Vacuum Attachment for Chemical Reactor Catalyst Removal
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Solution Overview
Problem
Vacuuming catalyst out of chemical reactor tubes often damages the catalyst and is time-consuming, as it requires ensuring uniform catalyst levels and can disrupt the reactor environment, making it difficult to maintain the correct outage level.
Innovation Solution
A vacuum attachment system with a shuttle mechanism that automatically adjusts vacuum levels by exposing a window opening to ambient air, reducing pressure when the desired outage level is reached, and using a secondary air pathway to fluidize catalyst particles without disturbing those deeper in the reactor, minimizing damage and ensuring efficient removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If vacuum is applied to remove catalyst from reactor tubes, then catalyst removal efficiency is improved, but catalyst damage increases
Solution Approach 1:
The patent changes the vacuum parameter dynamically by introducing air through the window opening at controlled positions. The window opening allows ambient air to enter the vacuum conduit, reducing the vacuum level progressively as the conduit descends into the reactor tube. This parameter change enables catalyst removal while limiting damage by controlling the vacuum intensity at different depths.
Solution Approach 2:
The window opening acts as an intermediary element between the vacuum conduit and ambient air. It controls the introduction of air into the vacuum system, serving as a mediator that regulates the vacuum level. This intermediary mechanism allows gradual reduction of vacuum pressure, preventing excessive catalyst damage while maintaining removal efficiency.
2Productivity
If vacuum level is increased to speed up catalyst removal, then productivity is improved, but catalyst damage worsens
Solution Approach 1:
The patent implements a dynamic vacuum control system where the vacuum level changes continuously as the conduit moves into the reactor tube. The window opening position relative to the conduit bottom creates a dynamic air intake mechanism that automatically adjusts vacuum pressure based on depth. This dynamic adjustment maintains high removal speed while preventing excessive damage through progressive vacuum reduction.
3Measurement precision
If vacuum is applied to ensure uniform catalyst levels, then measurement precision is improved, but time consumption increases
Solution Approach 1:
The patent employs a feedback mechanism where the window opening position provides visual or measurable indication of the conduit's depth within the reactor tube. As the conduit descends and the window opening emerges from the catalyst surface, this provides feedback on the outage level. The feedback allows operators to stop vacuuming at the correct level, ensuring uniform catalyst levels while minimizing time consumption through clear stopping criteria.
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 effectively reduces catalyst damage and ensures consistent vacuuming to the correct outage level, improving efficiency and reducing operational time by automatically controlling vacuum pressure and using external air to assist in particle removal.
Implementation Method 1
a vacuum source in communication with the second conduit to convey a fluid from outside of the chemical reactor to the first end of the vacuum conduit
Implementation Method 2
The pressure inside the vacuum conduit is less than the atmospheric pressure, so that the catalyst particles are moved into the vacuum conduit by the pressure difference
Implementation Method 3
using a secondary air pathway to fluidize catalyst particles without disturbing those deeper in the reactor
Data Source
AI summary
A device and method for vacuuming solid particles out of a chemical reactor tube. One embodiment comprises the step of substantially reducing the vacuum level applied to the vacuum conduit when the conduit reaches a desired depth within the reactor tube by using means responsive to the depth to which the vacuum conduit is inserted into the reactor tube.