Socket Fluid Distributor for Uniform Trickle-Bed Reactant Flow
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Solution Overview
Problem
Conventional multi-tubular reactors face challenges in evenly distributing reactants due to differential pressures caused by non-uniform catalyst layers, leading to overflow and uneven distribution, especially in trickle-bed reactors.
Innovation Solution
A socket-type fluid distributor is designed with a mixing flow path, separate input portions for gas and liquid reactants, and a flow control portion to align accurately within the reactor, allowing for even distribution of reactants in the form of droplets, airflow, or sprays, and offsetting differential pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a conventional multi-tubular reactor is used, then the heat exchange area is increased, but the reactant distribution becomes uneven due to differential pressure
Solution Approach 1:
The distributor is segmented into multiple independent flow paths, each leading to a separate reactor tube. This segmentation allows each flow path to independently compensate for differential pressure variations, ensuring uniform reactant distribution across all tubes while maintaining the multi-tubular configuration's large heat exchange area
Solution Approach 2:
The distributor incorporates adjustable flow control elements that can modify flow resistance parameters in each branch. By changing these parameters, the system compensates for differential pressure differences caused by non-uniform catalyst layers, thereby achieving uniform reactant distribution despite the multi-tubular structure
2Manufacturing precision
If the liquid reactant level is increased to improve distribution, then the distribution improves, but overflow occurs when the tray is filled above a certain level
Solution Approach 1:
The distributor acts as an intermediary device between the liquid reactant source and the reactor tubes. It incorporates flow regulation mechanisms that control the liquid flow rate to each tube, ensuring uniform distribution without requiring excessive liquid levels that would cause tray overflow
Solution Approach 2:
The distributor utilizes hydraulic principles to regulate liquid flow through pressure-controlled openings and flow paths. By managing the hydraulic pressure and flow distribution, the system achieves uniform reactant delivery to all tubes while preventing liquid overflow from the tray
3Ease of manufacture
If the distributor structure is simplified, then the manufacturing cost decreases, but the ability to compensate for differential pressure is reduced
Solution Approach 1:
The distributor implements local quality variations through selectively positioned flow control openings and varying flow path resistances in different branches. This localized differentiation enables effective differential pressure compensation while maintaining a relatively simple overall structure that is cost-effective to manufacture
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 socket-type fluid distributor ensures even distribution of reactants to each unit reactor, preventing overflow and maintaining reaction efficiency by aligning at an accurate position and controlling reactant form and pressure to counteract differential pressures.
Implementation Method 1
the flow control portion is configured such that a pressure of a mixed reactant passing through the flow control portion is greater than a differential pressure generated in the catalyst filling portion
Implementation Method 2
a mixing flow path formed in a central portion of the distributor body and formed to penetrate through the distributor body
Data Source
Figure 1
Figure 2
AI summary
A socket-type fluid distributor for distributing and supplying a gas and/or liquid reactant into a reactor body. The socket-type fluid distributor includes: a distributor body, a partial region of which is inserted into the reactor body; a mixing flow path formed in a central portion of the distributor body such that the mixing flow path penetrates through the distributor body into the reactor body; a gas reactant input portion disposed above the distributor body and having a gas flow path; a liquid reactant input portion disposed between the distributor body and the gas reactant input portion and having a liquid flow path; and a flow control portion formed in the mixing flow path.