Rotary Disk Catalyst Feeder Pressure Control
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Solution Overview
Problem
Existing methods for controlling the feed rate of particulate materials, such as catalysts, in rotary disk feeders lack precise control over the speed of the metering disk and the pressure and flow rate of inert gas, leading to inconsistent catalyst delivery and potential reactor control issues.
Innovation Solution
A method involving a unit body metering disk with vertical passages, a drive mechanism, and a variable pressure and volume inert gas feed to the upper surface of the disk, allowing control over the speed of the disk, inert gas pressure, and flow rate to manage the particulate material feed effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a rotary disk feeder is used to handle particulate catalyst materials, then the feed rate can be controlled by rotating the disk, but the control precision over feed rate is insufficient leading to inconsistent catalyst delivery
Solution Approach 1:
The patent implements feedback control by monitoring the actual feed rate and adjusting the rotary disk speed and inert gas flow rate accordingly. The control system receives feedback on catalyst delivery consistency and modifies operating parameters to maintain precise feed rate control, resolving the contradiction between control precision and delivery consistency.
Solution Approach 2:
The patent changes multiple parameters simultaneously - rotary disk speed, inert gas pressure, and inert gas flow rate - to achieve precise control over catalyst feed rate. By coordinating adjustments across these parameters, the system achieves both high control precision and reliable consistent delivery, overcoming the limitations of single-parameter control.
2Productivity
If the rotary disk speed is increased to improve productivity, then more catalyst can be fed to the reactor, but the control over feed rate becomes less precise
Solution Approach 1:
The patent employs dynamic control where the rotary disk speed is continuously adjusted based on real-time feedback rather than operating at fixed high speeds. This allows the system to achieve high productivity when needed while maintaining precise control through active regulation, resolving the trade-off between productivity and control precision.
Solution Approach 2:
The control system monitors catalyst feed rate and provides feedback to adjust rotary disk speed dynamically. This feedback mechanism ensures that even at high productivity levels, the feed rate remains precisely controlled, overcoming the limitation that higher speeds reduce control precision.
3Reliability
If inert gas flow rate is increased to clear particulates from the feeder, then catalyst delivery consistency improves, but the system becomes more complex
Solution Approach 1:
The inert gas system serves multiple functions simultaneously: it clears particulates from the feeder, maintains consistent catalyst delivery, and provides a controlled atmosphere. By combining these functions into a single multi-functional system, the patent achieves improved reliability without proportionally increasing device complexity.
Solution Approach 2:
The patent merges the particulate clearing function with the catalyst delivery function by using the same inert gas flow path for both purposes. This integration reduces the number of separate systems needed, achieving consistent catalyst delivery while limiting the increase in overall system complexity.
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 ensures a consistent and controlled feed of catalysts to the reactor, improving the uniformity of catalyst delivery and reaction control by adjusting the speed and gas flow parameters within specific ranges.
Implementation Method 1
a variable pressure and volume feed for an inert compressed gas to the upper surface of said metering disk
Implementation Method 2
a method and apparatus for handling fluidizable finely divided solid materials
Implementation Method 3
a drive means; a bottom plate having at least one passage there through positioned to receive finely divided particulate material from said metering disk
Data Source
AI summary
The feed rate of a supported particulate catalyst through a unit body rotary disc catalyst feeder may be controlled by controlling the feed of nitrogen to the upper surface of the rotary disc.