Vortex Mixing Device for Hydroprocessing Reactor Interbeds
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Solution Overview
Problem
In down-flow hydroprocessing reactors, poor interbed fluid mixing leads to temperature maldistribution, hot spots, and reduced reactor performance, necessitating improved mixing devices with a lower vertical footprint for efficient operation and retrofitting existing reactors.
Innovation Solution
A vortex-type mixing device with a horizontal top plate, base plate, inwardly-curved vanes, a vertical weir ring, and a bubble cap, designed to enhance mixing of gas and liquid phases in the interbed space of multi-bed reactors, reducing pressure drop and increasing throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional mixing devices are used in the interbed space, then fluid mixing can be achieved, but the vertical footprint is large which reduces catalyst loading volume
Solution Approach 1:
The mixing device transitions from a vertical stacking arrangement to a horizontal radial flow arrangement. Fluid enters at the periphery and moves radially inward through the mixing chamber, utilizing horizontal space rather than vertical space. This dimensional change allows effective mixing to occur within a compressed vertical envelope, thereby increasing catalyst loading volume without sacrificing mixing performance.
Solution Approach 2:
The mixing chamber employs curved surfaces including a domed top surface and a rounded bottom surface with a central outlet aperture. These curved geometries promote smooth fluid flow patterns and enhance mixing efficiency while maintaining a compact vertical profile. The spherical-like geometry allows the device to achieve effective mixing in a smaller vertical space compared to traditional linear or angular designs.
2Productivity
If the interbed space is reduced to increase catalyst loading, then reactor throughput is improved, but fluid mixing becomes insufficient leading to temperature maldistribution
Solution Approach 1:
The device utilizes hydraulic principles to create a vortex flow pattern within the mixing chamber. The radial flow design combined with the curved surfaces generates rotational motion that enhances liquid-gas mixing and heat transfer. This hydraulic vortex action ensures uniform temperature distribution and effective fluid mixing within the reduced interbed space, preventing hot spots while maintaining high reactor throughput.
Solution Approach 2:
The mixing device changes the flow parameters of the liquid and gas streams by converting axial flow into radial and rotational flow components. This parameter transformation creates enhanced mixing conditions and improved heat transfer coefficients, allowing uniform temperature distribution to be achieved in a more compact interbed space, thereby supporting higher reactor throughput.
3Temperature
If mixing efficiency is increased to eliminate hot spots, then temperature distribution improves, but pressure drop increases
Solution Approach 1:
The distributed outlet apertures around the central outlet create a porous-like flow distribution pattern. Multiple small flow paths are provided instead of a single large opening, which distributes the pressure drop across numerous pathways. This approach maintains effective mixing and uniform temperature distribution while minimizing the overall pressure drop through the mixing device.
Solution Approach 2:
The outlet is segmented into multiple distributed apertures rather than a single centralized outlet. This segmentation creates multiple parallel flow paths that reduce resistance to flow and minimize pressure drop. Simultaneously, the distributed outlets maintain effective mixing by releasing fluid at multiple locations, ensuring uniform temperature distribution without the penalty of high pressure drop.
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 vortex-type mixing device achieves effective fluid mixing with a reduced vertical footprint, enhancing reactor performance, throughput, and allowing for efficient retrofitting of existing reactors, while minimizing pressure drop and maintaining uniform temperature distribution.
Implementation Method 1
A vortex-type mixing device with a horizontal top plate, base plate, inwardly-curved vanes, a vertical weir ring, and a bubble cap, designed to enhance mixing of gas and liquid phases in the interbed space of multi-bed reactors
Implementation Method 2
vortex-type mixing device... achieves effective fluid mixing with a reduced vertical footprint
Data Source
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AI summary
The present invention is directed to a vortex-type mixing device for a down- flow hydroprocessing reactor. In particular, the device improves the effectiveness of an existing mixing volume in mixing the gas phase and liquid phase of two-phase systems. According to the present invention, the mixing device helps create a highly arcuate flow to incoming effluents and a high degree of mixing within a constrained interbed space of a hydroprocessing reactor.