Serpentine Reactor Components with Varying Cross-Section
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Solution Overview
Problem
Current components for high-pressure ethylene reactors have circular cross-sections, which prioritize cost over efficiency, leading to issues with pressure drop, erosion, and fouling, with no existing designs featuring non-circular cross-sections for serpentine fluid reactors.
Innovation Solution
Development of components with a smoothly varying cross-section and aspect ratio (ARQ) from 1.0 to 1.5, optimized using computational models and fluid dynamics simulations to minimize pressure drop and erosion, and potentially reduce fouling, while maintaining cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If circular cross-section components are used, then manufacturing cost is minimized, but pressure drop and erosion rate increase
Solution Approach 1:
The patent applies asymmetry by transitioning from traditional circular cross-sections to non-circular cross-sections with varying aspect ratios (ARQ from 1.0 to 1.5). This asymmetric geometry optimizes fluid flow characteristics, reducing pressure drop and erosion rates while maintaining manufacturing feasibility through standardized fabrication processes.
Solution Approach 2:
The patent implements local quality by varying the cross-sectional geometry along the length of reactor components. Different sections have different ARQ values, with inlet and outlet regions having ARQ near 1.0 and intermediate sections having ARQ up to 1.5. This localized geometric optimization addresses specific flow conditions in different regions, minimizing both pressure drop and erosion where they occur most severely.
2Device complexity
If circular cross-section components are used, then manufacturing simplicity is maintained, but fouling and recirculation increase
Solution Approach 1:
The non-circular cross-sections with varying ARQ create asymmetric flow patterns that prevent stagnant zones and recirculation. The optimized geometry promotes uniform flow distribution throughout the component, reducing areas where fouling and coke deposition can accumulate, thereby addressing the harmful effects without significantly increasing geometric complexity.
3Reliability
If non-circular cross-section components are designed, then pressure drop and erosion are minimized, but manufacturing complexity increases
Solution Approach 1:
The patent applies parameter changes by systematically varying the ARQ parameter along the component length within a controlled range (1.0 to 1.5). This parameter optimization achieves significant reductions in pressure drop and erosion while keeping the geometric variations within manufacturing capabilities. The controlled parameter range ensures that components can be fabricated using existing processes.
Solution Approach 2:
The patent implements dynamics by making the cross-sectional geometry variable rather than static. The ARQ changes continuously along the length of the component, adapting the flow characteristics to local conditions. This dynamic geometric adjustment optimizes performance throughout the component while maintaining manufacturability through progressive geometric transitions.
Data Source
AI summary
Some embodiments of the present invention provide components for a serpentine fluid reactor which is optimized for one or more objective functions of interest such as pressure drop, erosion rate, fouling, coke deposition and operating costs. The components are designed by computer modeling the components individually and collectively in which the cross section of flow path is substantially circular under industrial conditions to validate the model design and its operation. Then iteratively the component designs are deformed and the operation of the deformed part(s) is modeled and compared to values obtained with other deformed models until the value of the objective function is optimized (e.g. at an extreme) or the change in the objective function is approaching zero.