Fluidized Bed Reactor Screw Conveyor Solid Circulation
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Solution Overview
Problem
Existing fluidized bed reactor systems require additional gas for solid conveyance, leading to increased costs and inefficiencies, especially at high temperatures and pressures, and are limited in height and volume due to the need for gas velocity and separate reactors for reactions and solid circulation.
Innovation Solution
Incorporating a screw conveyor that penetrates through the upper portion of the fluidized bed reactor to discharge solid particles externally, reducing the need for additional gas and enabling simultaneous reaction and solid conveyance, with a multi-stage configuration to enhance height and volume efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a fast fluidized bed is used for solid conveyance, then solid circulation capability is improved, but additional gas consumption increases and operational costs increase
Solution Approach 1:
The system divides solid circulation into two functional zones: the bubbling fluidized bed for reaction processes and the fast fluidized bed dedicated to solid conveyance. This segmentation allows each zone to operate at optimal gas velocities for its specific function, reducing overall gas consumption while maintaining effective solid circulation capability.
Solution Approach 2:
The bubbling fluidized bed serves dual purposes: it performs chemical reactions and simultaneously contributes to solid circulation. This multi-functionality reduces the need for additional gas that would otherwise be required if a separate system were used for both reaction and solid conveyance.
2Productivity
If gas velocity in the fast fluidized bed is increased to increase solid circulation amount, then solid conveyance efficiency is improved, but gas consumption and operational costs increase further
Solution Approach 1:
By separating the functions of reaction and solid conveyance into different bed zones, the system allows the fast fluidized bed to operate at high gas velocities for efficient solid circulation without the penalty of heating and pressurizing excess gas that would be required if all gas flow were directed through a single reactor volume.
Solution Approach 2:
The system utilizes different gas velocity parameters in different zones: lower gas velocities in the bubbling fluidized bed for reactions and higher gas velocities in the fast fluidized bed for solid conveyance. This parameter optimization allows efficient solid circulation while minimizing overall gas consumption and associated costs.
3Length of moving object
If the height for solid circulation is increased, then solid circulation capability is improved, but much more gas is required
Solution Approach 1:
The vertical structure is segmented into distinct functional zones with the bubbling fluidized bed at the lower portion for reactions and the fast fluidized bed above for solid conveyance. This segmentation enables efficient solid circulation over height without requiring excessive gas, as each zone contributes to the overall circulation process at its optimal operating conditions.
Solution Approach 2:
The system replaces the need for mechanical lifting or pumping mechanisms with a gas-driven fluidized bed system that uses gas-solid interactions to achieve solid circulation over height. This substitution eliminates the need for complex mechanical systems while efficiently handling vertical solid transport.
4Reliability
If two separate reactors are used for reactions and solid circulation, then reaction performance is improved, but reactor volume and system complexity increase
Solution Approach 1:
The system merges the reaction function and solid circulation function into a single integrated reactor structure. The bubbling fluidized bed performs chemical reactions while the fast fluidized bed section handles solid conveyance, eliminating the need for separate reactors and reducing overall system volume and complexity.
Solution Approach 2:
The integrated reactor design allows the same reactor volume to serve multiple functions: chemical reaction in the bubbling zone and solid circulation in the fast fluidized bed zone. This multi-functionality reduces the total reactor volume required compared to using separate dedicated reactors for each function.
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 solution reduces gas usage, allows for unencumbered solid particle circulation, and minimizes reactor volume by enabling efficient solid conveyance and reaction performance without the need for additional gas, thus lowering operational costs and increasing flexibility in high-temperature and high-pressure applications.
Implementation Method 1
a screw conveyor (30) configured to penetrate through an upper portion of the fluidized bed reactor (10) and to discharge solid particles to an outside from the fluidized bed reactor (10)
Implementation Method 2
A fluidized bed reactor is a device that injects solid particles therein and injects gas through a plenum and a gas distributor located on a lower portion of the reactor, and changes behavior of the solid particles to be similar that of fluids by making the solid particles float
Data Source
AI summary
A fluidized bed reactor is provided. The fluidized bed reactor includes a screw conveyor configured to penetrate through an upper portion of the fluidized bed reactor and to discharge solid particles to an outside from the fluidized bed reactor. The screw conveyor is configured to have an upper end protrude from the upper portion of the fluidized bed reactor and a lower end located at a height equal to or higher than a height of a distributor of the fluidized bed reactor.