reactor portion, and a template transition portion connecting the template riser and the template lower reactor portion. The method may further include one or more of constructing or operating a scaled-up fluid catalytic reactor based on the template fluid catalytic reactor.