Staged Gas-Solid Reactor Flow Ratios for Higher Reactant Conversion
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Solution Overview
Problem
Conventional gas-solid reactors are limited by thermodynamic equilibrium, restricting the conversion and yield of intermediate products, particularly in reactions involving metal oxides with multiple valence states, necessitating additional downstream units and increased capital and energy costs.
Innovation Solution
The implementation of reactor designs with multiple inlets and outlets for gas and solid phases, allowing for staged injections and extractions to manipulate thermodynamic conditions and achieve higher product conversions and yields.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional single-path reactor design is used, then device complexity is low, but reactant conversion and product yield are limited by thermodynamic equilibrium
Solution Approach 1:
The reactor is divided into multiple segments with separate inlets and outlets for gas and solid phases. Each segment can independently control flow ratios and reaction conditions, allowing the system to overcome thermodynamic equilibrium limitations by creating multiple reaction paths rather than relying on a single conventional reactor design.
Solution Approach 2:
The invention introduces an additional dimension to the conventional reactor design by implementing multi-phase flow paths with independent control. Instead of a single through-flow path, the system uses multiple inlet/outlet pairs that enable staged injections and extractions, effectively adding a new degree of freedom to manipulate thermodynamic conditions and achieve higher conversions.
2Productivity
If additional downstream units are added to overcome conversion limits, then product yield improves, but capital costs and energy consumption increase
Solution Approach 1:
The reactor performs preliminary conversion actions within its own structure by incorporating multiple staged reaction zones with independent flow control. This preliminary action achieves high conversion rates before the effluent leaves the reactor, eliminating or reducing the need for additional downstream processing units that would otherwise be required to achieve the same product yield.
Solution Approach 2:
The invention merges multiple reaction stages and flow paths into a single integrated reactor system. By combining what would traditionally require separate downstream units into one multi-functional reactor with staged inlets and outlets, the system achieves high product yield while reducing overall energy consumption and equipment requirements.
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
Enhances product quality and yield, reduces energy consumption, and decreases capital costs by overcoming thermodynamic limitations, enabling more efficient gas-solid reactions.
Implementation Method 1
the conversion of feedstock as well as the yield of target product are restricted by thermodynamic equilibrium due to the presence of only one path for the gas and solid stream in the reactors
Data Source
AI summary
Reactor configurations may include one or more staged inlets and/or one or more staged outlets for gaseous and solid feedstocks. In one embodiment of the present disclosure, a reactor design for gas-solid reaction with one or more additional outlet for gas and/or solid phase is provided. In yet another embodiment, the design for a gas-solid reactor with one side inlet and two outlets for gas phase is described. In one embodiment, a reactor design with pairs of inlet and outlet for both gas and solid phase is provided. In another embodiment, a reactor design with one or more side inlets but only one outlet for gas phase is provided. In yet another embodiment, a reactor design with two inlets at the top/bottom of reactor and two side outlets for gaseous phase is described. In yet another embodiment, a reactor design with one or more side inlets and outlets for both gas and solid phases is provided.