Screenless Reactor Secondary Containment for Catalyst Retention
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Solution Overview
Problem
Radial flow reactors face issues with corrosion and plugging of screens, leading to catalyst loss and increased costs due to the need for frequent replacements and downtime during operational changes and start-ups, where temperature and pressure fluctuations affect the containment of catalyst particles.
Innovation Solution
A screenless reactor design with a secondary containment system using a louvered screen affixed to a partition by standoff supports, where the screen has slots or openings sized less than 90% of the catalyst particles, preventing catalyst loss while allowing fluid flow, and a louvered partition with apertures covered by louvers to maintain a stable catalyst free surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a screen or mesh is used to hold catalyst particles in place, then catalyst containment is improved, but corrosion and plugging occur over time leading to catalyst loss and increased maintenance costs
Solution Approach 1:
The invention removes the screen or mesh component entirely from the reactor design, extracting the source of corrosion and plugging problems. Instead of using a screened surface to hold catalyst particles, the system relies on fluid dynamics and reactor geometry to contain catalyst while allowing continuous operation without screen replacement or cleaning
Solution Approach 2:
The invention changes the operating parameters by controlling fluid velocity and reactor configuration to achieve catalyst containment without physical screens. By adjusting flow rates and reactor dimensions, the system maintains catalyst containment through hydrodynamic control rather than mechanical barriers
2Loss of substance
If a screen with small apertures is used to prevent catalyst particle passage, then catalyst loss is reduced, but fluid flow is restricted and pressure drop increases
Solution Approach 1:
The screen component is completely removed from the system, eliminating the aperture restriction problem. Catalyst containment is achieved through alternative means that do not involve physical filtering, thereby maintaining full fluid flow capacity through the reactor bed
3Ease of manufacture
If a screenless reactor design is used to eliminate corrosion and plugging, then maintenance costs are reduced, but catalyst loss occurs during cooling and heating cycles
Solution Approach 1:
The invention implements preliminary containment measures by configuring reactor geometry and flow patterns before catalyst loss can occur during thermal cycles. The reactor design pre-establishes hydrodynamic conditions that prevent catalyst escape even during temperature fluctuations and operational changes
Solution Approach 2:
The system controls fluid velocity and reactor parameters to maintain catalyst containment during thermal cycles. By adjusting operating parameters during heating and cooling transitions, the invention prevents catalyst loss without requiring screens that would cause corrosion and plugging
Data Source
AI summary
A secondary containment system is used with a screenless reactor. The secondary containment system includes a screen sized to prevent the passage of catalyst particles, and is affixed to the screenless reactor with supports to hold the screen a desired distance from the reactor.