Rotary Reactor Disk Configuration for Continuous Granular Flow
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Solution Overview
Problem
Existing rotary tube reactors operate as batch systems, limiting continuous processing and controlling the flow of granular material, which restricts production rates and efficiency.
Innovation Solution
A continuous rotary reactor vessel design with a first and second disk configuration, featuring a material feed opening and discharge openings to control the flow of granular product, allowing for a controlled depth of dead bed accumulation and continuous processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a batch reactor system is used with disks to restrict ambient atmosphere and control grain flow, then the reaction zone can be properly maintained and grain movement controlled, but the production rate is limited and processing is intermittent
Solution Approach 1:
The patent transforms the batch reactor operation into continuous operation by modifying the disk structure. The first disk includes a material feed opening that continuously introduces granular material into the reaction zone, while the second disk includes discharge openings that continuously remove processed material. This eliminates the intermittent loading and unloading cycles of batch operation, enabling continuous processing and significantly increasing productivity.
Solution Approach 2:
The reactor is divided into distinct functional zones using two disks: an inlet zone, a reaction zone, and a discharge zone. The first disk segments the inlet zone from the reaction zone with a material feed opening, while the second disk segments the reaction zone from the discharge zone with discharge openings. This segmentation allows each zone to operate continuously with its specific function, maintaining reaction conditions while enabling continuous material flow through the system.
2Productivity
If the tube is rotated to overcome grain angle of repose and produce gravity flow, then gas-to-grain contact is facilitated, but control over grain movement and residence time is limited
Solution Approach 1:
The disks introduce local quality variations in the granular material flow path. The material feed opening in the first disk and the discharge openings in the second disk create localized control points where material entry and exit are precisely managed. This allows different regions of the reaction zone to have different material residence times and flow characteristics, enabling better control over grain movement while maintaining continuous rotation for gas-to-grain contact.
Solution Approach 2:
The continuous flow system with controlled material feed and discharge openings creates a feedback mechanism where material residence time in the reaction zone is regulated. The balance between material introduction rate through the feed opening and removal rate through discharge openings, combined with rotational speed, provides controlled grain movement and adjustable residence time, optimizing both throughput and reaction completeness.
3Productivity
If feed flaps are oriented to scoop granular material into the reaction zone during rotation, then continuous material introduction is achieved, but complex flap mechanisms are required
Solution Approach 1:
The patent extracts the material introduction function from complex mechanical flap mechanisms and implements it through simple geometric openings in the disks. The material feed opening in the first disk and discharge openings in the second disk provide continuous material flow through the reaction zone during rotation without requiring movable flaps or complex actuation mechanisms. This simplifies the device while achieving continuous material introduction.
4Reliability
If the reaction zone is loaded with granular material until a desired grain bed is achieved, then proper reaction conditions are established, but the system operates in batch mode with limited production rate
Solution Approach 1:
The patent enables continuous maintenance of proper reaction conditions by continuously introducing material through the feed opening and removing processed material through discharge openings. The reaction zone maintains a stable grain bed similar to batch operation, but material flow through the zone is continuous rather than intermittent. This allows the system to achieve both reliable reaction conditions and high production rates simultaneously.
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
Enables continuous processing with improved reaction efficiency and higher throughput by controlling the flow of granular material, increasing the depth of material in the reaction zone and optimizing production rates.
Implementation Method 1
the rotation overcomes the grain's angle of repose and thereby produces gravity flow through the tube
Implementation Method 2
the rotation overcomes the grain's angle of repose
Implementation Method 3
rotation facilitates gas-to-grain contact by the overturning action it provides
Data Source
AI summary
A continuous reactor vessel for a rotary reactor having a first disk and a second disk separating three zones wherein the first disk includes a material feed opening spaced from its peripheral edge by an inlet peripheral spacing and configured to receive a material inlet tube, the second disk including an axial extension spaced from the second peripheral edge having at least one axially extending side wall and an end cap with at least one reaction zone discharge opening in the extension. The at least one opening allowing for a continuous and controlled reactor discharge rate of the associated granular product from the reaction zone into the discharge zone, the discharge opening being spaced from the second peripheral edge by an outlet peripheral spacing such that the peripheral spacings define a controlled depth of a dead bed accumulation of the associated granular product in the reaction zone.