Slurry phase reactor with internal cyclone separator

Abstract

A system for processing a hydrocarbon feed has a final stage reactor and an internal separator with a cyclonic separator that forms a substantially gaseous stream and a substantially non-gaseous stream. The substantially gaseous stream is sent directly from the final stage reactor and separator to further downstream processing.

Description

[0001] background

[0002] 1. Field

[0003] This disclosure relates to slurry-phase reactors and methods for processing hydrocarbon feedstocks such as residual oil.

[0004] 2. Description of related technologies

[0005] A common method for processing hydrocarbon feedstocks is hydrocracking in a slurry-phase reactor, such as an upflow bubble column reactor. This slurry-phase method, often referred to as VCC technology, generally involves two main reaction processes: liquid-phase hydrotreating (LPH) of the main cracked hydrocarbon feedstock and gas-phase hydrotreating (GPH) of the treated and further cracked hydrocarbons. Typically, the hydrocarbon feedstock is first mixed with one or more additives and hydrogen. The combined feedstock is then fed into the bubble column reactor with hydrogen at high pressure and temperature, initiating a cracking reaction. Cracking is generally induced by elevated temperatures (thermal cracking) or acid catalysts (catalytic cracking). Hydrocracking is a specific type of cracking reaction that occurs in a hydrogen-rich environment. Additives may or may not enhance the chemical reaction with the hydrocarbon feedstock. Additional hydrodesulfurization (hydrotreating sulfur-containing compounds to produce hydrogen sulfide byproducts), hydrodenitrogenation (hydrogenating nitrogen-containing compounds to produce ammonia byproducts), olefin saturation, aromatic saturation, and isomerization reactions may also occur. The products then enter a separator to produce steam reforming products and unreformed liquid slurry products.

[0006] Referring to Figure 1, a prior art slurry-phase reactor and separation system 10 for converting vacuum residue into lighter, more valuable products is shown. System 10 may include multiple reactors 12, 14, and 16, a thermal separator 18, and a cyclone separator 20. Hydrocarbon feed 22 is directed into reactors 12, 14, and 16 arranged in series, operating at 100 to 350 bar, typically around 200 bar. Hydrocarbon feed 22 may be vacuum residue feed, slurry oil, coal tar, viscous cracked tar, atmospheric residue, coal feed, etc. Alternative hydrocarbon feeds may include bitumen, coal + hydrocarbon oil mixtures, mixtures of plastics and residue oil, and mixtures of biomass and petroleum. Additives, such as carbon-based materials, may be added to feed 22. Other additives may include iron or other metal-based catalysts, carbon-based materials impregnated with various metals, and sodium salts. The products from reactors 12, 14, and 16 are discharged as a three-phase mixture of vapor, liquid, and solids. After cooling the mixture using various methods, including heat exchange with a colder stream, injection of H2, and injection of liquid hydrocarbons such as gas oil, to stop further reaction and reduce coke formation, the product is sent to a thermal separator 18, which forms a first stream 24 consisting of unconverted liquid slurry material and additives (multiple additives) and a second, lighter gaseous fluid stream 26, which may be referred to as vapor product. Vapor product 26 is sent to a cyclone separator 20. The cyclone separator 20 is a separator that uses inertia and helical vortices to remove liquid droplets and solid particles before the fluid stream enters the gas phase (GPH) reactor for further hydrotreating. The GPH reactor can be a hydrotreating unit or a mixer of hydrotreating and hydrocracking reactors.

[0007] Thermal separators and cyclone separators are expensive vessels to manufacture because they operate at high temperatures and pressures. Therefore, there is a continuous need for new devices and methods to reduce the capital costs of such systems.

[0008] Overview

[0009] In some aspects, this disclosure provides a system for processing hydrocarbon feedstock. The system may include a plurality of reactors arranged in series. The plurality of reactors may include a final reactor comprising: a vessel; an inlet formed in the vessel for receiving the hydrocarbon feedstock; a reactor section formed in the vessel that receives the hydrocarbon feedstock via the inlet; and a separator section formed in the vessel, configured to generate a substantially gaseous stream and a substantially non-gaseous stream. The separator section may include: a nozzle separating the reactor section from the separator section, the nozzle having an opening guiding the hydrocarbon feedstock, hydrogen, and reaction products from the reactor section to the separator section, from which the substantially non-gaseous stream exits the vessel; a first outlet formed in the vessel; at least one cyclone separator configured to generate a substantially gaseous stream; and a second outlet from which the substantially gaseous stream exits the vessel.

[0010] In some aspects, this disclosure provides a method for processing a hydrocarbon feedstock. The method may include the steps of: passing the hydrocarbon feedstock through a plurality of reactors arranged in series; forming a substantially gaseous stream and a substantially non-gaseous stream in a final reactor of the plurality of reactors, wherein the substantially gaseous stream is generated by at least one cyclone separator; and feeding the substantially gaseous stream directly from the final reactor to the separator.

[0011] It should be understood that examples of certain features of this disclosure have been summarized quite extensively in order to better understand the detailed description that follows and to facilitate understanding of the contribution to the art. Of course, other features of this disclosure will be described below and, in some cases, will form the subject matter of the appended claims. Brief description of the attached diagram

[0013] For a detailed understanding of this disclosure, reference should be made to the following detailed description of preferred embodiments in conjunction with the accompanying drawings, wherein the same elements have been assigned the same reference numerals, and wherein:

[0014] Figure 1 schematically illustrates a prior art VCC slurry phase reactor and separation system;

[0015] Figure 2 An embodiment of a VCC slurry phase reactor and separation system according to this disclosure is illustrated schematically;

[0016] Figure 3 A final reactor is schematically illustrated according to one embodiment of this disclosure; and

[0017] Figure 4 A final reactor including a cyclone separator is schematically illustrated according to one embodiment of this disclosure.

[0018] Detailed Explanation

[0019] refer to Figure 2 This disclosure illustrates a slurry-phase reactor and separation system 30 according to one embodiment of the present disclosure for producing products such as naphtha, diesel, and gas oil from a hydrocarbon feedstock 22. The hydrocarbon feedstock 22 may include coal tar, slurry oil, atmospheric residue, vacuum residue, coal, biomass, plastics, viscous cracked tar, or solvent-deasphalted asphalt, etc. The hydrocarbon feedstock 22 may also include any hydrocarbon stream in which a majority (i.e., more than 50%) boils at a temperature above 350 degrees Celsius (662 degrees Fahrenheit). Feedstock 22 may include lighter materials, defined as materials having a standard boiling point above 500 degrees Celsius. System 30 may include multiple reactors 32, 34, 36 arranged in series and a cyclone separator 20. Reactors 32, 34, 36 may be any container having a body suitable for simultaneously reacting three phases, i.e., solid, liquid, and gas, to form contents using an upward flow, backmixing flow manner. Reactor 32 is considered a “first-stage” reactor because it is the first reactor through which the oil feedstock 22 reacts with additives. Reactor 36 is considered the “final” reactor because it is the last reactor through which the oil feed 22 reacts with additives. Reactors 32, 34, and 36 contain catalysts or additives suspended in a fluid through which hydrogen flows. The flow pattern can be agitated turbulence or bubbly flow. In reactors 32, 34, and 36, feed 22 can react with one or more additives such as activated carbon, iron or other metal-based catalysts, carbon types impregnated with various metals, or sodium salts at approximately 100-350 bar, typically 200 bar. The essentially gaseous stream 47 exiting the final reactor 36 enters cyclone separator 20, where liquid droplets and solid particles are removed before the gaseous stream enters the GPH reactor for further hydrogenation treatment. The terms catalyst and additive are used interchangeably. The same or different additives can be used in each reactor 32, 34, and 36.

[0020] Figure 3 One embodiment of the final reactor 36 is described. The final reactor 36 includes a vessel 37, within which a reactor section 38 and a separator section 42 are formed. A nozzle 43 has an opening that guides the effluent 45 from the reactor section 38 axially, i.e., aligned with the length of the vessel 37, to the separator section 42. The nozzle 43 can be any structure with an opening that restricts fluid flow. Thus, the inlet of the nozzle 43 has a larger cross-sectional flow area than the outlet of the nozzle 43. In one embodiment, the upper end 39 of the separator section 42 may be formed concave to slope towards the vapor outlet 46. As discussed above, the reactor section 38 is configured to react the slurry from the reactor 34; for example, to react the slurry from the reactor 34 under high pressure and in the presence of hydrogen.

[0021] Separator section 42 is configured to produce two product streams. A first stream 47, comprising substantially gaseous material, exits from the top vapor outlet 46 to the cyclone separator 20. A second stream 48, comprising substantially non-gaseous material, such as unconverted liquid and solid, exits from the second outlet 50. "Substantially" means that at least a majority of stream 47 is gaseous and a majority of stream 48 is unconverted liquid and solid. In embodiments, "substantially" can mean at least 60%, 70%, 80%, or 90%.

[0022] In this implementation, one or more streams of cold hydrogen gas 52 may be injected into the separator section 42 via a quench inlet 53 to cool the slurry and slow down the coking reaction. "Cold" means the hydrogen gas is colder than the slurry in the separator section 42. Additionally, a flushing fluid 54, such as vacuum gas oil (VGO), may be injected via a quench inlet 55 into the lower end 41 of the separator section 42 or any other section of the separator section 42 to cool and dilute the liquid slurry. This also slows down the coking reaction and prevents slurry blockage. The VGO may be a product of a vacuum distillation (VDC) column that recovers gas oil from hydrocarbon feedstocks or other hydrocarbon liquids.

[0023] In this implementation, the liquid level may not be maintained in separator section 42. Instead, the liquid level may be maintained in the outlet pipe (not shown). The separated liquid slurry can be delivered to the hot low-pressure separator during normal operation. For start-up, shutdown, and emergency operations, the liquid can be directed to the start-up or discharge drum.

[0024] In one implementation, the baffles can be positioned to induce a detour in the flow of effluent 45, which then improves gas-liquid separation in the separator section 42. For example, baffle 56 can be positioned laterally relative to container 37 such that axially aligned flow from nozzle 43 impinges on baffle 56 and is redirected radially to the wall forming container 37. Typically, most of the fluid flow has been redirected to a direction different from the direction of fluid flow before the impact. Alternatively, an elbow inlet 58 can be fitted to and in fluid communication with outlet 46 and oriented to receive most of the non-axial flow, such as radial flow. Elbow inlet 58 can be a curved tubular member bent at least partially radially outward toward the opening. The detour path formed by baffles 56, 58 increases the residence time of the fluid in separator section 42, which subsequently increases the amount of gas separated from the liquid and solid.

[0025] It should be noted that Figure 2 and Figure 3The separator included in vessel 36 eliminates the need for the separate thermal separator 18 of Figure 1. The main conversion product 47 is fed directly from the final reactor 36 to the cyclone separator 20 without further phase separation. While some embodiments of the separation section 42 within reactor vessel 36 may not provide the same level of fluid phase separation as a thermal separator, the cyclone separator 20 will generally provide sufficient phase separation prior to further hydrogenation or other treatments. It should also be noted that... Figure 2 The implementation scheme is easily adaptable to many different implementation schemes. For example, although three reactors are shown, more or fewer reactors can be used.

[0026] Figure 4 Another embodiment of the final reactor is described. The final reactor 70 is similar to... Figure 3 The reactor 70 is a combination of a final reactor and a separator 36. Specifically, the final reactor 70 includes a vessel 37 having a reactor section 38, a separator section 42, a nozzle 43 guiding the effluent 45 to the separator section 42, and a baffle plate such as a plate 56. Furthermore, the separator section 42 receives one or more cold hydrogen streams 52 and a flushing liquid 54 as previously described.

[0027] The difference is that the final reactor 70 includes a cyclone separator 80 located within the separator section 42 of vessel 37. The separator section 42 forms a first stream 82 comprising a substantially gaseous stream exiting from the top vapor outlet 46 and a second stream 84 comprising a substantially non-gaseous stream, such as unconverted liquid and solids, exiting from the second outlet 50. "Substantially" means that at least a majority of stream 47 is gaseous and a majority of stream 48 is unconverted liquid and solids. In embodiments, "substantially" can mean at least 60%, 70%, 80%, or 90%.

[0028] Cyclone separator 80 uses rotational effects and gravity to separate liquid droplets from a gaseous stream. The vapor flows in a spiral pattern within a cylindrical container with a truncated conical cross-section. More concentrated components impinge on the inner surface of the cyclone separator wall and are discharged to the bottom, while lighter components are discharged from the top. Cyclone separator 80 may comprise one or more stages. The configuration and / or number of cyclone separator stages depend on the desired level of separation. For example, in some embodiments, cyclone separator 80 may be configured to produce a gaseous stream 47 that can be hydrogenated without any further separation.

[0029] It should be noted that Figure 2 and Figure 3The separator included in vessel 36 eliminates the need for the separate thermal separator 18 of Figure 1. The main conversion product 47 is fed directly from the final reactor 36 to the cyclone separator 20 without further phase separation. While some embodiments of the separator section 42 within reactor vessel 36 may not provide the same level of fluid phase separation as a thermal separator, the cyclone separator 20 will generally provide sufficient phase separation prior to further hydrogenation or other treatments. It should also be noted that... Figure 2 The implementation scheme is easily adaptable to many different implementation schemes. For example, although three reactors are shown, more or fewer reactors can be used.

[0030] Some components of system 30 are described in U.S. Patent 4,851,107, the contents of which are incorporated herein by reference for all purposes. Although the foregoing is directed to embodiments of this disclosure, other and further embodiments of this disclosure may be devised without departing from the essential scope of this disclosure, which is defined by the appended claims.

Claims

1. A system for processing hydrocarbon feedstock (22), comprising: A plurality of reactors (32, 34, 36) arranged in series, the plurality of reactors (32, 34, 36) including a final reactor (36), the final reactor (36) comprising: a vessel (37), an inlet formed in the vessel (37) for receiving a hydrocarbon feed (22), a reactor section (38) formed in the vessel (37) receiving the hydrocarbon feed (22) via the inlet; and a separator section (42) formed in the vessel (37), the separator section (42) being configured to form a substantially gaseous stream (47) and a substantially non-gaseous stream (48), the system being characterized in that: A nozzle (43) separates the reactor section (38) from the separator section (42), the nozzle (43) having an opening to guide the hydrocarbon feed (22), hydrogen and reaction products from the reactor section (38) to the separator section (42). Essentially non-gaseous streams (48) are discharged from the container (37) through the formation of the first outlet (50) in the container (37). At least one cyclone separator (80) located within the separator section (42) and configured to produce a substantially gaseous stream (47); and Basically, the gas stream (47) exits from the second outlet (46) of the container (37); and Positioned in the container (37) and configured to redirect the flow from the nozzle (43) to the guide plate (56) forming the wall of the container (37).

2. The system according to claim 1, characterized in that, The plurality of reactors (32, 34, 36) arranged in series also include a first-stage reactor (32), wherein the first-stage reactor (32) is the first reactor through which the hydrocarbon feed (22) reacts and the final-stage reactor (36) is the last reactor through which the hydrocarbon feed (22) reacts, wherein the hydrocarbon feed (22) reacts with at least a first additive in the first-stage reactor (32) and with at least a second additive in the final-stage reactor (36).

3. The system according to claim 2, characterized in that, The first additive is selected from one of the following: activated carbon, metal-based catalyst, metal-impregnated carbon type and sodium salt, and the second additive is selected from one of the following: activated carbon, metal-based catalyst, metal-impregnated carbon type and sodium salt.

4. The system according to claim 2, characterized in that, The first additive is iron, and / or the second additive is iron.

5. The system according to claim 1, characterized in that, At least one cyclone separator (80) is a multi-stage cyclone separator.

6. The system according to claim 1, characterized in that, A quench inlet (53) is formed in the container (37), the quench inlet (53) receiving at least one of the following: cooled hydrogen and depressurized gas oil or other cold hydrocarbon streams.

7. A method for processing hydrocarbon feedstock (22), comprising: The method involves passing a hydrocarbon feed (22) through a plurality of reactors (32, 34, 36) arranged in series, the plurality of reactors (32, 34, 36) including a final reactor (36), the final reactor (36) including a vessel (37), wherein the vessel (37) has a reactor section (38) and a separator section (42), the method being characterized in that: The reactor section (38) is separated from the separator section (42) by a nozzle (43) having an opening to guide the hydrocarbon feed (22), hydrogen and reaction products from the reactor section (38) to the separator section (42); In the final reactor (36) of the plurality of reactors (32, 34, 36) arranged in series, a substantially gaseous stream (47) and a substantially non-gaseous stream (48) are formed, wherein the substantially gaseous stream (47) is generated by at least one cyclone separator (80). The flow from the nozzle (43) is redirected to the wall forming the container (37) using a deflector (56) positioned in the container (37); and The essentially gaseous stream (47) is fed directly from the final reactor (36) to the separator.

8. The method of claim 7, further characterized in that: The plurality of reactors (32, 34, 36) arranged in series were operated at 200-350 bar. Add solid additives to the hydrocarbon feed (22); and Gaseous hydrogen is allowed to flow through the hydrocarbon feed (22).

9. The method of claim 7, characterized in that, The hydrocarbon feed (22) is one of the following: (i) atmospheric residue, (ii) vacuum residue, (iii) coal, (iv) coal tar, (v) biomass, (vi) plastics, (vii) slurry oil, and (viii) viscous cracked tar.

10. The method of claim 7, characterized in that, Most of the hydrocarbon feed (22) boils at 350 degrees Celsius (662 degrees Fahrenheit).

11. The method of claim 7, characterized in that, The plurality of reactors arranged in series (32, 34, 36) also includes a first-stage reactor (32), and Its characteristics also include: First, the hydrocarbon feed (22) is reacted in the first-stage reactor (32); and Finally, the hydrocarbon feed (22) is reacted in the final reactor (36). The hydrocarbon feed (22) is reacted with at least a first additive in a first-stage reactor (32) and with at least a second additive in a final-stage reactor (36).

12. The method of claim 11, characterized in that, The first additive is selected from one of the following: activated carbon, metal-based catalyst, metal-impregnated carbon type and sodium salt, and the second additive is selected from one of the following: activated carbon, metal-based catalyst, metal-impregnated carbon type and sodium salt.

13. The method of claim 11, characterized in that, The first additive is iron, and / or the second additive is iron.

14. The method of claim 7, characterized in that, The substantially non-gaseous stream (48) comprises liquid produced via at least one cyclone separator (80) located within the separator section (42) of the final reactor (36).

Images