Vacuum-Based Catalyst Unloading System for Acid Plant Converter Beds

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Solution Overview

Problem

Current systems for unloading and loading catalyst converter beds in acid plants are inefficient, leading to material loss, environmental risks, and safety concerns, requiring excessive equipment and manpower, and inefficient storage solutions.

Innovation Solution

A vacuum-based system with a cyclone and dust collector, combined with a material sorting mechanism and storage containers, facilitates efficient unloading and loading of catalyst and rock materials by minimizing dust emission and optimizing material separation and storage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If current systems and methods are used for unloading and loading catalyst converter beds, then the process can be completed, but material loss, dust generation, and inefficiency increase significantly

Engineering Contradiction:

Improvecatalyst material lossVSAvoidunloading and loading efficiency

Core Design Contradiction:

Loss of substanceVSProductivity

Solution Approach 1:

The patent replaces traditional mechanical unloading systems with a vacuum-based system. A vacuum source creates negative pressure to draw catalyst material and dust through hoses into a cyclone separator, eliminating the need for mechanical conveyors or manual handling that cause material loss and inefficiency

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention uses pneumatic principles by employing a vacuum source to create airflow that transports catalyst material through the system. The vacuum-generated airflow carries material through hoses and into the cyclone separator, enabling efficient material movement without mechanical contact

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Object-generated harmful factors

If current unloading systems are used, then material can be removed from converter beds, but dust emission and environmental risks increase

Engineering Contradiction:

Improvecatalyst dust emissionVSAvoidenvironmental safety

Core Design Contradiction:

Object-generated harmful factorsVSReliability

Solution Approach 1:

The patent converts the harmful dust that would normally be emitted into a beneficial separated material stream. The cyclone separator uses centrifugal force to separate dust particles from the airflow, capturing what would otherwise be harmful emissions and returning clean material to the converter bed

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The cyclone separator acts as an intermediary device between the vacuum source and the converter bed. It mediates the material flow by separating dust particles from the carrier airflow, allowing clean catalyst material to be returned to the converter while capturing dust for proper disposal

Inventive Principle:

Principle #24Intermediary (Mediator)

3Device complexity

If traditional unloading methods are used, then converter beds can be emptied, but excessive equipment and manpower are required

Engineering Contradiction:

Improveequipment requirementsVSAvoidoperation simplicity

Core Design Contradiction:

Device complexityVSEase of operation

Solution Approach 1:

The vacuum-based system serves multiple functions with a single integrated setup. The vacuum source not only removes material from the converter bed but also transports it through the cyclone separator and enables dust-free return loading, eliminating the need for separate equipment for each operation

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 system reduces material loss, enhances safety and environmental protection, decreases equipment and labor needs, and improves storage efficiency by effectively sorting and containing catalyst and rock materials during the unloading and loading processes.

Implementation Method 1

a cyclone operatively connected to the vacuum source through the dust collector

Methodology Applied

Scientific EffectCentrifugal force: Centrifugal Force

Implementation Method 2

The system may include a vacuum source; a dust collector connected to the vacuum source by a first vacuum hose

Methodology Applied

Scientific EffectVacuum suction: Suction

Data Source

PatentUS10457501B2Systems and methods for converter bed unloading and loading

Publication Date: 2019.10.29 CYCLONE CATALYST PROPERTIES LLC

AI summary

A system and method for loading material from a converter bed, such as that in a converter of an acid plant, is provided. The system, may include a vacuum source; a dust collector connected to the vacuum source by a first vacuum hose; a cyclone operatively connected to the vacuum source through the dust collector, wherein the cyclone may be connected to the dust collector by a second vacuum hose; a drop-out hopper operatively attached to the cyclone by a valve, such as an air actuated valve, wherein the drop-out hopper includes a first feed hose; and one or more material storage containers operatively associated with the cyclone via a second feed hose. The method of loading material into a converter bed may include providing a system for loading the material in the converter bed; setting up the system; and loading the material into the converter bed.