Reactor Vortex Mixing for Uniform Catalyst Concentration

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Solution Overview

Problem

Existing laboratory-scale testing units for catalysts in catalytic cracking processes face challenges in simulating conditions effectively, particularly in maintaining uniform reactant concentration and mechanical stability, often leading to vortex formation and compromised apparatus stability.

Innovation Solution

A reactor design featuring a confined vessel with a support assembly and basket forming an inverse frustoconical shape, promoting fluid vortex formation, and a circulating device that continuously circulates fluid through both upflow and downflow zones, ensuring uniform reactant concentration and enhanced mixing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If high impeller speeds are used to achieve intense mixing and uniform reactant concentration, then mixing efficiency is improved, but mechanical stability of the apparatus is compromised

Engineering Contradiction:

Improvemixing efficiencyVSAvoidmechanical stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The basket and support assembly are configured to define an inverse frustoconical shape, which promotes the formation of a fluid vortex within the downflow zone. This curved geometric design enables effective fluid mixing and circulation without requiring high impeller speeds, thereby maintaining mechanical stability while achieving intensive mixing through vortex-driven flow patterns

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The system utilizes fluid circulation through the downflow and upflow zones to achieve mixing, replacing reliance on high-speed mechanical impeller rotation. The fluid dynamics created by the inverse frustoconical geometry generate vortex flows that provide intensive mixing action while reducing mechanical stress on the apparatus components

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Reliability

If baffles are positioned within the downflow zone to reduce and disturb fluid flow, then vortex formation is prevented, but device complexity increases

Engineering Contradiction:

Improvevortex controlVSAvoidapparatus structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The inverse frustoconical shape defined by the basket and support assembly inherently promotes controlled vortex formation within the downflow zone, eliminating the need for additional baffles or flow-disturbing elements. The curved geometry naturally guides fluid flow patterns to achieve desired mixing and circulation while maintaining apparatus simplicity

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The design removes the need for separate baffle components by integrating vortex-promoting functionality directly into the geometric configuration of the basket and support assembly. This extraction of the vortex control function from auxiliary components to the primary structure simplifies the overall device while maintaining effective fluid circulation

Inventive Principle:

Principle #2Taking out (Extraction)

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 design achieves intense gas mixing and particle fluidization, maintaining uniform reactant concentration and improving mechanical stability, allowing for accurate catalyst testing and reaction modeling with increased gas flow and efficient product analysis.

Implementation Method 1

an upflow zone defined between the inlet screen and outlet screen, the inlet screen and the outlet screen containing a quantity of particulate catalyst, a circulating device positioned above said upflow zone and configured to continuously circulate fluid upwardly though said upflow zone and downwardly through said downflow zone

Methodology Applied

Scientific EffectFluidization: Fluidisation

Implementation Method 2

the support assembly and the basket configured to promote the formation of a fluid vortex within a portion of the downflow zone

Methodology Applied

Scientific EffectVortex formation: Vortex Ring

Data Source

PatentUS10220363B2Reactor and multifunctional riser and downer simulator incorporating the same

Publication Date: 2019.03.05 UNIVERSITY OF WESTERN ONTARIO

AI summary

A reactor comprises a reactor vessel defining a confined reactor volume, a support assembly extending about a periphery of the confined reactor volume, a basket positioned within the reactor vessel and supported by the support assembly, the basket having an interior surface and an exterior surface, a downflow zone being defined between the exterior surface of the basket and an interior surface of the confined reactor volume, an inlet screen positioned adjacent to one end of the interior surface and an outlet screen positioned adjacent to an opposite end of the interior surface, an upflow zone defined between the inlet screen and outlet screen, the inlet screen and the outlet screen containing a quantity of particulate catalyst, and a circulating device positioned above said upflow zone and configured to continuously circulate fluid upwardly though said upflow zone and downwardly through said downflow zone, the support assembly and the basket configured to promote the formation of a fluid vortex within a portion of the downflow zone.