Ring-Pipe Gas Distributor for Uniform Bubble Column Mixing
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Solution Overview
Problem
Existing gas distributors in bubble column reactors suffer from non-uniform reactant distribution, creation of dead zones, and improper mixing, which adversely affect conversion levels and product selectivity in slurry hydrocracking reactions.
Innovation Solution
A gas and liquid distributor system comprising a pre-distributor plate and ring-shaped pipes with alternate nozzle directions and caps to break large gas bubbles into smaller ones, promoting uniform gas distribution and enhanced mixing, thereby eliminating dead zones and improving heat and mass transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional gas distributors are used in bubble column reactors, then the structure is simple, but non-uniform reactant distribution and dead zones occur
Solution Approach 1:
The gas distributor is divided into multiple functional components: a pre-distributor plate with multiple outlets positioned at different locations, and a main distributor positioned above it. This segmentation allows each component to handle specific aspects of gas distribution, achieving uniform reactant distribution throughout the reactor while maintaining reasonable structural complexity through modular design.
Solution Approach 2:
The invention introduces a vertical dimension to gas distribution by positioning the pre-distributor plate below the main distributor at different heights. Gas is introduced through the pre-distributor plate first, then distributed further by the main distributor above it, creating a multi-level distribution system that eliminates dead zones and ensures uniform reactant distribution throughout the three-dimensional reactor volume.
2Ease of operation
If large gas bubbles are introduced into the reactor, then the gas distribution system is simple, but mixing is improper and dead zones are created
Solution Approach 1:
The gas distribution function is segmented between the pre-distributor plate and main distributor. The pre-distributor plate breaks up large gas bubbles into smaller bubbles through its multiple outlets positioned at different locations, while the main distributor further distributes the gas uniformly. This segmentation transforms a simple gas introduction system into an effective mixing system that eliminates dead zones.
Solution Approach 2:
The pre-distributor plate performs preliminary gas distribution and bubble breaking before the gas reaches the main distributor. By pre-breaking large bubbles into smaller ones and distributing them across multiple outlets at different positions, the system prepares the gas for more effective final distribution and mixing, improving overall mixing quality without complicating the main distributor design.
3Productivity
If conventional single-level distribution is used, then the device structure is simple, but conversion levels are adversely affected
Solution Approach 1:
The invention transitions from a single-level gas distribution system to a multi-level system with the pre-distributor plate positioned below the main distributor at different vertical heights. This dimensional change ensures comprehensive gas distribution throughout the reactor volume, improving contact between reactants and catalyst in slurry hydrocracking, thereby enhancing conversion levels while maintaining manageable structural complexity through standardized component design.
Solution Approach 2:
The gas distribution function is segmented into two stages: preliminary distribution through the pre-distributor plate with multiple outlets at different positions, and final distribution through the main distributor above it. This segmentation ensures thorough mixing and reactant distribution required for high conversion levels in slurry hydrocracking, while each segment remains structurally simple and manufacturable.
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 system ensures uniform gas distribution, reduces dead zones, and enhances mixing, leading to higher reaction efficiency, better conversion, and optimal dissolution of gas in the liquid phase for improved yield and near isothermal conditions.
Implementation Method 1
A gas distributor is used to inject the gas into the slurry. The gas distributor governs the bubble size distribution and rise velocities of the gas bubbles
Implementation Method 2
Bubble column reactors are preferred for conducting slurry hydrocracking reactions owing to their excellent heat and mass transfer characteristics
Implementation Method 3
A gas and liquid distributor system comprising a pre-distributor plate and ring-shaped pipes with alternate nozzle directions and caps to break large gas bubbles into smaller ones
Implementation Method 4
The gas distributor governs the bubble size distribution and rise velocities of the gas bubbles
Implementation Method 5
enhanced mixing, thereby eliminating dead zones and improving heat and mass transfer
Implementation Method 6
Bubble column reactors are preferred for conducting slurry hydrocracking reactions owing to their excellent heat and mass transfer characteristics
Implementation Method 7
optimal dissolution of gas in the liquid phase for improved yield and near isothermal conditions
Data Source
AI summary
Bubble column reactor assemblies are provided, an assembly (100) comprising: a reactor vessel (102) comprising a bottom end and a top end. A pre-distributor plate (114) having a bottom surface and a top surface, disposed in the 5 reactor vessel (102) such that the bottom surface faces the bottom end of the reactor vessel (102). A gas distributor (106) is disposed below the pre-distributor plate (114) to receive and inject gas into a liquid prior to distribution of gas and liquid by the pre-distributor plate (114). The gas distributor (106) comprises: a common manifold (108) and a plurality of ring-shaped pipes disposed along a length of the 10 common manifold (108); and a plurality of nozzles disposed along an outer circumference of each ring-shaped pipe of the plurality of ring-shaped pipes to inject gas and create vortexes for uniform distribution of the gas in the liquid.