Refractory Flow Disruptors for Riser Reactor Mixing
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Solution Overview
Problem
In catalytic cracking riser reactors, non-uniform mixing of feedstock and catalyst due to temperature differentials and reactor slip leads to reduced reaction efficiency and yield, with existing solutions like baffles facing issues of erosion, corrosion, and mechanical stress.
Innovation Solution
A continuous refractory lining with flow disruptors extending inward from the reactor wall, disrupting flow patterns and enhancing mixing, while providing thermal and abrasion resistance, and mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If metal baffles or contact devices are used to create turbulence and improve mixing, then mixing uniformity is improved, but erosion and corrosion resistance deteriorates
Solution Approach 1:
The patent uses refractory material flow disruptors that are sacrificial and can be easily replaced. These flow disruptors are designed to erode and wear down over time, protecting the more expensive metal reactor and baffle structures. The refractory material serves as a consumable component that absorbs the erosive and corrosive effects, extending the life of the underlying metal structure.
Solution Approach 2:
The patent employs composite construction by lining the metal reactor and baffles with refractory materials. This composite structure combines the structural strength and thermal resistance of refractory materials with the mechanical strength of metal substrates. The refractory coating provides erosion and corrosion protection while the metal structure provides structural integrity.
2Stability of the object's composition
If metal baffles are used to improve mixing, then turbulence is increased, but mechanical stress and temperature gradient damage worsens
Solution Approach 1:
The refractory flow disruptors are designed as sacrificial components that can withstand thermal cycling and mechanical stress without compromising the underlying metal structure. They absorb the thermal gradients and mechanical stresses, protecting the metal baffles from thermal fatigue and mechanical failure.
Solution Approach 2:
The refractory material acts as an intermediary layer between the hot process materials and the metal baffle structure. This intermediate layer protects the metal from direct exposure to extreme temperatures and thermal cycling, reducing thermal stress and preventing condensation of reactants on the metal surface.
3Productivity
If conventional baffles are used to disrupt flow patterns, then mixing is improved, but erosion at baffle locations worsens
Solution Approach 1:
The refractory flow disruptors are sacrificial components designed to erode in place of the metal reactor walls and baffle structures. They are positioned at locations where erosion is most severe and serve as a protective barrier, absorbing the erosive impact of the fluidized catalyst and process materials.
Solution Approach 2:
The patent converts the harmful erosive forces into a beneficial protective mechanism. The refractory flow disruptors are deliberately positioned to intercept and absorb the erosive impact of the fluidized bed materials, transforming the harmful erosion into a controlled wear pattern that protects the underlying metal structure from damage.
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 solution improves reaction efficiency by mitigating reactor slip, increasing conversion, and offering corrosion and thermal stability, reducing mechanical failures and heat transfer issues.
Implementation Method 1
flow disruptors that extend inward into the reactor interior and disrupt flow patterns of the feedstock and catalyst
Implementation Method 2
A continuous refractory lining is on the reactor wall
Implementation Method 3
The riser creates a highly corrosive and erosive environment that combines high temperatures and a high flow rate of chemically active materials
Data Source
AI summary
An embodiment of the invention includes a riser reactor for reacting a feedstock and catalyst. The riser reactor wall defines an interior. A continuous refractory lining is attached to the reactor wall and defines a plurality of flow disruptors that extend inward from the wall into the reactor interior and disrupt flow patterns of the feedstock and catalyst.