Tangential Nozzle Inlets for Multiphase Fluid Mixing
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Solution Overview
Problem
Conventional fluid distribution systems in catalytic reactors suffer from poor gas-liquid mixing, limited tolerance for tray deviations, suboptimal spray discharge, and inadequate catalyst bed wetting, leading to inefficient catalyst utilization and reduced process efficiency.
Innovation Solution
A reactor system with a primary and secondary feed distribution unit, featuring a nozzle tray with tangentially oriented liquid inlets and trusses for improved fluid distribution, promoting spiral flow and even distribution of multi-phase fluids across the catalyst bed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional chimneys with lateral openings are used for liquid flow, then liquid can enter the chimney through lateral openings, but gas-liquid mixing is limited due to low turbulence around liquid streams
Solution Approach 1:
The patent introduces curved or spiral liquid inlet channels within the chimney structure, replacing straight lateral openings. This curvature creates turbulent flow patterns as liquid enters the chimney, significantly enhancing gas-liquid mixing efficiency while maintaining adequate liquid flow into the chimney
Solution Approach 2:
The patent modifies the flow parameters by changing the inlet geometry from simple lateral openings to curved/spiral channels. This parameter change increases turbulence intensity and mixing efficiency without compromising the quantity of liquid flow into the chimney
2Ease of operation
If static liquid height on the tray is used as the driving force for liquid flow into the chimney, then liquid flow is passive, but the system has poor tolerance for deviations from levelness of the distributor tray
Solution Approach 1:
The curved or spiral inlet channels create a self-regulating flow pattern that is less sensitive to tray levelness variations. The geometry guides liquid flow into the chimney regardless of minor tray deviations, improving reliability while maintaining ease of operation
Solution Approach 2:
By changing from a static height-driven flow mechanism to a geometry-driven turbulent flow mechanism, the system becomes more tolerant of tray levelness deviations while maintaining adequate liquid flow into the chimney
3Ease of manufacture
If conventional distributor trays are used, then construction is simpler, but spray discharge of fluids onto the underlying catalyst bed is suboptimal
Solution Approach 1:
The patent incorporates curved or spiral liquid inlet channels within the distributor tray structure. This curvature enhances spray discharge performance by creating turbulent flow patterns that improve fluid distribution onto the catalyst bed, while the overall tray structure remains manufacturable
4Device complexity
If conventional chimneys are used, then fewer contact points with catalyst bed are provided, but larger distance from chimney to bed is required to wet the catalyst surface
Solution Approach 1:
The curved or spiral inlet channels create enhanced spray patterns that increase the effective contact points between fluid and catalyst bed. This allows for adequate catalyst bed wetting with a shorter distance from chimney to bed, reducing the overall reactor height requirement
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 gas-liquid mixing, improves catalyst bed wetting, and increases tolerance for tray deviations, resulting in more uniform distribution and efficient catalyst utilization, while minimizing reactor height and fabrication material usage.
Implementation Method 1
Each liquid inlet is disposed tangentially to an inner surface of the distal body portion... promoting spiral flow of liquid on the inner surface of the distal body portion
Implementation Method 2
fluid distribution apparatus for a reactor... even distribution of fluids to a catalyst bed disposed beneath the fluid distribution apparatus
Data Source
Figure 1~2
Figure 3
Figure 4A~4B
AI summary
Systems and apparatus for mixing, cooling, and distributing multiphase fluid mixtures within a reactor, wherein reactor internal apparatus of the present invention provides not only improved fluid mixing and distribution to each underlying catalyst bed surface, but also offers other advantages including: decreased mixing tray height; easier maintenance, assembly and disassembly; and decreased amounts of fabrication material. In an embodiment, fluid may be evenly distributed to a catalyst bed from a fluid distribution unit comprising a nozzle tray including a plurality of nozzles, wherein the nozzles include at least one liquid inlet disposed tangentially to an inner surface of the nozzle.