Stackable Structural Reactor Monolith Design
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Solution Overview
Problem
Existing reactors in cylindrical tubes face inefficiencies near the center due to inadequate heat transfer and suffer from metallic creep and thermal expansion issues, leading to reduced performance and throughput.
Innovation Solution
A stackable structural reactor with a monolith design featuring annular fins and an expandable inner tube system that maintains contact with the outer tube, enhancing heat transfer and accommodating thermal expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the reactor occupies substantially all of the space within the cylindrical outer tube, then the reactor structure is compact and space-efficient, but heat transfer to the center region is insufficient and catalytic reactions are limited to outer portions
Solution Approach 1:
The reactor is segmented into multiple monoliths stacked together, with each monolith containing a plurality of hollow spherical beads. This segmentation creates numerous internal surfaces and flow paths that enhance heat distribution throughout the reactor volume, particularly improving heat transfer to previously underheated central regions while maintaining compact overall structure.
Solution Approach 2:
The invention introduces a radial dimension for heat transfer by positioning heating elements on the outer tube surface that radiate heat inward through the reactor wall and monolith structures. This multi-dimensional heat transfer approach ensures thorough heating of the catalyst support throughout the entire reactor volume, not just at the outer portions.
2Strength
If the reactor is inserted into a metallic outer tube for structural support, then the reactor has mechanical strength and stability, but metallic creep and thermal expansion cause the tube diameter to grow over time, creating gaps between the reactor and tube
Solution Approach 1:
The reactor system incorporates expandable monoliths that can dynamically adjust their outer diameter. When the metallic outer tube undergoes creep or thermal expansion, the monoliths expand accordingly to maintain continuous contact with the tube inner surface, ensuring sustained heat transfer efficiency and structural reliability over the reactor's operational lifetime.
Solution Approach 2:
The monoliths are designed with adjustable physical parameters, specifically their expandability. By changing the diameter parameter of the monoliths in response to tube deformation, the system compensates for creep and thermal expansion effects, maintaining optimal contact and heat transfer performance throughout the reactor's service life.
3Productivity
If the reactor operates at high temperatures (850-900°C) and high pressures (20-30 bar) for industrial processes, then the reactor achieves high productivity and throughput, but the high pressure creates large hoop stress that the tube material has difficulty resisting
Solution Approach 1:
The reactor is divided into multiple stacked monoliths, which segment the internal pressure loads. This segmentation distributes the hoop stress across multiple structural units rather than concentrating it in a single large-volume reactor, enabling the system to withstand high operating pressures (20-30 bar) more effectively while maintaining high throughput for industrial applications.
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 reactor design significantly increases throughput and maintains performance by ensuring consistent contact and efficient heat transfer, addressing the limitations of prior art reactors.
Implementation Method 1
The reactor fits within a cylindrical tube, and which effectively transfers heat from the tube to the interior of the reactor, or from the interior of the reactor to the tube
Implementation Method 2
Over a period of years, creep in the metal outer tube causes the diameter of the tube to grow. Even a few millimeters of growth in the tube diameter creates an undesirable gap between the reactor and the surrounding tube
Implementation Method 3
The monolith of the reactor is expandable in a radial direction
Data Source
AI summary
A reactor including a monolith having a plurality of fins in an annular arrangement for receiving fluid flow through the reactor. The monolith is disposed within a generally cylindrical outer tube, and around a corrugated inner tube. The reactor includes a device for urging the monolith radially outward, so as to maintain contact between the monolith and the outer tube.