Urea Reactor Perforated Baffles Phase Separation
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Solution Overview
Problem
Urea reactors have a relatively low efficiency of conversion, resulting in significant unconverted matter in the reactor effluent, which requires expensive downstream separation and recovery processes.
Innovation Solution
A reactor design featuring a vertical shell with internal perforated baffles arranged in a two-dimensional pattern, where each baffle comprises individual tiles with side walls and top faces having different-sized perforations to preferentially route liquid and vapor phases, enhancing heat and mass transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional urea reactor design is used, then the reactor structure is simple, but the conversion efficiency is low resulting in significant unconverted matter
Solution Approach 1:
The reactor internal volume is divided into several compartments separated by perforated baffles with tiles, creating multiple reaction zones that improve conversion efficiency while maintaining a manageable structural complexity through modular design
Solution Approach 2:
Different regions of the reactor are given different functions through selectively perforated tiles - some areas promote liquid flow while others facilitate vapor flow, optimizing local conditions for heat and mass transfer to enhance overall conversion efficiency
2Productivity
If downstream separation equipment is added to recover unconverted matter, then conversion recovery is improved, but the equipment cost and process complexity increase
Solution Approach 1:
The reactor performs preliminary separation and conversion functions through its internal baffle structure, pre-processing the reaction mixture before it leaves the reactor, thereby reducing the burden on downstream separation equipment and potentially eliminating or simplifying recovery processes
3Productivity
If heat and mass transfer between phases is enhanced, then conversion yield increases, but the reactor design complexity increases
Solution Approach 1:
Perforated tiles with selectively sized holes act as porous structures that facilitate intensive heat and mass transfer between liquid and vapor phases while maintaining a relatively simple overall reactor design through the use of standardized perforated components
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 improved reactor design enhances the separation between vapor and liquid phases and increases heat and mass transfer rates, leading to higher urea conversion yields and potentially reducing reactor size and costs.
Implementation Method 1
said first perforations being arranged to provide a preferential route for the liquid phase
Implementation Method 2
said second perforations being arranged to provide a preferential route for the vapor phase
Implementation Method 3
The heat and mass transfer between the liquid phase and the vapor phase is crucial for the overall conversion of reactants to urea
Implementation Method 4
The heat and mass transfer between the liquid phase and the vapor phase is crucial for the overall conversion of reactants to urea
Data Source
AI summary
A reactor for the synthesis of urea comprising a vertical shell and perforated baffles or trays (3) arranged to define compartments of the reactor, wherein each baffle comprises an array of individual perforated tiles (10) wherein each tile (101) comprises side walls (101A-101D) and a top face (101F), the side walls having first perforations for the liquid and said top face having second perforations for the gas, wherein said second perforations are smaller than said first perforations, and the tiles are distributed over the baffle with a two-dimensional pattern where adjacent tiles are separated by gaps (17).