U.S. patent application number 13/853364 was filed with the patent office on 2015-11-05 for wire standoffs for stackable structural reactors.
This patent application is currently assigned to Catacel Corp.. The applicant listed for this patent is CATACEL CORP.. Invention is credited to Brian L. Davis, Joseph W. Whittenberger, William A. Whittenberger.
Application Number | 20150314257 13/853364 |
Document ID | / |
Family ID | 54010729 |
Filed Date | 2015-11-05 |
United States Patent
Application |
20150314257 |
Kind Code |
A9 |
Whittenberger; William A. ;
et al. |
November 5, 2015 |
WIRE STANDOFFS FOR STACKABLE STRUCTURAL REACTORS
Abstract
A wire standoff suitable for use in a tubular reactor, such as a
reformer, is described. The wire standoff includes a portion or
segment positioned between an outer reactor tube and one or more
reactor components located within the tube. The reactor components
and the outer tube are prevented from coming into directed contact
with one another by the positioning of the wire standoff. The wire
standoff can be secured to a reactor component at one of its ends
or to a washer located between stacked reactor components.
Prevention of the reactor components from contact with the outer
tube promotes fluid flow through the reactor and can enhance heat
transfer and reactor efficiency for carrying out catalytic
reactions.
Inventors: |
Whittenberger; William A.;
(Leavittsburg, OH) ; Whittenberger; Joseph W.;
(Ravenna, OH) ; Davis; Brian L.; (Ravenna,
OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
CATACEL CORP. |
Garrettsville |
OH |
US |
|
|
Assignee: |
Catacel Corp.
Garrettsville
OH
|
Prior
Publication: |
|
Document Identifier |
Publication Date |
|
US 20130259767 A1 |
October 3, 2013 |
|
|
Family ID: |
54010729 |
Appl. No.: |
13/853364 |
Filed: |
March 29, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61619001 |
Apr 2, 2012 |
|
|
|
Current U.S.
Class: |
422/198 ;
422/310 |
Current CPC
Class: |
B01J 19/325 20130101;
B01J 2219/3085 20130101; B01J 19/305 20130101; C01B 3/384 20130101;
Y02P 20/10 20151101; B01J 2219/2459 20130101; C01B 2203/1064
20130101; B01J 2219/2455 20130101; B01J 2219/2482 20130101; C01B
2203/1023 20130101; B01J 2219/3221 20130101; C01B 3/38 20130101;
G01V 1/3808 20130101; B01J 8/008 20130101; B01J 2219/2488 20130101;
C01B 2203/107 20130101; F28D 2021/0022 20130101; B01J 19/249
20130101; B01J 2219/2496 20130101; B01J 2219/30475 20130101; F28F
3/083 20130101; Y02P 20/124 20151101; B01J 2219/2485 20130101; B01J
2219/2487 20130101; B01J 2219/249 20130101; C01B 2203/1058
20130101; G01V 1/003 20130101; B01J 2208/00884 20130101; B01J
2208/06 20130101; F28F 9/0075 20130101; F28F 13/06 20130101; B01J
19/2485 20130101; B01J 2219/2486 20130101; B01J 8/025 20130101;
B01J 2219/32275 20130101; B01J 2219/32466 20130101; C01B 2203/1052
20130101; B01J 2219/2443 20130101 |
International
Class: |
B01J 8/00 20060101
B01J008/00 |
Claims
1. A reactor comprising: a) an outer tube; b) one or more reactor
components, the one or more reactor components having an outer
circumferential face, the one or more reactor components being
positioned in the outer tube; c) a wire standoff, a portion of the
wire standoff being positioned between the outer tube and the one
or more reactor components to prevent the one or more reactor
components from contacting the outer tube.
2. The reactor of claim 1, the wire standoff having a diameter in
the range of 0.25 to 10 mm.
3. The reactor of claim 1, the outer circumferential face of the
one or more reactor components being spaced at least 0.25 to 10 mm
from the outer tube.
4. The reactor of claim 1, the wire standoff being secured to at
least one of the one or more reactor components.
5. The reactor of claim 4, the wire standoff having an end portion
having a straight segment, the end portion extends inward into the
at least one reactor component through its outer circumferential
face.
6. The reactor of claim 1, the portion of the wire standoff
positioned between the outer tube and the outer circumferential
face of the one or more reactor components being in direct contact
with the outer tube and the one or more reactor components.
7. The reactor of claim 1, further comprising a washer being
positioned in the outer tube.
8. The reactor of claim 7, the wire standoff being secured to the
washer.
9. The reactor of claim 8, the wire standoff having an end portion,
the end portion being secured to the washer.
10. The reactor of claim 9, the end portion of the wire standoff
having a hook for securing the end potion to the washer.
11. The reactor of claim 10, the hook of the end portion of the
wire standoff having a bend angle in the range of 70 to 180
degrees.
12. The reactor of claim 7, the washer having an opening for
securing the wire standoff
13. The reactor of claim 12, the wire standoff having an end
portion, the end portion extends through the opening in the washer
for securing the wire standoff to the washer.
14. The reactor of claim 7, the wire standoff having a hook forming
an open slot, the washer being positioned in the open slot of the
hook for securing the wire standoff to the washer.
15. The reactor of claim 1, further comprising a first washer and a
second washer positioned in the outer tube, the wire standoff
having a first end portion and a second end portion, the first end
portion of the wire standoff being secured to the first washer and
the second end portion of the wire standoff being secured to the
second washer.
16. The reactor of claim 15, the first end portion of the wire
standoff having a hook for securing the first end potion to the
first washer and the second end portion of the wire standoff having
a hook for securing the second end portion to the second washer,
wherein the hook of the first end portion and the hook of the
second end portion have a bend angle in the range of 70 to 180
degrees.
17. A wire standoff for use in a reactor comprising: a metal wire,
the metal wire having a portion positioned between an outer tube
and a reactor component of the reactor such that the portion
directly contacts the outer tube and the reactor component and the
outer tube and the reactor component are not in direct contact with
one another; the metal wire having a first end portion and a second
end portion, the first end portion and the second end portion of
the metal wire secured to a reactor component or a washer
positioned inside the outer tube.
18. The wire standoff of claim 17, the metal wire having a hook
forming an open slot, the washer being positioned in the open slot
of the hook for securing the metal wire to the washer
19. The wire standoff of claim 17, the first end portion of the
metal wire having a hook for securing the first end potion to the
washer.
20. The wire standoff of claim 17, the reactor component having an
outer diameter surface plane, the first end portion of the metal
wire extends inward into the reactor component through its outer
circumferential face for securing the first end portion to the
reactor component.
Description
[0001] This application claims the benefit of U.S. Provisional
Application No. 61/619,007, filed Apr. 2, 2012, which is
incorporated herein by reference in its entirety.
FILED OF THE INVENTION
[0002] The present invention relates to improved stackable
structural reactors having increased efficiency and productivity,
and in particular, improved stackable structural reactors having
one or more wire standoff arrangements for increased heat transfer
and reactor efficiency.
BACKGROUND
[0003] Reactor components for carrying out catalytic reactions,
such as those used to produce syngas and hydrogen, can generally
contact reactor tubes exposed to a heat source, for example a
furnace, to support reactions. In contrast, other types of
reactions, such as exothermic reactions, can require a cooling
source, such as a cooling jacket. The reactor tubes can be loaded
with various arrangements of components, such as foil-supported or
structured catalysts in the form of fans, fins, foams, coils or
monoliths. In some instances, the reactor components can be
expandable, such as those formed from foil, for example, a fan.
[0004] To improve heat transfer and fluid flow through a reactor,
the fit of foil-supported catalysts can be enhanced. In a reactor
tube, expandable catalyst-coated reactor components can be
positioned to increase heat transfer, such as being located near
the reactor wall exposed to a heating or cooling source. Thus, it
is desirable to fit reactors with accessories to promote increased
heat transfer and reactor efficiency, such as features that create
turbulent fluid flow through the reactor components. Various
embodiments of wire standoffs and arrangements of the same for
improving performance of reactors are discussed herein.
BRIEF SUMMARY
[0005] A reactor including an outer tube that houses one or more
reactor components and a wire standoff. The one or more reactor
components can have a circular diameter and have an outer
circumferential face, such that the outer diameter surface of the
one or more reactor components is not in direct contact with the
outer tube. The wire standoff can include a portion thereof that is
positioned between the inner wall surface of the outer tube and the
outer diameter surface of the one or more reactor components. As
arranged, the wire standoff prevents the one or more reactor
components from touching the inner wall surface of the outer tube
but the wire itself can be in direct contact with the tube wall and
the one or more reactor components. The wire standoff can be
secured to the one or more reactor components or one or more
washers also located in the outer tube.
[0006] A wire standoff for use in a reactor. The wire standoff can
be a metal wire. The metal wire can have a portion positioned
between an outer tube and a reactor component of the reactor,
wherein the reactor component is located within the outer tube. As
arranged in the reactor, the portion of the metal wire separating
the outer tube and reactor component from touching can itself be in
direct contact with the outer tube and the reactor component. The
metal wire can have a first end portion and a second end portion
defining its terminal ends. The first end portion of the metal wire
can be secured to a reactor component or washer contained in the
reactor. Similarly, the second end portion can be secured to a
reactor component or washer of the reactor. For purposes of
securing either end portion of the metal wire to a washer, the
metal wire can have a hook. The metal wire can have an end portion
having a straight segment for securing the wire to a reactor
component, such as a fan, wherein the end portion extends inward
into a reactor component and past its outer circumferential
face.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The following figures illustrate various aspects of one or
more embodiments of the present invention, but are not intended to
limit the present invention to the embodiments shown.
[0008] FIG. 1 shows a cross-section view of a reactor tube having
multiple wire standoffs arranged along the outer diameter face of
reactor components and between the outer tube and the
components.
[0009] FIG. 2 shows a perspective view of a stack of reactor
components having multiple wire standoffs arranged along the outer
diameter face of the reactor components wherein the wire standoffs
traverse the face of multiple components.
[0010] FIG. 3 shows a cross-section view of a wire standoff
arranged on a washer for purposes of securing the wire standoff on
the washer.
[0011] FIG. 4 shows a cross-section view of a wire standoff
arranged on a washer for purposes of securing the wire standoff on
the washer.
[0012] FIG. 5 shows a perspective view of a stack of reactor
components having multiple wire standoffs arranged along the outer
diameter face of the reactor components.
[0013] FIG. 6 shows a cross-section view of a wire standoff
arranged on a washer for purposes of securing the wire standoff on
the washer.
[0014] FIG. 7 shows a cross-section view of a wire standoff
arranged through an opening in a washer for purposes of securing
the wire standoff on the washer.
[0015] FIG. 8 shows a perspective view of a stack of reactor
components having multiple wire standoffs arranged along the outer
diameter face of the reactor components.
[0016] FIG. 9 shows a perspective view of a wire standoff having
hook ends for securing the wire standoff to a reactor component or
washer.
[0017] FIG. 10 shows a perspective view of a stack of reactor
components having multiple wire standoffs arranged along the outer
diameter face of the reactor components.
[0018] FIG. 11 shows a perspective view of a wire standoff having a
zig-zag pattern and end portions having a straight segment for
securing the wire standoff to a reactor component.
[0019] FIG. 12 shows a perspective view of a stack of reactor
components having multiple wire standoffs arranged along the outer
diameter face of the reactor components.
[0020] FIG. 13 shows a perspective view of a wire standoff having
straight ends for securing the wire standoff to one or more reactor
components.
DETAILED DESCRIPTION
[0021] As used herein, when a range such as 5-25 is given, this
means at least or more than 5 and, separately and independently
less than or not more than 25. Materials of construction for all
reactor components or parts thereof, such as catalyst supports,
fans, monoliths, coils, washers and inner and outer tubes, as
discussed herein, can include any suitable material as known in the
art, for example, metal, non-ferrous metal, metal foil, steel,
stainless steel, alloys, foils, non-metals such as plastics or
glass, ceramic, or combinations thereof
[0022] The reactors as described herein, sometimes referred to as a
stackable structural reactors ("SSR"), can include multiple
catalyst support components arranged around or stacked on a center
support, such as a central rod or mandrel, pipe, post or the like,
in order to form a monolith of general annular cross section as
viewed in the direction of flow of fluid through the reactor. The
monolith or stacked catalyst supports can occupy all or a portion
of the annular space between two concentrically arranged tubes,
such as a reactor or outer tube and an inner tube. Alternatively,
reactor components can fill a reactor tube with or without a center
support such that no center hollow section is formed concentric
tubes. As described herein, various modifications and embodiments
of the reactors and associated reactor components can be used in
connection with wire standoffs to promote heat transfer and reactor
efficiency.
[0023] The outer tube 3 having an inner wall face and an outer wall
face, such as a reformer tube, can house one or more reactor
components 2, such as vertically stacked fans 2, arranged on a
central rod 1. The diameter of the outer tube 3 is preferably
constant along its entire length. Reactor components 2, such as
fans, can be constructed to have a central opening or aperture 12
for receiving the central rod 1 such that the components can slide
on the central rod and be positioned in the outer tube. For
example, a cylindrical rod 1 can be used as shown to support the
reactor components 2 having centered circular openings 12. The
cylindrical rod 1 can have a diameter about the same or slightly
less than the diameter of the openings 12 in the reactor
components. The central rod 1 can have a length to accommodate the
length of the outer tube 3.
[0024] The central rod 1 can further include a bracket, bushing,
base plate and the like for providing a stop fitting so the
components do not slide off of the central rod. The base plate can
be located at or near the bottom end of the central rod and can
have a shape and diameter or dimensions to permit ease of install
in the outer tube. For instance, the stop plate can have a circular
shape with a diameter about the same or less than the inner
diameter of the outer tube. The central rod can be preloaded with
any number of reactor components or washers before being inserted
into an outer tube.
[0025] As shown in the figures, the fans 2 can be stacked
vertically, one on top of another, to form layers of reactor
components 2. Although reactor components are shown vertically
stacked herein, the components can be arranged in alternative ways
such as horizontal to accommodate orientation of a reactor or
certain technology requirements. Washers 4 as described below can
be inserted between one or more reactor components (e.g., fans) 2
as desired, for example, each fan can be separated by a washer
wherein the washer creates an open space between the components.
Washers 4, in the shape of rings, can function as spacers and the
reactor components and washers can be arranged in an alternating
series. Stacked reactor components can be arranged vertically as
desired, for example, in the range of 0.5 to 4 feet, to create a
subassembly. Multiple subassemblies can be stacked together in a
reactor, for example from 1 to 60 subassemblies can be stacked. The
stacked subassemblies can have a height in the range of 2 to 60
feet.
[0026] Fluid 10, such as gas or liquid, to be reacted generally
flows vertically, either up flow or down flow 10a, 10b as desired,
through the outer tube 3 and through each component 2 arranged on
the central rod 1. Reactor components 2 direct fluid flow in other
non-vertical directions to increase heat transfer, for example fans
direct or guide fluid flow radially (perpendicular to the overall
vertical direction) towards the outer tube wall. The fans can be in
contact with or near the inner wall surface of the outer tube 3,
which effectively transfers heat from the exterior of the reactor
to the reactor components 2 and fluid 10 contained therein.
Preferably, the fans located within the outer tube have a diameter
less than the inner diameter of the reactor tube to create a gap or
free space 7 between the outer circumferential face of the fans and
the inner wall surface of the outer tube. The gap 7 between the
outer diameter face of the fans and the inner wall surface of the
outer tube can be at least 0.5, 1, 2, 3, 5, 10 or 15, mm and
preferably in the range of 0.5 to 6, and more preferably 1 to 3 mm.
The gap 7 promotes heat transfer and forces fluid flow traveling
toward the inner wall surface of the reactor wall to be directed
back towards the inner portion of the reactor.
[0027] The stacked arrangement of reactor components 2 is designed
to promote heat transfer for carrying out catalytic reactions such
that reactor components 2 and washers 4 can be coated with a
catalyst to effectively distribute catalyst contact with most of
the volume of fluid 10 flowing through the reactor. Catalytic
material for coating reactor components is known in the art and can
include, but is not limited to, nickel, palladium, platinum,
zirconium, rhodium, ruthenium, iridium, cobalt and oxides of
aluminum, cerium, and zirconium.
[0028] As discussed below, wire standoffs 5 can have various
designs and configurations and can be positioned and arranged in
many ways with the reactor components 2 and washers 4. Turning to
the figures, FIG. 1 shows a reactor having wire standoffs 5
arranged inside an outer tube 3 for preventing the reactor
components and washers from contacting the inner wall surface of
the outer tube. As shown, the reactor components 2 are arranged
vertically in a stacked manner with alternating washers within the
outer tube 3. The reactor components are arranged on a central rod
1 that traverses the length of the outer tube. To prevent the
stacked reactor components and washers from sliding downward and
off of the central rod, a stop plate 6 is positioned at or near the
bottom end of the central rod 1. Fluid 10 can flow through the
reactor components 2 and downward/upward through the outer tube 1.
Fluid 10 contacts catalyst supports for carrying out reactions in
the outer tube.
[0029] Secured to the washers 4 or reactor components 2, wire
standoffs 5 are positioned around the outer diameter surface of the
components 2 or washers 4. The wire standoffs 5 can be made of any
suitable material, such as metal, steel, stainless steel, alloys,
such as nickel and/or chromium, foil, and non-metal materials such
as plastic. For example, the wire standoff can be a metal wire,
cable, cord or filament. Preferably, the wire standoffs 5 are
flexible such that suitable structural modifications can be made to
alter the wire standoff to a particular reactor component or
components. The wire standoffs 5 can be preferably made from
circular diameter flexible wire that can have a constant diameter
along the entire length of the wire. The wire standoff can have a
circular diameter of at least 0.25, 0.5, 0.75, 1, 1.5, 2, 2.5, 3,
3.5, 4, 4.5, 5, 6, 7, 8, 9 or 10 mm, and preferably in the range of
0.25 to 5 mm, and more preferably 0.5 to 2 mm. Optionally, square
or alternate cross section shapes can be used for making the wire
standoffs as desired.
[0030] The wire standoffs 5 can be designed to extend lengthwise,
such as vertically, along the outer diameter face 2a of one or more
reactor components 2 as shown in the figures. In some instances,
the wire standoffs 5 can traverse vertically across at least one
reactor component or in other cases across substantially the entire
reactor sleeve of stacked components. Traversing the across the
outer diameter surface 2a of one or more reactor components 2, the
wire standoffs 5 prevent the one or more reactor components, and
any washers 4 in the stack, from directly contacting the outer tube
3. As shown in the cross-section view, multiple wire standoffs 5
can be arranged to ensure a substantially constant annular gap 7
between the outer diameter face of the reactor components and
washers and the inner wall surface of the outer tube. Any number of
wire standoffs can be used to ensure the annular gap, for example,
1, 2, 3, 4, 5, 6, 7, 8, 9 or 10 wire standoffs can be used. The gap
7 between the outer diameter face of the reactor components and
washers and the inner wall surface of the outer tube 3 created by
the wired standoffs can be at least 0.25, 0.5, 1, 2, 3, 4, 5 or 10,
mm and preferably in the range of 0.5 to 6, and more preferably 1
to 3 mm.
[0031] The wire standoffs 5 can have inward-facing end portions 5a
at each end (first and second) such that the inward-facing end
portions bend or extend into a reactor component 2 or around a
washer 4 as shown, which can prevent the end portions 5a of the
wire standoff 5 from catching against the reactor tube 3 during
installation or operation. The wire standoff has two ends, a first
end or end portion and a second end or end portion. FIG. 1 shows an
end portion 5a of the wire standoff having a hook for securing the
end potion 5a to the washer 4. The hook of the end portion 5a of
the wire standoff can have a bend angle in the range of 70 to 180
degrees. As shown, an end portion of a wire standoff can extend
inward through the outer diameter surface plane 2a of a reactor
component 2, such as a fan, over the top surface of a washer 4 and
bend downward at about a 90-degree angle around the inner diameter
face 4a of the washer 4 to secure the wire standoff 5. In this
arrangement, the end portion 5a of the wire standoff has a
90-degree hook for securing the wire standoff to the washer.
[0032] Separate from the end portions 5a, the wire standoff 5 has
another portion, such as a middle section or portion, positioned
between the outer diameter surface of the reactor components 2a and
the inner wall surface of the outer tube 3. The wire standoffs 5
can be spaced radially around the diameter of a washer 4 as desired
and along other washers located above and/or below as shown to
provide perimeter coverage to the reactor components.
[0033] FIG. 2 shows two wire standoffs 5 positioned diagonally
across the outer diameter surface of three stacked reactor
components 2. Each reactor component has an opening 12 for
accommodating a central rod for positioning the components in a
stacked arrangement in an outer tube. Washers 4 in the shape of
rings having an outer diameter 4b, a flat body section and an inner
diameter 4a are positioned between each reactor component 2. The
first and second end portions 5a of the two wire standoffs 5 are
secured to the top most washer and the bottom most washer. The
first and second end portions of the wire standoffs extend inward
towards the center of the reactor components and traverse across
the top of the flat body section of each washer 4. As can be seen
at the bottom most washer, the end portions 5a of the wire
standoffs are bent near the inner diameter 4a of the washers such
that the end portions extend downward to hook around the inner
diameter 4a of the washers. As noted above, the wire standoffs 5
can have a hook portion for securing the wires to the washers,
wherein the hook portion can have a bend in the 70 to 180 degree
range.
[0034] As arranged in an outer tube, the fans 2 have multiple
radial fluid ducts 2b, 2c for directing fluid flow 10 through the
reactor. As shown, the radial fluid ducts are of approximately
triangular shape and extend outward from the center opening 12 to
form a circular cross section as viewed from the top of the fans 2.
The radial fluid ducts terminate along the outer diameter face of
each fan to form triangular openings facing the inner wall surface
of an outer tube. As viewed in the downward direction of fluid
flow, fluid flows in one end 10a of the stack of fans 2, radially
through the triangular-shaped ducts openly facing upward 2b towards
the outer diameter face of the fans 2 for contacting the reactor
tube, around the outer diameter face of the fans 2 into the
triangular-shaped ducts openly facing downward 2c, radially towards
the center of the fans 2 and onto the next fan and/or core in the
same manner until the fluid exits the stack of fans at the other
end 10b. In one arrangement, for example as shown in FIG. 2, the
fans 2 can be stacked in an arrangement that vertically aligns the
approximately triangular-shaped ducts openly facing upward 2b of
one fan with the approximately triangular-shaped ducts openly
facing downward 2c of the fan 2 positioned directly above or
below.
[0035] In between the two end portions 5a of each wire standoff 5
is a portion positioned between the outer tube and the outer face
of the reactor components 2 to prevent the components from coming
into contact with the outer tube (not shown). The middle portion
for ensuring a gap between the outer tube and reactor components
can traverse diagonally as shown along the outer diameter face of
the fans, or in another direction or pattern as desired, for
example, vertical or in a curved pattern, such as a "C" shape,
spiral, wave or zig zag pattern. Diagonal positioning of the middle
section of the wire standoffs 5 can be on an angle in the range of
5 to 70 degrees. Multiple wire standoffs can be arranged around the
outer diameter surface of the stacked fans 2 to provide 360 degree
coverage of the stacked components for ensuring a specified gap is
maintained around the components and between the inner wall of the
outer tube. Although three components are shown, the stack can
include more components and the wire standoffs can have a length to
accommodate any number of components.
[0036] The end 5a and middle portions of the wire standoffs 5 can
be secured to a washer 4 or a reactor component 2 in a number of
different ways. Wire standoffs as described herein can have one or
more securing features. For instance, each end portion 5a of a wire
standoff can have a different securing feature, such as a hook, and
the middle portion of that standoff can further include yet another
embodiment of a securing feature. The selection and variety of
securing features for a wire standoff can be chosen as desired. The
securing features of the wire standoffs are preferably integral to
the construction of the standoffs. For example, a metal wire can be
bent and manipulated to form a hook or notch at either end or the
middle portion for securing the wire standoff to a washer or
reactor component.
[0037] FIG. 3 shows one embodiment for securing an end portion 5a
of a wire standoff 5 to a washer 4. As shown, a cross-section view
of a washer 4 has an end portion 5a of a wire standoff 5 extended
along its width over the top of its body section. At the inner
diameter 4a of the washer 4, the end portion 5a of the wire
standoff has a bend at about a 90-degree angle such that the bent
end forms a hook that fits on the inner diameter 4a of the washer.
The hook prevents the wire standoff 5 from sliding or being pulled
off the washer 4 during installation or operation of the reactor.
The hook can be secured on the washer by tension. For example, the
wire standoff can be flexed or pushed on the washer to force the
hook around the inner diameter 4a of the washer 4. The end portion
5a of the wire standoff 5 can be welded, such as tack weld or laser
weld, on the washer 4 to permanently secure the wire standoff to
the washer.
[0038] FIG. 4 shows another embodiment for securing a wire standoff
5 to a washer 4. The end portion 5a of the wire standoff 5 can have
a hook portion that forms approximately a 180-degree bend for
hooking the end portion around the inner diameter 4a of a washer.
As shown, the inner diameter of the washer is in direct contact
with the inside surface of the hook of the end portion. The bend
angle of the hook can be less than 180 degrees, for example, at
least 120, 130, 140, 150, 160 or 170 degrees.
[0039] The wire standoffs 5 can be secured to washers 4 positioned
in the outer tube by means of end portions 5a of the wire standoffs
being inserted into openings or apertures 14 located in the washers
4, for example, in the body section. The washers 4 can have one or
more openings 14 for accommodating the end portion 5a of a wire
standoff. For example, a washer 4 can have 1, 2, 3, 4, 5, 6 or more
openings 14 for securing wire standoffs. The openings can be spaced
along the body section of the washer as desired and can be selected
to accommodate wire standoffs for providing coverage across the
entire face of stacked reactor components. The opening 14 can be
any shape and have dimensions greater than the diameter or
cross-section area of the end portion of the wire standoff. For
example, the washer openings 14 can be circular and have a circular
diameter of at least 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20 or 25
mm.
[0040] FIG. 5 shows a wire standoff 5 diagonally positioned across
the outer diameter face of two vertically-stacked fans 2 wherein
the wire standoff has two end portions 5a, a first and second, that
extend through openings 14 in the washers 4. The end portions 5a
can form a hook by having a bend in the range of 70 to 180 degrees.
The hook can be forced through the opening 14 in the washer to
secure the wire standoff. FIG. 7 shows an end portion 5a of a wire
standoff 5 extending downward through an opening 14 in a washer 4.
The end portion has a hook having a bend angle of about 90
degrees.
[0041] In another embodiment of securing a wire standoff to a
washer, FIG. 5 shows a wire standoff with a middle portion having a
hook or notch 5b that forms an open slot. The hook or notch 5b can
be an indented portion along the length of the wire standoff 5, for
example in the portion that is positioned between the outer tube
and reactor components. One or more notches 5b can be positioned
anywhere along the length of the wire standoff to align with the
desired reactor components 2. For instance, a washer 4 can be
positioned or nested in the open slot of the hook 5b for securing
the wire standoff to the washer. The wire standoff can be flexed or
forced around the inner diameter 4a of a washer to slide the open
slot of the middle portion over the washer for securing the wire
standoff. The remaining two end portions 5a of the wire standoff
can include securing features as discussed herein, such as a hook
having a bend angle in the range of 70 to 180 degrees. FIG. 6 shows
a cross-section view of a washer 4 positioned in the open slot of a
middle portion of a wire standoff having a notch 5b. As shown, the
inner diameter face 4a of the washer is in direct contact with the
open slot formed by the notch 5b in the wire standoff. It may be
desirable to have one or more open slot hooks 5b between the two
end portions 5a of a wire standoff for securing the standoff to
vertical arrangement of washers 4. Multiple open slots can provide
structural integrity and rigidity to the portions of the wire
standoff positioned between the outer tube and the outer diameter
face of the reactor components.
[0042] FIG. 8 shows another embodiment of a wire standoff 5. A wire
standoff can be designed to have a middle portion having a V-shape.
The angle of the V-shape can be in the range of 30 to 90 degree.
The V-shape of the middle portion can be arranged upward as shown
or downward for traversing across the outer diameter face of one or
more stacked reactor components. Alternatively, multiple V-shaped
wire standoffs can be arranged around the outer diameter face of
reactor components in an upward/downward alternating pattern to
provide 360-degree coverage of the outer diameter face of the
components for ensuring the reactor components do not come into
contact with the outer tube. Any number of wire standoffs can be
used to encompass the outer diameter face of one or more reactor
components. The V-shape portion can cover at least 1, 2, 3, 4 or
more reactor components, such as fans.
[0043] As shown in FIG. 9, the two end portions 5a of the V-shaped
wire standoff 5 can have a hook for securing the standoff to a
washer. The hook can have a bend angle in the range of 70 to 180
degrees. The hook can form a notch for nesting a washer or
alternatively the end portion can have a hook for extending through
an opening in a washer.
[0044] In another embodiment, a wire standoff can be secured to a
reactor component. An end portion 5a of a wire standoff can be a
straight section without a hook. The straight end portion can
extend inward into the at least one reactor component 2 through the
outer circumferential face, for example into a fluid channel or
duct 2b, 2c. For instance, as shown in FIG. 10, the straight
section or segment of the end portion 5a can extend into the flow
channel 2b, 2c of a fan reactor component 2. The end portion can be
secured to the reactor component by welding or tension caused by
flexing the wire standoff 5 to fit the end portion in the flow
channel 2b, 2c. The opposing end portion of the wire standoff can
be similarly secured to a reactor component or, alternatively, it
can be secured to a washer as described above.
[0045] FIG. 10 shows that the middle portion of a wire standoff,
between the two end portions 5a secured to reactor components, can
have a series of zig zags in an alternating "Z" pattern. Multiple
wire standoffs having a zig zag pattern can be used to encompass
the outer diameter face of one or more reactor components 2. As
arranged on the outer diameter face of reactor components, the wire
standoff can have a height of at least 3, 4, 5, 6, 7, 8, 9, 10 or
more reactor components or 4 to 30 inches.
[0046] FIG. 11 shows a wire standoff having a middle portion with a
zig zag pattern for being positioned between an outer tube and one
or more reactor components. Each end portion 5a of the wire
standoff 5 has a straight section or leg for extending inward
towards the center of the reactor. The straight section of the end
portions should have sufficient length to prevent the wire standoff
from detaching from the reactor components during installation. The
straight section of the end portions of the wire standoff can be in
the range of 20 to 80 mm.
[0047] The wire standoff 5 can be positioned on the outer diameter
face of the reactor components 2 by flexing or bending the standoff
to align both end portions with a flow channel in the one or more
fans. Once in position, the wire standoff can be released to
provide a non-flexed state thereby creating tension at both end
portions. The end portions 5a can press and provide a tension
fitting at the flow channels for securing the wire standoff to the
one or more reactor components. As noted above, the end portions 5a
of the wire standoffs can be welded to the flow channels 2b, 2c of
the reactor components 2 for securing them.
[0048] FIGS. 12 and 13 show another embodiment of a wire standoff 5
that can be secured to reactor components 2. Each end portion 5a of
a wire standoff can have a straight section that can extend into a
reactor component 2. The straight section can extend into the
reactor component in a direction that is substantially
perpendicular to the outer circumferential face of the reactor
component and the inner wall surface of the outer tube. In between
the two end portions 5a of each wire standoff is a portion
positioned between the outer tube and the outer face of the reactor
components to prevent the components from coming into contact with
the outer tube. As shown, the middle portion of the wire standoff
for ensuring a gap between the outer tube and reactor components
can be substantially straight and traverse diagonally along the
face of the components.
[0049] Diagonal positioning of the middle section of the wire
standoffs can be on an angle in the range of 5 to 70 degrees.
Multiple wire standoffs can be arranged around the outer diameter
surface of the stacked fans to provide 360 degree coverage of the
stacked components for ensuring a specified gap is maintained
around the components and between the inner wall of the outer tube.
Although three components are shown, the stack can include more
components and the wire standoffs can have a length to accommodate
any number of components.
[0050] While various embodiments in accordance with the present
invention have been shown and described, it is understood that the
invention is not limited thereto, and is susceptible to numerous
changes and modifications as known to those skilled in the art.
Therefore, this invention is not limited to the details shown and
described herein, and includes all such changes and modification as
encompassed by the scope of the appended claims.
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