RU2404848C2 - Method of fitting reactor cartridge in long tube and method of removing reactor cartridge therefrom - Google Patents

Abstract

FIELD: process engineering.

SUBSTANCE: invention relates to methods of fitting cartridge into long tub and withdrawing it therefrom and can be used in catalytic combustion and/or heat exchange for stacking cartridges in long tube. Reactor cartridge features cylindrical structure that comprises assemblage of spatially separated monoliths produced on tube or any other core. Each monolith is formed by a pair of flat and folded metal strips coiled on the tube. Said strips can be made from continuous or mesh-type material. Said folds are skewed to swirl gases flowing there through. Inlet device is attached to cartridge face, cartridge is fitted into long tube and said inlet device is detached from the cartridge. Said inlet device has centering mechanism and hooks to engage with pin jointed to cartridge. Cartridge removal is performed in a similar way.

EFFECT: simplified procedure.

12 cl, 7 dwg

Description

The present invention relates to the field of catalytic combustion and / or heat transfer. The invention provides a cartridge that can be used as a heat exchanger or a catalytic or non-catalytic reactor and which can be stacked together with similar cartridges in a long pipe. The invention also relates to a method for introducing a cartridge into or out of a long pipe and to a device for effecting such movement.

The cartridge of the present invention is designed to achieve the same objectives as the cartridge for the catalyst carrier described in the simultaneously filed US patent application 10/896302 (filed July 21, 2004), the disclosure of which is incorporated into this application by reference.

One of the objectives of the present invention is to eliminate the problems associated with the use of ceramic materials in the design and operation of catalytic reactors. A disadvantage of ceramic catalysts packed in a dense layer is their low thermal conductivity, which makes it difficult to transfer heat from the periphery of the reactor to its inner part. In this case, thermal incompatibility between the metal and ceramic parts of the reactor of the existing prior art leads, in the end, to the scattering of ceramic material, thereby limiting the operational life of the reactor. Like the device described in the aforementioned application, the construction of the present invention is completely made of metal, which naturally eliminates these problems.

Another objective associated with a catalytic reactor or heat exchanger is to enhance heat transfer between the wall of the reactor and the gases flowing therein. To solve this problem, in the aforementioned application, beveled or inclined folds define curved directions that swirl the gases as they exit the reactor. The present invention also provides a structure that enhances mixing and / or swirling of gases.

The cartridge according to the present invention can be used, for example, in the field of catalytic reforming of fuel to produce hydrogen, which is then used to generate electricity using a fuel cell or in any other industrial process, such as oil and gas processing, production of ammonia and fertilizers, hydrogenation of oils and chemicals and reduction of iron ore. The cartridge can be used as a catalytic or non-catalytic combustion chamber. The cartridge can also be used as a simple heat exchanger.

In one of its preferred embodiments, the present invention comprises a cartridge having a plurality of spatially separated monoliths restricting the channels for the passage of gases, and each monolith gives the gases flowing through the channels a swirl. Adjacent monoliths create turbulences in opposite directions. In particular, the direction of gas turbulence undergoes circulation during the transition from one monolith to the next. Such circulation causes turbulence in the mixing areas between the monoliths and enhances the heat transfer between the outer and inner parts of the monoliths.

Monoliths are formed mainly by pairs of flat and folded metal strips that are wound onto a core like a pipe or rod, forming a spiral structure. The folds of each of the folded strips are inclined with respect to the longitudinal axis of the strip. The inclined orientation of the folds gives the gas a swirl. The gaps between the monoliths contain mixing sections for gas. Separators can be introduced into these gaps to help maintain a constant distance and to prevent telescoping of the monolith layers under the influence of gas pressure. The strips can be ordinary strips of metal foil, or they can be made of a grid with small holes, further enhancing the mixing and transfer of heat by radiation.

The invention also relates to a method for manufacturing a catalytic combustion cartridge. In this method, pairs of flat and folded metal strips are fixed at certain intervals along the core and these pairs of strips are wound onto the core, rotating the core along its longitudinal axis for this purpose, as a result of which a multitude of spirally twisted monoliths separated by spaces are formed. The folded strips are made so that the folds are inclined to the longitudinal axis of the strip. If the cartridge is to be used as a catalytic combustion chamber, the strips can be coated with a suitable catalyst before they are wound into monoliths. After this, the monoliths can be enclosed in a mesh-like shell. Separators can also be placed between adjacent monoliths.

The invention also relates to a method for introducing a reactor cartridge and withdrawing from a long pipe. An insertion device is attached to the end of the cartridge, and the cartridge is removed from or inserted into a long pipe, which in general can be many times longer than the cartridge. The insertion device is then separated from the cartridge. The insertion device comprises a centering mechanism that centers the device inside a long pipe, and at least one hook that engages with a lifting pin or some other design on the cartridge.

The invention relates to the above input / output device. This device comprises a centering mechanism and a connector mounted on a centering mechanism that can engage with the reactor cartridge, and a rod that can be connected to the centering mechanism. The centering mechanism may include a brush or a roller cage or some other generally cylindrical structure, which is sufficiently well fitted to the pipe with a cartridge placed in it. The connector advantageously comprises one or more hooks designed to engage with the lifting pin or its equivalent mounted on the cartridge.

Thus, the main objective of the invention is to provide a reactor cartridge that can be used for catalytic or non-catalytic combustion, or for catalytic reforming, or for any other endothermic or exothermic catalytic reactions, or for simple heat transfer.

Another objective of the invention is the creation of an all-metal reactor cartridge having many monoliths, and the cartridge can be stacked together with other similar cartridges in a long pipe.

Another objective of the invention is the creation of a reactor cartridge, which contributes to the rapid transfer of heat through the cartridge and which eliminates the problems associated with the use of a dense ceramic layer.

Another objective of the invention is to provide a method of manufacturing a reactor cartridge.

The objective of the invention is to provide a method for introducing a reactor cartridge into a long pipe so that a stack of such cartridges is formed.

The objective of the invention is to provide a method for removing the reactor cartridge from the stack in a long pipe.

An object of the invention is also to provide a device for introducing a reactor cartridge into a long pipe or for withdrawing a cartridge from a long pipe.

The present invention is illustrated by drawings, in which:

figure 1 is a perspective view of a portion of the cartridge according to the present invention, showing the manufacture of the cartridge by winding flat and folded strips on a pipe or core;

FIG. 2 is a fragmentary perspective view showing an input / output device for use with a cartridge of the present invention; FIG.

figure 3 is a fragmentary perspective view of the device of figure 2, showing the use of the device to output the cartridge of the present invention from a long pipe;

Fig. 4 is a cross-sectional view of an input / output device showing the device in the engaged state with the end face of the cartridge of the present invention;

FIG. 5 is a fragmentary perspective view of the device of FIG. 2, showing an input / output device made in accordance with a preferred embodiment of the present invention, wherein the device is located near a cartridge to be inserted or removed;

FIG. 6 is a fragmentary perspective view of the device of FIG. 5, showing the device is engaged with the cartridge and showing the use of the device for lifting the cartridge;

Fig.7 is a perspective view of a cartridge according to the present invention, and the cartridge is placed inside the mesh material.

Figure 1 shows the basic structure and method of manufacturing a reactor cartridge according to the present invention. The cartridge is made up of a plurality of folded stripes 1, 2, 3 and a plurality of smooth stripes 4, 5, 6. The folded stripes have beveled folds, i.e. their folds are inclined with respect to the longitudinal axis of the strip. The strips, which are mainly made of metal foil, are welded to the pipe 7 and wound on it so as to form three monoliths, indicated by the reference numbers 8, 9 and 10. Monoliths are also called “honeycombs”, since they create many channels for gases passing through them mainly in the axial direction. Each of these channels is bounded by a part of a flat strip and a part of a folded strip adjacent to it.

Before assembly, the folded strips are oriented so that the folds of adjacent strips are not parallel. This orientation is achieved by simply reversing the orientation of each second folded strip before wrapping the bands to form monoliths. Such an appeal can be seen in FIG. 1, where it is shown that the folds of bands 1 and 3 are parallel to each other, but not parallel to the folds of strip 2.

As a result of this arrangement, neighboring monoliths in the final structure restrict the differently oriented channels for the gas flow. More specifically, when winding strips, the beveled folds limit the curved or spiral channels, and the direction of the curve or spiral in this monolith is different from the direction of the curve or spiral in any of the neighboring monoliths.

After winding, the resulting structure includes a cartridge with many monoliths. For the sake of simplicity of illustration, only three monoliths are shown in FIG. 1, but each cartridge may contain a different number of monoliths by attaching to the long pipe 7 more or fewer pairs of flat and folded strips.

The wound structure is preferably placed inside the mesh material 70, as shown in Fig.7. The mesh material protects the monoliths and helps to keep them together. The mesh may have a relatively fine mesh commensurate with that used in the manufacture of a conventional window mesh, or it may have a relatively large mesh similar to that used in the manufacture of a rabbit or chicken cage, i.e. have a mesh size of the order of 1 mm. Larger mesh has the advantage that it provides better heat transfer and, therefore, is preferred, but the invention assumes the use of both large and small mesh.

The material from which the folded and / or flat strip is made can be made of mesh. In this case, the mesh size may be relatively small, for example of the order of about 0.125 cm or less, so that the material will have sufficient surface area to accommodate a catalyst coating on it.

Figure 1 shows that the strip 6 can be made of mesh material, as evidenced by the fragmented mesh part 17. Similarly, the folded strip 1 can be made of mesh material, as evidenced by the fragmented mesh part 18. Instead of being made from the present nets, strips can consist of foil with holes made in it. Thus, it is assumed that the expression “mesh” also includes the case when at least one of the stripes is formed with many holes.

Thus, flat and folded strips can be made of both solid material and mesh, or flat and strips can be solid, and folded strips of net or vice versa. It is assumed that figure 1 contains all possible combinations in which any or all of the flat and / or folded strips may be of solid or mesh material. All such combinations are included in the scope of the invention.

The advantage of using a grid for flat and / or folded strips is that the grid enhances the flow and transfer of heat between the channels, and also contributes to radiation heat transfer.

Monoliths 8, 9 and 10 are separated by dividers 11, 12 and 13. In one of the preferred embodiments, the dividers have the shape of “spiders” shown in FIG. Spiders are made, as shown, from a flat strip of metal. The spiders 12 and 13, which are located between the monoliths, have a width that is twice as large as the width of the spider 11, which is located at the end of the cartridge. The reason for this feature is that when the stacks are stacked in a cylindrical long pipe “end to end”, the total width of the spiders at the ends of adjacent cartridges is equal to the total width of the outer spiders, which keeps the distance between adjacent monoliths in the cartridge constant.

In addition to the fact that the separators provide a constant distance between the monoliths, they also prevent the telescoping of the layers one after the other under the influence of the pressure of the gas passing through the cartridge. Instead of spiders, other means known in the art can also be used to prevent telescoping.

Each spider is formed by a plurality of petals, such as those shown under reference numbers 14, 15 and 16. The petals of neighboring spiders are deliberately arranged in relation to one another in different phases in order to create greater turbulence in the mixing areas and, accordingly, to enhance heat transfer through the entire cartridge volume .

The pipe 7 serves as a core onto which flat and folded strips are wound to form a spiral structure. It also serves to fix the monoliths in a spatially separated state, since pairs of strips are welded to the pipe. Consequently, the monoliths are held in spatially separated positions both by welding the strips to the pipe and by means of dividers.

Instead of a pipe, a solid rod can be used. A pipe is more preferable since it is easier to use an input / output device described below. If a pipe is used, it should be sealed, preferably with a baffle or plug in the middle or close to the middle of the pipe, to prevent gas from passing through the pipe. In other words, the pipe should play the role of a structural element, but not a gas pipeline.

Thus, the cartridge of the present invention contains many sequentially arranged monoliths. The distances between the monoliths, partially occupied by the separators, contain areas in which gases coming from different channels limited by the monoliths can mix. The beveled folds limit the curved channels in the monolith, swirling the gases leaving the monolith. Since the direction of the bevel turns from one monolith to another, the direction of the swirl also turns on each subsequent monolith. The circulation effect creates turbulence in the mixing space, increasing heat transfer between different gas flows, as well as between the outer wall of the long pipe in which the cartridge is located, and gas flows.

In one embodiment, the monoliths have a longitudinal length of about 5 cm and a diameter of about 10-15 cm with a length of the mixing space in the range of 0.625 to 1.25 cm. In a more general case and depending on flow conditions, the length may be approximately from 5 to 15 cm, the diameter can be from about 7.5 to 17.5 cm, and the distance between the monoliths can be in the range of about 0.3 to 2.5 cm. The monoliths are formed by wrapping flat and folded strips on the pipe or a rod with a diameter of about 1.9-5.0 cm. Many of these monoliths are easily It relies cartridge length of from about 7.5 to 15 cm. The numerical values given here are merely exemplary and are not intended to limit the invention to any particular size.

In a more specific example, the pipe may have a thickness of 100 cm and the strips have a width of 5 cm. If the distance between adjacent strips (monoliths) is 1.25 cm, 16 monoliths can be formed along the pipe or rod. In other words, there can be 16 monoliths in the cartridge, 8 of which give a swirl clockwise and 8 counterclockwise.

In the reactor tube, the cartridges are stacked one on top of another until the pipe is filled in height, which can be approximately 10 to 14 m. The cartridges can be fixed to a structural member such as a rod in the middle of the reactor tube.

The above dimensions are given as examples only and are not intended to limit the invention. In order to meet the needs of a particular application, the cartridge components of the present invention can be enlarged or reduced using an infinite variety of sizes. It is intended that the present invention include all variations.

Since the length of the cartridge according to the present invention is generally much less than the length of the reactor tube, it is necessary to provide a device for introducing and removing the cartridge. Each cartridge predominantly comprises in the middle a connecting device for engaging with the device associated with it in the device for insertion and removal. The connector may be a thread, a T-slot, or some other structure. The connecting device may be made in the pipe or be formed as a result of restriction by a spacer or spider. The insertion device allows the cartridge to be lowered into the reactor tube and, if necessary, withdrawn from the reactor tube. Further in the present description describes specific embodiments of the input device.

Briefly, a preferred method for assembling a cartridge for a catalytic reactor of the present invention is as follows. First, a rod or a clogged pipe is prepared, such as pipe 7. Next, a plurality of flat and folded strips are prepared, the folds being beveled. As noted above, some or all of these strips may consist of mesh material or solid material. If it is intended to use a cartridge for carrying out catalytic reactions (rather than using it, for example, as a simple heat exchanger), a catalyst coating is applied to the strips. The folded and flat coated strips are welded to the pipe using a tack weld at regular intervals so as to provide the desired distance between the monoliths. The bands are configured so that after the formation of monoliths is completed, the outer layer is folded. Between adjacent monoliths can be placed a separator, such as a spider.

The cartridge thus obtained, which at the same time contains a central rod or pipe, can be wrapped in a mesh material, as shown in FIG. 7, the mesh having either a large or a fine mesh. The mesh used to wrap the monoliths is different from the mesh material that may have been used to make some or all of the flat and pleated stripes. It is assumed that the mesh used to place the cartridge in it is itself a catalytic coating. The outer mesh material fixes the monoliths and prevents them from unwinding, and also reduces the risk of damage to the monoliths when the cartridge is inserted or removed. The grid also allows gas from inside the cartridge to come into contact with the walls of the reactor tube. The cartridge can then be supplemented with separators such as illustrated spiders or similar protective agents.

The present invention also relates to an input / output device, preferred for insertion and removal of a cartridge from a long pipe. The problem is how to remove the cartridge made as described above from a long pipe, the length of which can reach 14 meters. The cartridges are stacked in this pipe in an end-to-end manner. Since a long pipe can have a small diameter (of the order of 10-15 cm) with respect to its length, the visibility distance inside the long pipe is very limited. In many, or in most cases, it may be necessary to insert or remove cartridges from a long pipe without any visual feedback. The input device must be able to work in any orientation.

The connection between the I / O device and the cartridge must be such that both of these parts cannot be disconnected during the output process. Significant pushing and torsional forces may be required to separate the cartridge from the wall of the long pipe.

Thus, the input / output device used in the present invention contains three components:

1) a centering mechanism to maintain alignment with the central pipe of the multi-tiered reactor;

2) a connector that engages the device with the cartridge of a multi-tiered reactor; and

3) traction used to introduce the device and remove it.

Preferred connector designs of the present invention are in the form of a double fishing hook and a triple fishing hook. Figures 2-4 illustrate the shape of a double fishing hook, and Figures 5, 6 show the shape of a triple fishing hook.

Consider first the embodiment shown in FIGS. 2-5. The centering mechanism shown in this embodiment is a brush modified to engage the forms of the connector described below. The diameter of the brush is selected so that it fits easily, but tightly into the long pipe in which the reactor cartridge is located. The longitudinal axis of the brush practically coincides with the longitudinal axis of the long pipe. Thus, being inserted into the long pipe 23 (see FIGS. 3 and 4), the brush provides centering of the rod 25 along the longitudinal axis of the long pipe. One of the advantages of using a brush is that when it is introduced, it cleans the walls of a long pipe, making it easier to remove the cartridges.

The centering mechanism may take other forms. For example, a cylindrical cage (not shown) with two spoke "wheels" at each end can be used. The length of the cell must be at least equal to its circumference. The total diameter of the cage and rollers may be slightly smaller than the diameter of the long tube into which the cartridges are introduced. The cage should be enclosed between the rod and the connector. The advantage of the cell is that it can be moved inside a long pipe without resistance in any direction. On the other hand, the bristles of the brush 21 show some resistance to a change in direction.

As noted above, FIGS. 2-4 illustrate an embodiment in which the connector comprises a double fishing hook. In particular, these figures show J-shaped fishing hooks 27. The fishing hooks are attached to the ring 29. To facilitate connection with the centering mechanism, the ring preferably has an internal thread. Fishing hooks 27 may be formed from pins that are J-shaped, with the pins, as shown, mounted on opposite sides of the ring.

The double fishing hooks 27 engage with the lifting pin 31, which is best seen in FIG. 4. The lifting pin 31 is preferably fixed along the diameter of the pipe 33, which is a support for the monoliths entering the cartridge. In this embodiment, the use of a hollow pipe is contemplated. If the pipe is replaced with a solid shaft, the lifting pin is not used. In this case, the fishing hooks can be made so that they can capture any other element, for example a spacer, or a spider.

The engagement of the input-output device is as follows. The device is inserted into a long pipe and pushed towards the nearest reactor cartridge. When the device comes in contact with the nearest cartridge, it is rotated clockwise. When the fishing hooks rest against the lifting pin, rotating the device will cause the fishing hooks to slip under the lifting pin. Further, the rotation causes the fishing hooks to slip behind the hairpin, so that the ring can be firmly fixed at the end of the monolith. After turning the device, it is pulled up. This movement hooks fishing hooks with a lifting pin. Fishing hooks create positive engagement in any direction of rotation, making it possible to remove the reactor cartridge. The device is detached from the cartridge in the reverse order.

5 and 6 show an embodiment in which the connector comprises a triple fishing hook. This connector contains three separate fishing hooks 41, each of which is J-shaped. The hooks are bent outward from the center, so that the washer 43, wound over the combined hook trunks, will compress the hooks. A thick washer 45 is welded to the central support tube 47 of the cartridge. When the entire assembly, including the washer 43 and the fishing hooks 41, is pushed into the reactor cartridge, the fishing hooks spring apart to allow them to engage with the thick washer. When the output device is pulled out of the cartridge, as illustrated in FIG. 6, the cartridge is pulled outward together with the device due to the hooking of the hooks with a thick washer. The hooks can be detached from the thick washer by moving the washer 43 toward the hooks, as a result of which the hooks are sealed and disengage from the thick washer.

The thrust used in the manufacture of the input-output device may be the handle of a conventional chimney brush. The thrust is performed in the form of sections with a thread at each end, with the help of which it can, if necessary, be introduced and output. After pulling traction from a long pipe, sections can be removed, which will simplify further operations. The invention is not limited to the draft design described above: other designs may be used within the scope of the invention.

Although the invention is described mainly in the context of catalytic combustion or other catalytic reactions (such as steam reforming), it should be borne in mind that the open cartridge is not limited to its use in catalytic reactions. The cartridge of the present invention can be used to enhance traditional combustion, or it can be used as a simple heat exchanger. Similarly, an input / output device is not limited to its use in the field of catalytic or conventional combustion. The term "reactor" is used in the present description to mean all of the above features.

The invention can be modified in different directions. As noted above, it is possible to vary the size of the bands and change the number of monoliths in each cartridge. You can vary the bevel angle of the folds. The spacers are not limited to the spiders shown and may be replaced by equivalent devices or (in some cases) may be completely absent. These or other modifications that should be obvious to experts in this field should be considered in the spirit and scope of the following claims.

Claims (12)

1. A method of introducing a reactor cartridge into a long pipe, the cartridge having a generally cylindrical structure that contains a plurality of spatially separated monoliths, in which a) an input device is attached to the end of the cartridge; b) lowering the cartridge into a long tube, during which the cartridge remains connected to the insertion device; c) separating the insertion device from the cartridge. 2. The method according to claim 1, in which operations (a) to (c) are repeated for multiple cartridges. 3. The method according to claim 1, in which the insertion device is selected so that it contains a centering mechanism that fits snugly into the long pipe and at least one hook, and during the attachment operation, the hook is hooked with a lifting pin connected to the cartridge . 4. The method according to claim 1, in which during the separation operation the input device is rotated until the device is disengaged from the cartridge. 5. The method according to claim 1, in which the introducing device comprises a) a brush, which has dimensions that allow it to be inserted tightly into a long pipe and hold said device inside the pipe, and b) a connector attached to the brush, wherein said connector contains at least two hooks designed to engage with the reactor cartridge, the hooks being held inside the hole of the washer. 6. The method according to claim 1, in which the introducing device comprises a) a rod, b) a brush connected to the rod, and the brush has dimensions that allow it to be inserted tightly into a long pipe, and c) a lot of hooks having a J-shape, attached to the rod, and the hooks are located below the brush and configured to engage with a lifting pin attached to the reactor cartridge by rotating the specified device. 7. A method of removing a reactor cartridge from a long pipe, the cartridge having a generally cylindrical structure that contains a plurality of spatially separated monoliths, in which a) an input device is attached to the end of the cartridge; b) lift the cartridge from a long pipe, while the cartridge remains connected to the insertion device; c) separating the insertion device from the cartridge. 8. The method according to claim 7, in which operations from (a) to (c) are repeated for multiple cartridges. 9. The method according to claim 7, in which the introducing device comprises a centering mechanism that fits snugly into the long pipe and at least one hook, and at the attachment stage, the hook is hooked with a lifting pin connected to the cartridge. 10. The method of claim 9, wherein a centering mechanism comprising a brush is selected. 11. The method according to claim 7, in which the introducing device comprises a) a brush, which has dimensions that allow it to be inserted tightly into a long pipe and hold said device inside the pipe, and b) a connector attached to the brush, wherein said connector contains at least two hooks designed to engage with the reactor cartridge, the hooks being held inside the hole of the washer. 12. The method according to claim 7, in which the introducing device comprises a) a rod, b) a brush connected to the rod, and the brush has dimensions that allow it to be inserted tightly into a long pipe, c) a lot of hooks having a J-shape attached to the thrust, and the hooks are located below the brush and are made with the possibility of engaging with a lifting pin attached to the reactor cartridge by rotating the specified device.

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