Toroidal Bed Reactor Helical Flow for Uniform Particle Treatment
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Solution Overview
Problem
Existing methods for processing particulate materials, such as carbonaceous materials, often result in non-uniform treatment and inefficient gas/solid mixing, leading to suboptimal properties in the processed products.
Innovation Solution
A toroidal bed reactor system with a processing zone that establishes a predictable helical and circumferential particle flow path by controlling the angle and velocity of fluid flow, ensuring uniform particle treatment and gas/solid mixing, utilizing a chamber with a central conduit or pillar to create an annular processing zone and employing vanes or deflectors to direct the fluid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional processing methods are used for particulate materials, then the processing can be performed with simple equipment, but the particle treatment is non-uniform and gas/solid mixing is inefficient
Solution Approach 1:
The patent employs a toroidal (doughnut-shaped) reactor geometry with curved flow paths instead of conventional straight or simple cylindrical configurations. The fluid flow follows a helical path within the toroidal processing zone, creating predictable curved particle trajectories that enhance mixing uniformity and treatment consistency across all particles.
Solution Approach 2:
The toroidal processing zone is divided into distinct functional regions: an inner region where fluid is introduced at controlled angles, a middle processing region where particles follow helical paths, and an outer region where processed particles are removed. This segmentation allows optimized treatment in each zone while maintaining overall system efficiency.
2Productivity
If conventional mixing methods are used, then the equipment structure is simple, but the gas/solid mixing efficiency is low
Solution Approach 1:
The patent uses controlled fluid flow (gas or liquid) introduced through nozzles or tubes at specific angles (10°-75° to the tangent) to entrain and move particles along helical paths. The fluid acts as the primary mixing mechanism, replacing mechanical mixers and achieving superior gas/solid contact efficiency through hydrodynamic or pneumatic forces.
Solution Approach 2:
The system creates dynamic, continuously moving particle trajectories through the toroidal zone rather than static or simple circular motion. The helical flow pattern with vertical and horizontal displacement components ensures particles constantly change position and orientation, maximizing exposure to the fluid phase and enhancing mixing efficiency.
3Manufacturing precision
If particles are processed in simple flow patterns, then the residence time distribution is broad, but the treatment uniformity is poor
Solution Approach 1:
The toroidal geometry with helical flow paths creates more uniform residence times compared to simple cylindrical reactors. All particles traverse a similar path length through the processing zone, reducing residence time distribution breadth while ensuring uniform treatment exposure.
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
This approach achieves uniform particle treatment and enhanced gas/solid mixing, resulting in processed materials with improved properties, such as increased surface area and controlled mass distribution, suitable for producing activated carbon or charcoal.
Implementation Method 1
providing a flow of fluid into said chamber for entraining the particulate material
Implementation Method 2
the fluid flow is introduced into the processing zone at an angle of between 10° and 75° with respect to a tangent of the substantially circular transverse cross-section of the processing zone to establish a fluid flow following a substantially helical path
Implementation Method 3
The chamber preferably has a base inclined downwardly towards the centre of the chamber to bias particulate material in the flowing bed back towards the processing zone
Data Source
Figure 1~2
Figure 3~4
Figure 5A~5C
AI summary
The present invention presents a system for and method of processing a particulate material, for example carbonaceous materials, food products or minerals, to produce a processed material having more desirable properties. The method comprises the steps of: introducing the particulate material into a chamber; providing a flow of fluid into said chamber for entraining the particulate material via inlets at a lower end of the chamber; and providing an exhaust of fluid out of the chamber via an outlet at an upper end of the chamber. The chamber comprises a processing zone having a substantially circular transverse cross-section, the fluid flow being introduced into the processing zone at a non- perpendicular angle with respect to a tangent of the substantially circular transverse cross- section of the processing zone to establish a fluid flow following a substantially helical path in the processing chamber. Said processing zone is provided in a central region of said chamber. Individual particulate material during processing in the processing zone is entrained by the fluid flow exceeding the terminal velocity of the particulate material, exits the processing zone in a radially outward direction, circulates to a base of the chamber and then returns to the processing zone in a repeated cycle. Individual particulate material can increase in mass or aggregate to form a mass of particulate material with larger mass during processing until its terminal velocity exceeds the fluid flow and thereby exits the processing zone by descending through an opening at the base of the chamber under gravity. A toroidal bed reactor is also provided.