Reactor Vessel Tube Support Plates with Fluid-Exchange Cutouts

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Solution Overview

Problem

Existing methanol synthesis reactors face issues with support plates causing pressure drops and tube bending, bowing, or swaying due to mechanical constraints and coolant flow geometries, leading to restricted reactor dimensions and increased transport difficulties.

Innovation Solution

A reactor vessel design with transversely disposed support plates having fluid-exchange cutouts that allow tubes to thermally expand and minimize vibrations, while maintaining structural support and optimizing fluid flow, using a support plate with optimized cutouts and dividers to reduce hindrance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If support plates are inserted in offset fashion to fix tubes, then tube mechanical stability is improved, but pressure drop on coolant side increases

Engineering Contradiction:

Improvetube mechanical stabilityVSAvoidpressure drop

Core Design Contradiction:

Stability of the object's compositionVSObject-generated harmful factors

Solution Approach 1:

The support plate is segmented with fluid-exchange cutouts that divide the plate into multiple sections. These cutouts allow coolant to flow through the support plate itself, creating additional flow paths that reduce the overall pressure drop while the solid portions of the plate maintain tube support functionality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The fluid-exchange cutouts act as intermediaries that facilitate coolant flow through the support plate structure. Instead of coolant flowing around the entire support plate (creating high pressure drop), the cutouts provide intermediate flow paths that reduce resistance while still allowing the plate to perform its mechanical support function.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If long reactor tubes are used to achieve desired reactor volume, then reactor efficiency is improved, but pressure drop and tube bending increase

Engineering Contradiction:

Improvereactor efficiencyVSAvoidpressure drop and tube bending

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The long reactor tubes are divided into multiple sections by support plates with fluid-exchange cutouts. These segmented support structures provide intermediate support points that prevent tube bending and bowing while allowing coolant flow through the cutouts to minimize pressure drop across the entire tube length.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The support plate introduces a new dimensional element (transverse support with vertical flow channels) that addresses the long-tube problem without simply shortening the tubes. The cutouts create a third dimension for coolant flow (through the plate thickness) that reduces the horizontal flow path resistance.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Ease of operation

If reactor external dimensions are restricted for transport, then transport ease is improved, but reactor volume and efficiency decrease

Engineering Contradiction:

Improvetransport easeVSAvoidreactor efficiency

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The support plate design allows for optimized tube spacing and configuration that can adapt to different transport constraints. The fluid-exchange cutouts can be configured in various patterns to accommodate different reactor diameter restrictions while maintaining adequate coolant flow and heat transfer efficiency.

Inventive Principle:

Principle #15Dynamics

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 design minimizes pressure drops and prevents tube bending or swaying during transport and operation, enhancing reactor efficiency and reducing mechanical constraints, allowing for improved reactor dimensions and fluid exchange.

Implementation Method 1

the support plate has fluid-exchange cutouts between the tube openings

Methodology Applied

Scientific EffectFluid flow through cutouts:

Implementation Method 2

allow tubes to thermally expand

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 3

minimize vibrations

Methodology Applied

Scientific EffectVibration damping: Damping

Data Source

PatentUS20250308716A1Support plate for tubes in a reactor vessel

Publication Date: 2025.10.02 LAIR LIQUIDE SA POUR LETUDE & LEXPLOITATION DES PROCEDES GEORGES CLAUDE

AI summary

A device (1.1, 1.2) with a reactor vessel (2), a tube bundle (3) of multiple tubes (4), and at least one support plate (5), wherein the tube bundle (3) is disposed in the reactor vessel (2), wherein the support plate (5) is disposed in the reactor vessel (2) transversely to a longitudinal axis (6) of the reactor vessel (2), wherein each tube (4) of the tube bundle (3) is routed through a respective tube opening (7) of the support plate (5), wherein the support plate (5) supports the tubes (4) of the tube bundle (3) in the tube openings (7) transversely to the longitudinal direction of the tubes (4), wherein the support plate (5) has fluid-exchange cutouts (8) between the tube openings (7).