Tray Support Insert for Thermal Expansion in Chemical Reactors

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Solution Overview

Problem

Chemical reactor vessels face issues with tray expansion and contraction due to temperature and pressure changes, leading to potential damage and the need for adaptable internal configurations to accommodate changes in chemical feed and processes.

Innovation Solution

A tray support insert system, comprising a support grid skirt and catalyst support grid ring, allows for relative movement between trays and the reactor vessel walls, enabling expansion and contraction while supporting heavy loads and intense heat, and allowing reconfiguration of the reactor chamber to adjust catalyst bed sizes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If trays are rigidly supported within the reactor chamber, then structural stability is improved, but thermal expansion and contraction cause damage to reactor components

Engineering Contradiction:

Improvestructural stabilityVSAvoidthermal expansion damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The tray support system transitions from a rigid fixed support to a dynamic support that allows controlled movement. The insert provides support while permitting thermal expansion and contraction through controlled clearance and flexibility, enabling the tray to move dynamically with temperature changes rather than being constrained rigidly.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The tray support insert acts as an intermediary element between the tray and the reactor chamber walls. This intermediate structure absorbs and manages thermal stresses, providing a buffer that protects both the tray and reactor components from direct thermal expansion damage while maintaining structural support.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If the reactor chamber internal configuration is fixed, then manufacturing simplicity is improved, but adaptability to changes in chemical feed and processes deteriorates

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidprocess adaptability

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The tray support system is divided into separate modular components including the insert, tray, and support structures that can be independently manufactured and assembled. This segmentation allows the internal configuration to be reconfigured by replacing or repositioning modular components without rebuilding the entire reactor chamber.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The support insert and tray assembly creates a dynamic, reconfigurable internal configuration. The tray can be repositioned vertically along the reactor chamber using the support insert mechanism, allowing the reactor to adapt to different chemical feed requirements and process conditions while maintaining a simple fixed chamber structure.

Inventive Principle:

Principle #15Dynamics

3Strength

If the quench section is positioned at lower elevation, then structural support is improved, but the ability to reconfigure catalyst bed sizes deteriorates

Engineering Contradiction:

Improvestructural supportVSAvoidcatalyst bed reconfiguration

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The quench section is supported by a dynamic tray support insert system that allows vertical repositioning. The tray can be moved to different elevations along the reactor chamber while maintaining structural support, enabling flexible reconfiguration of catalyst bed sizes and positions without compromising structural integrity.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The quench section is extracted from a fixed structural position and made independently repositionable using the tray support insert. This allows the quench section to be moved to optimal positions for different process requirements while the support structure remains separate and adaptable.

Inventive Principle:

Principle #2Taking out (Extraction)

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 tray support insert system effectively accommodates thermal expansion and contraction, reduces reactor chamber size for upper catalyst beds, and increases size for lower catalyst beds, enhancing process flexibility and component durability.

Implementation Method 1

The tray support insert allows for expansion and contraction of metal components within the reactor in response to changes in temperature and pressure

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 2

The tray support insert allows for expansion and contraction of metal components within the reactor in response to changes in temperature and pressure

Methodology Applied

Scientific EffectThermal contraction: Thermal Contraction

Data Source

PatentUS10293321B2Tray support inserts for chemical reactor vessels and methods of use

Publication Date: 2019.05.21 SHELL USA INC

AI summary

A tray support insert and method of use for supporting one or more trays within a reactor chamber. The tray support insert includes at least one annular member which rests upon a support shoulder within the reactor chamber.