Ripple Packing Element for Gas-Solids Stripping
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Solution Overview
Problem
In Fluidized Catalytic Cracking (FCC) processes, existing structured packing elements face challenges such as lower stripping efficiency, gas and steam maldistribution, and higher steam usage, leading to inefficient catalyst regeneration and increased operating costs due to difficulties in controlling catalyst particle flow and preventing back-mixing and channeling in large volume fluidized beds.
Innovation Solution
The introduction of a ripple packing element with corrugated or ribbed planar stanchions arranged in alternating intersecting planes, forming a three-dimensional lattice configuration, which enhances gas and catalyst flow by creating angled channels that funnel particles into open areas, promoting radial mixing and counter-current fluidization, thereby improving stripping efficiency and reducing steam requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional structured packing elements are used in fluidized beds, then the device complexity is reduced, but stripping efficiency decreases and steam consumption increases
Solution Approach 1:
The patent transitions from conventional two-dimensional planar packing elements to three-dimensional ripple packing elements with corrugated surfaces. This dimensional enhancement creates additional flow paths and contact surfaces, improving gas-catalyst interaction and stripping efficiency while maintaining manageable structural complexity through modular design
Solution Approach 2:
The ripple packing elements incorporate corrugated surfaces with curved peaks and valleys instead of flat planes. These curved geometries promote turbulent flow patterns and enhance mixing between gas and catalyst particles, thereby improving stripping efficiency without requiring excessively complex structural arrangements
2Reliability
If conventional packing elements are used, then the structure is simpler, but gas and steam maldistribution occurs and channeling increases
Solution Approach 1:
The ripple packing elements feature locally varied geometries with peaks, valleys, and corrugated surfaces that create zones of different flow resistance. This local variation in structure promotes uniform gas and steam distribution by preventing channeling, as the complex local geometries redirect flow paths throughout the bed
Solution Approach 2:
The packing bed is segmented into multiple ripple packing elements with alternating orientations. This segmentation breaks up potential channeling paths and ensures that gas and steam flow is distributed uniformly across the entire bed cross-section, improving reliability of flow distribution
3Ease of operation
If higher steam to catalyst ratios are used to maintain fluidization, then catalyst fluidization is improved, but steam consumption increases and equipment load increases
Solution Approach 1:
The ripple packing elements create flow patterns that enhance natural gas-catalyst interaction and heat transfer. The corrugated surfaces promote self-fluidization of the catalyst bed through improved gas distribution and reduced channeling, allowing adequate fluidization at lower steam rates and reducing steam consumption
4Area of stationary object
If conventional packing elements are used, then the number of elements required is higher, but the contact area between gas and catalyst is insufficient
Solution Approach 1:
By transitioning to three-dimensional ripple packing elements with corrugated surfaces, the effective contact area between gas and catalyst is dramatically increased. The peaks, valleys, and ridges of the corrugated surfaces provide additional interaction surfaces without requiring a proportional increase in the number of packing elements
Solution Approach 2:
Multiple functional features (flow distribution, mixing enhancement, and contact surface provision) are merged into a single ripple packing element design. This integration achieves large gas-catalyst contact area while reducing the total number of discrete elements needed compared to conventional flat packing designs
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 ripple packing element increases stripping efficiency, reduces the number of elements needed for similar performance, and decreases steam consumption, achieving better contact between catalysts and fluids while minimizing back-mixing and channeling, resulting in improved catalyst regeneration and reduced operating costs.
Implementation Method 1
at least one gas stream flowing counter-currently to the solid particles causing fluidization of the solid particles within the ripple packing elements
Implementation Method 2
creating angled channels that funnel particles into open areas, promoting radial mixing and counter-current fluidization
Data Source
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AI summary
A device for the intimate mixing of solid particles and a gaseous medium within a gas-solid fluidized bed, comprising a plurality corrugated and/or ribbed planar stanchions arranged in alternating intersecting planes that provide a plurality of open spaces between or adjacent the alternating intersecting planar stanchions. The element has a three-dimensional lattice configuration and the corrugated and/or ribbed planar stanchions are formed from metal having peaks and valleys or ribs, such that the peaks and valleys or ribs are angled at less than 90 degrees from the fall-line of the planar stanchion when assembled into the element. The angled peaks and valleys or ribs form channels that enhance lateral movement of catalyst particles into the spaces between the stanchions to provide improved vapor/solids mixing and contact.