US20020031459A1 - Fouling tolerant fixed bed reactor (law858) - Google Patents

Fouling tolerant fixed bed reactor (law858) Download PDF

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Publication number
US20020031459A1
US20020031459A1 US09/351,648 US35164899A US2002031459A1 US 20020031459 A1 US20020031459 A1 US 20020031459A1 US 35164899 A US35164899 A US 35164899A US 2002031459 A1 US2002031459 A1 US 2002031459A1
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US
United States
Prior art keywords
reactor
feedstock
bed
catalyst bed
fixed bed
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US09/351,648
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English (en)
Inventor
Ramesh Gupta
Salvatore Joseph Rossetti
David Charles Dankworth
Jeffrey L. Kaufman
David Lee Vannauker
James Philip Bailor
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
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Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Priority to US09/351,648 priority Critical patent/US20020031459A1/en
Priority to JP2001509287A priority patent/JP4794103B2/ja
Priority to PCT/US2000/019068 priority patent/WO2001003822A1/fr
Priority to CA002379369A priority patent/CA2379369C/fr
Priority to DE60005366T priority patent/DE60005366T2/de
Priority to EP00947307A priority patent/EP1200183B1/fr
Priority to US09/712,654 priority patent/US6846469B1/en
Priority to US09/933,939 priority patent/US6692705B2/en
Priority to US09/974,561 priority patent/US6689329B2/en
Publication of US20020031459A1 publication Critical patent/US20020031459A1/en
Abandoned legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
    • B01J8/008—Details of the reactor or of the particulate material; Processes to increase or to retard the rate of reaction
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
    • B01J8/02—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds
    • B01J8/0242—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds the fluid flow within the bed being predominantly vertical
    • B01J8/025—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds the fluid flow within the bed being predominantly vertical in a cylindrical shaped bed
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
    • B01J8/02—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds
    • B01J8/0278—Feeding reactive fluids
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G49/00—Treatment of hydrocarbon oils, in the presence of hydrogen or hydrogen-generating compounds, not provided for in a single one of groups C10G45/02, C10G45/32, C10G45/44, C10G45/58 or C10G47/00
    • C10G49/002—Apparatus for fixed bed hydrotreatment processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2208/00—Processes carried out in the presence of solid particles; Reactors therefor
    • B01J2208/00008—Controlling the process
    • B01J2208/00654—Controlling the process by measures relating to the particulate material
    • B01J2208/00707—Fouling

Definitions

  • An embodiment of the instant invention is directed to a reactor having bypass apparatus for extending the operating life of the reactor.
  • An embodiment of the invention is directed to a reactor for reacting a feedstock, said reactor comprising,
  • a fixed catalyst bed for reaction of said feedstock said reactor containing a bypass apparatus disposed within said fixed catalyst bed
  • bypass apparatus being aligned with the direction of flow of said feedstock, and wherein said bypass apparatus comprise
  • a cage member comprising a first elongated hollow member having a top wall, side walls and a bottom wall said cage member having openings therein, and
  • a second hollow elongated member for passing said feedstock therethrough, said second hollow elongated member being disposed within and protruding through said top wall of said cage member and wherein said second elongated member extends above said catalyst bed through said cage member.
  • a further embodiment of the invention is directed to a method for extending the operating life of a fixed bed reactor for reacting a feedstock in which a feedstock is contacted with a fixed bed of catalytic material contained in said reactor said fixed bed of catalytic material having a top and bottom layer and wherein the pressure drop across said top layer of said fixed bed of catalyst material increases during reaction of said feedstock due to fouling of said top layer of said fixed bed of catalytic material, comprising the sequential steps of (a) introducing said hydrocarbon feedstock into said fixed bed of catalytic material, (b) as said top layer of said fixed bed of catalytic material fouls, bypassing an increasing amount of said feedstock to said bottom layer of said fixed bed of catalytic material.
  • the FIGURE depicts one possible embodiment of the invention.
  • the second elongated member ( 1 ) is disposed within a cage member ( 2 ).
  • the cage member ( 2 ) has an upper enclosed portion (top wall and upper portion of the side walls) ( 3 ) and a lower perforated portion (bottom wall and lower portion of sidewalls) ( 4 ).
  • the bypass apparatus are located within the fixed bed ( 5 ) of a reactor ( 6 ).
  • the second hollow elongated member may have a cap ( 7 ) over the portion of the member extending above the catalyst bed.
  • the FIGURE likewise shows an optional layer of inert material ( 8 ) disposed within the catalyst bed in which the bypassed material is distributed.
  • An embodiment of the present invention finds particular applicability in connection with increasing the cycle life of a fixed bed of catalyst particles contained within a hydroprocessing reactor in which a hydrocarbon feedstock is processed during the carrying out of any one of a multitude of chemical reactions.
  • Such reactors are typically used for the conversion or treatment of hydrocarbon or chemical feedstocks in the presence of a vapor phase, such as hydrogen containing treat gas.
  • Nonlimiting reactors for which the present invention can be utilized include those used for hydroconversion of heavy petroleum feedstocks to lower boiling products; the hydrocracking of distillate boiling range feedstocks; and hydrotreating of various petroleum feedstocks, such as light hydrocarbons, naphtha and distillate boiling range streams. More particularly, the reactors on which the present invention are practiced are those having one fixed bed reaction or catalyst bed. This invention is also applicable to reactors having more than one catalyst bed but in which only the top portion of any of the fouling prone beds is bypassed.
  • the bypass apparatus utilized herein can be particularly beneficial in preventing the fouling of a fixed catalyst bed utilized for contacting, a stream of hydrocarbon feedstock with a conventional reforming or hydroprocessing catalyst.
  • the bypass apparatus allows the feedstock to bypass the upper portion or layer of the catalyst bed once fouling occurs, enabling the bed to be run for substantially longer periods of time as compared to running without the bypass apparatus.
  • the second hollow elongated member extends both above the catalyst bed and into the catalyst bed.
  • the cage member can be either partially or fully embedded or buried in the bed such that the section having openings therein discharges and distributes the bypassed hydrocarbon feed to an elevation within the bed below the top fouling layer of the bed.
  • the cage is closed at the top except for where the first hollow elongated member extends therethrough.
  • the entire cage member may have openings therein, including in the top, sides, and bottom.
  • a cage member having an enclosed top is depicted in the FIGURE with openings in the bottom and sidewalls of the lower portion of the cage member.
  • the second elongated member extends through the first hollow elongated cage member preferably terminating substantially at the portion having openings therein. This allows for distribution of the bypassed hydrocarbon feedstock through the openings in the cage member.
  • the second elongated member may stop short of the openings, or extend to an area within the portion of the cage member having openings.
  • the bottom of the cage member will likewise be enclosed and only the sidewalls will have the openings in the lower portion of the cage member.
  • the openings in the cage member will begin at a depth in the bed below the top layer of the catalyst bed.
  • the entire cage length can have openings therein.
  • a catalyst bed where only the top surface of the bed becomes fouled it would be desirable to bypass feedstock, just below the fouled surface.
  • FIG. 1 there is illustrated a conventional catalytic reactor vessel ( 6 ) containing a fixed bed of catalyst particles ( 5 ). Shown is one bypass apparatus. However, the invention may comprise a plurality of bypass apparatus spaced over the catalyst bed. Furthermore, each individual bypass apparatus may extend into the catalyst bed to different depths.
  • the bypass apparatus are inserted into the catalyst bed such that the cage is buried into the bed and the second hollow elongated member extends above the top surface of the bed.
  • the cage member is perforated or is made from a material having openings and acts as a distributor for the hydrocarbon feed passing through the first hollow elongated member.
  • the perforations may simply be made in the material of which the cage member is constructed, or a portion of the cage member can be constructed of a mesh type material.
  • the area of the cage having openings therein is easily determinable by the skilled artisan. Only the sidewalls may have openings, or other areas of the cage member such as the top and bottom walls may likewise have openings therein.
  • the size of the openings be large enough so that any small quantity of the particulates that are entrained in the bypassed flow are able to leave the cage and get distributed into the bed.
  • the openings will range in size from about 1 ⁇ 8 inch (0.31 cm) to about 1 ⁇ 2 inch (1.25 cm) wide holes or slits.
  • the openings can be sized small enough so that any bypassed foulant particulates will be retained within the cage.
  • Bypass foulant particles are small particles contained in the hydrocarbon feed that are bypassed through the second hollow elongated member and which contribute to fouling of the catalyst bed.
  • the bypass apparatus is embedded within the fixed catalyst bed such that the bottom of the cage is contained within the catalyst bed and the bypassed feed is distributed to the bottom layer of the catalyst bed.
  • the bottom layer of the catalyst bed is the area located beneath the area of the bed where substantial fouling during reactor operation occurs. This area is readily recognized by the skilled artisan.
  • the top layer is the area above the bottom layer from the surface of the bed to a depth within the bed where substantial fouling occurs during reactor operations.
  • the bottom of the catalyst bed is the portion of the bed located at least about 2.5 feet (75 cm) from the bed surface. However, depending upon the given operation, it is possible for the bottom layer of the bed to be located as little as about 6 inches (15 cm) from the catalyst bed surface. In such a case, only the top surface of the bed becomes fouled and will be bypassed.
  • the skilled artisan taking into consideration the reactor and operation being performed, can determine the area of the catalyst bed to be bypassed.
  • One or more bypass apparatus may be utilized in any given bed.
  • the cage member may extend through the catalyst bed to the same or different depths within the beds bottom layer.
  • the bypass apparatus utilized herein maintain the catalytic bed integrity and prevent the high exit velocities of the second elongated member from eroding the bed or causing the bed to slump, increase pressure drop, and deteriorate unit performance.
  • the reactor is operated by introducing the hydrocarbon feedstock to be reacted in the catalyst bed along with a suitable treat gas, if necessary, such as hydrogen.
  • the feedstock can be a liquid, vapor, or mixture thereof.
  • the reactor is operated at suitable conditions for the process being run. Such conditions are known in the art and are not modified by use of the bypass apparatus being utilized herein.
  • the feedstream undergoes the desired chemical reaction as it moves through the catalyst bed. At the beginning, when the catalyst bed is clean and no foulants have deposited at the bed top, a majority of the flow will go through the catalyst bed instead of the bypass apparatus.
  • bypass apparatus particularly the second hollow elongated member, typically tubes
  • the second hollow elongated members are typically sized to provide a pressure drop of a factor of about 5 to about 25 higher relative to the clean bed.
  • the second hollow elongated members are sized to have a flow resistance which is significantly higher than the flow resistance of the clean bed.
  • the pressure drop through a clean (unfouled) top four feet layer of the catalyst bed would be typically 0.5 to 2 psi in a typical hydroprocessing reactor.
  • the bypass tubes will be sized to have a flow resistance of about 10 to 50 psi with total flow in the tubes. With this bypass arrangement, the pressure drop through the top four feet section of the bed will never exceed 50 psi. If the bypass tubes were not used, the pressure drop could be significantly higher than 50 psi upon fouling which would necessitate a reactor shutdown or throughput reduction.
  • the bypass apparatus can be any suitable structure that meets the criteria set forth herein.
  • both the second hollow elongated member and the cage member will be tubular in structure.
  • the bypass apparatus will be constructed from material compatible with the operating conditions of the reactor.
  • suitable materials may include metals such as carbon steel and stainless steel, ceramic materials, and other composite materials such as carbon fiber reinforced materials.
  • the second hollow elongated member, through which the feedstock is bypassed may be of any diameter or width depending upon the amount and rate of material one wishes to bypass to the bottom, unfouled layer of the catalyst bed. Such diameters are easily determined by the skilled artisan.
  • the diameter of the second hollow elongated member can range from about 0.25 inch (0.625 cm) to about 12 inch (30 cm), more preferably from about 0.5 inch (1.25 cm) to about 6 inch (15 cm), and most preferably from about 0.5 inch (1.25 cm) to about 3 inch (7.5).
  • the cage member likewise, may be of any diameter.
  • bypass apparatus For example, from about 3 inch (7.5 cm) to about 20 inch (50 cm), more preferably from about 4 inch (10 cm) to about 12 inch (30 cm), and most preferably from about 4 inch to about 10 inch.
  • the number of bypass apparatus utilized is dependent upon the size of the reactor and the flow rates in the reactor. As indicated earlier, the number of bypass apparatus is chosen such that the bypass apparatus offer higher resistance to flow than the clean beds, less resistance than a fouled bed. One or more bypass apparatus may be utilized. When determining the number and location of the bypass apparatus, the skilled artisan will take into consideration localized velocities, residence times, temperature distribution, etc. The number and location of the apparatus will be chosen such that the units performance is maintained.
  • the section of the cage member having perforations functions as a distributor for the bypassed feedstock into the catalyst bed through the second hollow elongated member. It is preferred that the area surrounding the cage perforations be packed with a layer of packing material of a size that will assist in the distribution of the bypassed feedstock through the catalyst bed.
  • the packing material allows any particulates flowing into the bypass apparatus to be dispersed upon exiting the cage openings.
  • the packing material could be any inert material such as alumina balls typically used to support catalyst in a fixed bed.
  • the packing material could also be any other material or even catalyst particles. Catalyst particles, if chosen, will be of an appropriate size to distribute the feedstock being bypassed. Use of particles for distribution is merely optional and is not required. Typically, the particles will range in size from about 1 ⁇ 4 inch (0.625 cm), up to about 3 (7.5 cm) to about 4 (10 cm) inches. In addition to alumina balls, several other packing materials that are typically used in packed towers could also be used.
  • the second hollow elongated member may have a device at the top to facilitate separation of particulates from the bypassed hydrocarbon feed.
  • a cap as is shown in the FIGURE could be used.
  • the downward moving hydrocarbon feed from the reactor inlet is forced to change its direction by the cap so that the feed can move upward and then enter the bypass apparatus. While the flow direction of the feed is changed by the cap, the inertia of the particulates prevent these particulates from changing their flow direction These particulates separate out and accumulate at the bed top.
  • a separation device allows the bypassing of a relatively particulate free feed to bypass the fouled top section of the bed, and fouling in the interior sections of the bed is minimized.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Organic Chemistry (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Engineering & Computer Science (AREA)
  • General Chemical & Material Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Devices And Processes Conducted In The Presence Of Fluids And Solid Particles (AREA)
  • Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)
US09/351,648 1999-07-13 1999-07-13 Fouling tolerant fixed bed reactor (law858) Abandoned US20020031459A1 (en)

Priority Applications (9)

Application Number Priority Date Filing Date Title
US09/351,648 US20020031459A1 (en) 1999-07-13 1999-07-13 Fouling tolerant fixed bed reactor (law858)
JP2001509287A JP4794103B2 (ja) 1999-07-13 2000-07-13 耐ファウリング性の固定床反応器
PCT/US2000/019068 WO2001003822A1 (fr) 1999-07-13 2000-07-13 Reacteur a lit fixe tolerant l'encrassement
CA002379369A CA2379369C (fr) 1999-07-13 2000-07-13 Reacteur a lit fixe tolerant l'encrassement
DE60005366T DE60005366T2 (de) 1999-07-13 2000-07-13 Verschmutzungstoleranter festbettreaktor
EP00947307A EP1200183B1 (fr) 1999-07-13 2000-07-13 Reacteur a lit fixe tolerant l'encrassement
US09/712,654 US6846469B1 (en) 1999-07-13 2000-11-14 Method for extending operating life of a fixed bed reactor
US09/933,939 US6692705B2 (en) 1999-07-13 2001-08-22 Fouling tolerant fixed bed reactor with multi-tier bypass device
US09/974,561 US6689329B2 (en) 1999-07-13 2001-10-10 Fouling tolerant fixed bed reactor with virtual second bed

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US09/351,648 US20020031459A1 (en) 1999-07-13 1999-07-13 Fouling tolerant fixed bed reactor (law858)

Related Child Applications (2)

Application Number Title Priority Date Filing Date
US09/933,939 Continuation-In-Part US6692705B2 (en) 1999-07-13 2001-08-22 Fouling tolerant fixed bed reactor with multi-tier bypass device
US09/974,561 Continuation-In-Part US6689329B2 (en) 1999-07-13 2001-10-10 Fouling tolerant fixed bed reactor with virtual second bed

Publications (1)

Publication Number Publication Date
US20020031459A1 true US20020031459A1 (en) 2002-03-14

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Family Applications (3)

Application Number Title Priority Date Filing Date
US09/351,648 Abandoned US20020031459A1 (en) 1999-07-13 1999-07-13 Fouling tolerant fixed bed reactor (law858)
US09/712,654 Expired - Lifetime US6846469B1 (en) 1999-07-13 2000-11-14 Method for extending operating life of a fixed bed reactor
US09/974,561 Expired - Fee Related US6689329B2 (en) 1999-07-13 2001-10-10 Fouling tolerant fixed bed reactor with virtual second bed

Family Applications After (2)

Application Number Title Priority Date Filing Date
US09/712,654 Expired - Lifetime US6846469B1 (en) 1999-07-13 2000-11-14 Method for extending operating life of a fixed bed reactor
US09/974,561 Expired - Fee Related US6689329B2 (en) 1999-07-13 2001-10-10 Fouling tolerant fixed bed reactor with virtual second bed

Country Status (6)

Country Link
US (3) US20020031459A1 (fr)
EP (1) EP1200183B1 (fr)
JP (1) JP4794103B2 (fr)
CA (1) CA2379369C (fr)
DE (1) DE60005366T2 (fr)
WO (1) WO2001003822A1 (fr)

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Publication number Priority date Publication date Assignee Title
JP4350507B2 (ja) * 2001-06-21 2009-10-21 エクソンモービル リサーチ アンド エンジニアリング カンパニー 改良されたファウリング耐性固定床反応器
CN100434155C (zh) * 2003-08-18 2008-11-19 国际壳牌研究有限公司 分配装置
FR2875715B1 (fr) * 2004-09-28 2006-11-17 Inst Francais Du Petrole Reacteur a lit fixe de catalyseur comportant des moyens de derivation des ecoulements a travers le lit
RU2283174C1 (ru) * 2005-03-03 2006-09-10 Институт Катализа Им. Г.К. Борескова Сибирского Отделения Российской Академии Наук Реактор для проведения каталитических процессов
FR2924950B1 (fr) * 2007-12-17 2012-02-24 Inst Francais Du Petrole Plateau filtrant de predistribution avec tube deverseur pour reacteur a lit fixe a co-courant descendant de gaz et de liquide
FR3083716B1 (fr) 2018-07-10 2020-07-31 Axens Dispositif de distribution d’un fluide, apte a etre dispose dans un reacteur comprenant un lit catalytique fixe
US10478794B1 (en) 2019-02-26 2019-11-19 Chevron Phillips Chemical Company Lp Bi-modal radial flow reactor
US11420171B1 (en) * 2021-03-01 2022-08-23 Chevron Phillips Chemical Company Lp Flow bypass device for a vessel containing solid particles
EP4337376A1 (fr) 2021-05-13 2024-03-20 Shell Internationale Research Maatschappij B.V. Procédé d'hydrotraitement de matériaux à partir de sources renouvelables

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Also Published As

Publication number Publication date
WO2001003822A1 (fr) 2001-01-18
US6689329B2 (en) 2004-02-10
JP2003504179A (ja) 2003-02-04
CA2379369C (fr) 2008-10-14
EP1200183B1 (fr) 2003-09-17
US6846469B1 (en) 2005-01-25
DE60005366D1 (de) 2003-10-23
JP4794103B2 (ja) 2011-10-19
CA2379369A1 (fr) 2001-01-18
US20020081249A1 (en) 2002-06-27
EP1200183A1 (fr) 2002-05-02
DE60005366T2 (de) 2004-07-22

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