Quench supply and mixing system

In reactors with multiple catalyst beds, the process includes a critical inter-bed cooling stage required for effective control of exothermic reactions and maintenance of the optimum catalyst operating temperature. Cooling is achieved by controlled supply of a cooling medium, which is thoroughly mixed with the heated process stream leaving the preceding catalyst bed, reducing the mixture temperature to the specified value before it enters the next catalyst bed. A mixing system ensuring flow homogenisation and uniform temperature distribution.

Design features

The mixing system consists of three key elements:

• a collection tray designed to receive and initially distribute the reaction stream from the upper catalyst bed
• a mixing chamber where intensive mass and heat transfer takes place between the hot reaction stream and the cooling medium
• a cooling-medium supply system consisting of piping, nozzles or distribution devices that control the flow rate and uniformity of coolant injection

Proper design and operation of this system prevent local overheating, minimise the risk of thermal catalyst deactivation, maintain the required process selectivity, ensure the specified reactant conversion and, overall, guarantee stable and safe operation of a multi-bed catalytic reactor under conditions of intensive heat release.

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