📋 Case Study
Catalytic Reactor Distributor Plate Retrofit for Ammonia Synthesis Loop
Channeling and maldistribution causing localized hot spots (>520°C) and catalyst sintering
🏗️ Project Overview
Revamp of 3,000 tpd Haber-Bosch reactor in Louisiana
🎯 Challenge
Channeling and maldistribution causing localized hot spots (>520°C) and catalyst sintering
🔧 Design Approach
Laser-scanned bed geometry → multiphase CFD → optimized orifice pattern with graded resistance to equalize superficial velocity ±5%
📐 Design Diagram
AI-generated project design illustration
📐 Key Calculations
Superficial Gas Velocity
Q/A
Result: 0.18 m/s
Target uniformity window for Fe₃O₄ catalyst
Orifice Discharge Coefficient
Cd = Q/(A√(2ΔP/ρ))
Result: 0.62
Calibrated for high-pressure H₂/N₂ mixture at 150 bar
📊 Results
Radial temperature spread reduced from ±32°C to ±4.5°C; catalyst life extended by 40%💡 Lessons Learned
- •Discharge coefficient varies significantly with gas composition and pressure — empirical calibration required
- •Distributor plate must account for radial void fraction gradients
✅ Key Takeaways
- 1Discharge coefficient varies significantly with gas composition and pressure — empirical calibration required
- 2Distributor plate must account for radial void fraction gradients