Slurry Reactor Filter Guard for Failure Detection

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Solution Overview

Problem

Existing filtration systems in slurry reactors fail to effectively protect downstream equipment from mechanical failures of filter elements or piping connections, leading to potential leaks and degradation of product quality, and lack efficient backflushing mechanisms.

Innovation Solution

A filter system with multiple bundles of filter elements connected to fluid collection conduits, plenums, and transfer conduits, incorporating guard filters for failure detection and protection, and optimized backflushing mechanisms to maintain system integrity and product quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If multiple filter elements are used in the slurry reactor, then the filtration capacity and productivity are improved, but the risk of mechanical failure and system leakage increases

Engineering Contradiction:

Improvefiltration capacityVSAvoidsystem integrity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

A guard filter is introduced as an intermediary component in the fluid collection conduit, positioned between the multiple filter elements and the downstream equipment. This guard filter acts as a backup barrier that intercepts catalyst particles if any primary filter element fails, thereby maintaining system reliability while allowing the use of multiple filter elements for high productivity

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The guard filter is installed in advance as a protective measure against potential filter element failures. It provides a safety cushion that prevents catastrophic system failure and product quality degradation, allowing the system to operate with higher filtration capacity without proportionally increasing the risk

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Manufacturing precision

If filter elements are installed within the slurry reactor, then the separation efficiency is improved, but the complexity of maintenance and backflushing operations increases

Engineering Contradiction:

Improveseparation efficiencyVSAvoidmaintenance accessibility

Core Design Contradiction:

Manufacturing precisionVSEase of repair

Solution Approach 1:

The filter system is segmented into multiple independent filter elements that are individually accessible through the reactor wall. Each filter element can be independently backflushed and maintained without shutting down the entire reactor or accessing the harsh slurry environment, thereby maintaining high separation efficiency while simplifying maintenance operations

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The guard filter serves as an accessible intermediary component located in the fluid collection conduit outside the slurry reactor. It can be easily maintained and replaced without exposing personnel to the harsh slurry environment, while the primary filter elements inside the reactor maintain high separation efficiency

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If backflushing operations are performed frequently to remove catalyst build-up, then the filter rate is maintained, but the system complexity and operational time increase

Engineering Contradiction:

Improvefilter rateVSAvoidbackflushing operational time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The filter system is divided into multiple independent filter elements with individual backflushing capabilities. This segmentation allows for selective backflushing of only those elements that require it, rather than backflushing the entire system, thereby maintaining high filter rates while minimizing operational time and system complexity

Inventive Principle:

Principle #1Segmentation

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 system ensures robust separation of liquid hydrocarbons from catalysts, detects filter failures, and protects downstream equipment, maintaining product quality and reactor operation even in case of filter or piping failures, while allowing for effective backflushing and maintenance.

Implementation Method 1

one or more bundles of a plurality of filter elements for separating liquid from a mixture of liquid and solid in the reactor

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Implementation Method 2

The guard filter operates as a failure detection device as well as protection to downstream equipment in the event that any of the filter elements fail

Methodology Applied

Scientific EffectPhysical filtration and particle interception: Filter (physical)

Data Source

PatentUS8022109B2Product filtration system for slurry reactors

Publication Date: 2011.09.20 EXXONMOBIL TECHNOLOGY & ENGINEERING CO

AI summary

A filter system for use in a three-phase slurry reactor is provided. The filter system comprises one or more bundles of a plurality of filter elements for separating liquid from a mixture of liquid and solids contained in the reactor. Each filter bundle is connected to a product transfer conduit transporting separated liquid to a location outside of and downstream from the reactor. The transfer conduit is provided with means for backflushing the filter bundle and guard filter means.