Device for catalytic reforming of hydrocarbons with flow distributor and method for reforming hydrocarbons

Abstract

The present invention provides a reforming reactor and a method for using the same, wherein a flow distributor distributes process gas circumferentially to a reaction zone. A feed is injected into the reactor and enters a non-reaction zone. The non-reaction zone has two parts, a first part receiving the feed and a second part receiving a purge gas. The purge gas will flow from the second part to the first part to prevent the feed from flowing from the first part to the second part. The combined gas can be transferred to the reaction zone for catalytic reforming. The first part and the second part can be separated by a flow distributor having two horizontal parts connected to opposite ends of a vertical part.

Description

Technical Field

[0001] The present invention generally relates to an apparatus and method for catalytic reforming of hydrocarbons, and more particularly to an apparatus and method for increasing the productivity of such an apparatus. Background Art

[0002] The reforming of petroleum raw materials is an important process for producing useful products. For example, the reforming process can be used for separating and upgrading hydrocarbons to provide transportation fuels, such as producing naphtha feed streams and upgrading the octane number of naphtha from gasoline production. In addition, hydrocarbons in the feed stream from the raw material petroleum source can also be used to produce required aromatic chemical precursors for the production of plastics, detergents and other products. Therefore, reforming can be used to produce required chemical precursors.

[0003] The catalytic reforming process is well known in the art. The main reactions that occur are dehydrogenation of cycloalkanes to aromatics, dehydrocyclization of paraffins, isomerization of paraffins and cycloalkanes, hydrocracking of paraffins to light hydrocarbons and the formation of coke deposited on the catalyst. The formation of coke on the catalyst causes the catalyst to gradually lose activity over time. Therefore, the catalyst needs to be regenerated and / or replaced. Continuous transport of catalyst from and to the reactor is very desirable.

[0004] Typically, in such reactors, the hydrocarbon feedstock and hydrogen-rich gas are preheated and fed to a reforming zone that typically comprises two to five reactors in series. The effluent from the first reactor is withdrawn, heated and passed to the second reactor. The effluent from the second reactor is withdrawn, reheated and passed to the third reactor. The withdrawal and reheating of the effluent continues until the last reactor, which is usually referred to as runoff. The effluent from the last reactor is withdrawn and further processed.

[0005] The effluent stream of raw material / partial conversion is usually transferred to the reactor stack via the non-reactive section. The catalyst flows downward through the non-reactive section in the conduit to avoid contacting the effluent stream of raw material / partial conversion in the non-reactive zone. This empty space is needed to meet the hydraulic requirements in some reactors. In other reactors, this space is needed for reactor inspection, maintenance and repair. Specifically, the non-reactive zone usually contains a significant amount of pipelines and mechanical equipment for the flow of impact fluid.

[0006] The process gas typically comes from an inlet pipe where it is distributed to the radial reaction zones. There is a continuing need to provide a solution for effectively and efficiently distributing the process gas to the reaction zones through the non-reaction zones while maintaining an appropriate pressure drop of the fluid flowing therein. Summary of the invention

[0007] Reactors and methods of reforming hydrocarbons using such reactors have been invented that include a flow distributor that reduces the volume of a non-reactive zone and does so with minimal increase in pressure drop. According to various aspects, the flow distributor has two generally horizontal portions connected by at least one generally vertical portion. It has been surprisingly found that such a flow distributor effectively and efficiently distributes process gas evenly to the circumference of the reactor and reduces undesirable turbulence in the non-reactive portion.

[0008] As described above, the conduits in the non-reactive portion cause flow shock, turbulence and uneven distribution around the reactor circumference, wherein the conduits are positioned to promote the process gas from the non-reactive zone into the reactive zone. The present application discloses a configuration for a flow distributor that evenly directs the process gas downward toward the fan shape, thereby reducing flow shock and turbulence. Therefore, by addressing the flow shock of the catalyst delivery pipe, outlet elbow and other equipment structures located in the non-reactive zone, the flow distributor provides a more uniform distribution to the reactive zone.

[0009] Thus, in at least one aspect, the present invention can be characterized as providing a radial flow reactor, the radial flow reactor comprising: a non-reaction zone, which is divided into a first part and a second part by a flow distributor, wherein the flow distributor comprises a first horizontal part, a second horizontal part, and a first vertical part connecting the first horizontal part and the second horizontal part, and wherein when viewed from the top, the second horizontal part comprises a sector shape; a reaction zone, which is disposed below the non-reaction zone and is separated from the non-reaction zone by a plate; an inlet for a hydrocarbon feed stream in the non-reaction zone; and an outlet for an effluent stream in the non-reaction zone, the outlet being in fluid communication with the reaction zone. Both the inlet and the outlet can be disposed in the second part of the non-reaction zone. The second horizontal part can include a plurality of sections, each section having a sector shape when viewed from the top. The first horizontal part can include an upper horizontal part, and the second horizontal part can include a lower horizontal part. The flow distributor can also include a second vertical part, and both the first vertical part and the second vertical part can extend between the upper horizontal part and the lower horizontal part. The first vertical part can be connected to the second vertical part. The flow distributor can also include a third vertical part having a planar profile shape. The first vertical portion may be attached to both the third vertical portion and the second vertical portion.The non-reactive zone may include a channel, and the flow distributor may be formed from a plurality of segments, each segment being sized to be removed through the channel and passed into and out of the reactor.

[0010] In a second aspect, the present invention can be broadly characterized as providing a radial flow reactor, the radial flow reactor comprising: a non-reaction zone, which is divided into a first portion and a second portion by a flow distributor, wherein the flow distributor comprises a first horizontal portion, a first vertical portion, and a second vertical portion, wherein both the first vertical portion and the second portion are connected to the first horizontal portion; a reaction zone disposed below the non-reaction zone, the reaction zone being a radial flow reaction zone; an inlet for a hydrocarbon feed stream in a lower portion of the non-reaction zone; and an outlet for an effluent stream in a lower portion of the non-reaction zone, the outlet being fluidly connected to the reaction zone through a central tube. When viewed from the top, the angle between the first vertical portion and the second vertical portion may be between 60 degrees and 180 degrees. The flow distributor may also include a second horizontal portion. The second horizontal portion may include a plurality of sections, each section having a sector shape when viewed from the top. The angle of the first horizontal portion from the horizontal plane may be 15 degrees. The angle of the second horizontal portion from the horizontal plane may be 0 degrees. The non-reactive zone may include a channel, and the flow distributor may be formed of a plurality of sections, each section being sized to be removed through the channel and passed into and out of the reactor. The flow distributor may also include a second horizontal portion and a third vertical portion, and wherein each of the vertical portions extends between the two horizontal portions.

[0011] In a third aspect, the present invention is generally characterized as providing a method for reforming hydrocarbons in a reactor by: injecting a hydrocarbon stream into a non-reactive zone of the reactor via an inlet, wherein the non-reactive zone of the reactor is divided into a first portion and a second portion by a flow distributor, the flow distributor comprising an upper horizontal portion, a lower horizontal portion, and a first vertical portion; transferring hydrocarbons from the hydrocarbon stream from the first portion of the non-reactive zone to the reaction zone of the reactor; transferring catalyst particles to the reaction zone, wherein the catalyst particles are retained in a catalyst section within the reaction zone; transferring hydrocarbons in a radial direction through the catalyst section; and transferring effluent from the reaction zone to an outlet through the first portion of the non-reactive zone of the reactor. The method may also include: injecting a purge gas stream into the second portion of the non-reactive zone of the reactor; and transferring purge gas from the purge gas stream from the second portion of the non-reactive zone to the first portion. The method may also include forming a flow distributor from a plurality of sections, each section being sized to be removed through a channel and transferred into and out of the reactor.

[0012] Further aspects, embodiments and details of the invention (all of which may be combined in any manner) are set forth in the following detailed description of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] One or more exemplary embodiments of the present invention will be described below in conjunction with the following drawings, in which:

[0014] Figure 1A reactor unit according to one or more aspects of the present invention is shown;

[0015] Figure 2 is a side cross-sectional view of a portion of a reactor unit according to one or more aspects of the present invention;

[0016] Figure 3 is a top cross-sectional view of a portion of a reactor unit according to one or more aspects of the present invention; and,

[0017] Figure 4 is a side perspective side cutaway view of a portion of a reactor unit according to one or more aspects of the present invention. DETAILED DESCRIPTION

[0018] As described above, a reactor and method for reforming hydrocarbons have been invented that includes a flow distributor that passes a process gas through a non-reactive zone and does so with minimal increase in pressure drop and minimal turbulence. With these general principles in mind, one or more embodiments of the invention will be described with the understanding that the following description is not intended to be limiting.

[0019] refer to Figure 1 The present invention relates to a reforming reactor 8 for a hydrocarbon feed stream 12. The hydrocarbon feed stream 12 typically contains cycloalkanes and paraffins having a boiling point in the gasoline distillation range. Preferred feed streams 12 include straight run naphtha, thermally cracked or catalytically cracked naphtha, partially reformed naphtha, raffinate from aromatic compound extraction, and the like. Typically, such feed streams 12 have been hydrotreated to remove contaminants, especially sulfur and nitrogen. The gasoline distillation range feed stream 12 can be a full-range naphtha having an initial boiling point of 40°C to 70°C and a final boiling point in the range of 160°C to 220°C, or a selected fraction thereof. The feed stream 12 can be heated in a feed heater 10 and transferred to the reforming reactor 8 together with the catalyst in the catalyst delivery line 9.

[0020] The operating conditions for the reforming process generally include an absolute pressure selected within the range of 100 kPa to 7,000 kPa (14.5 psi to 1015 psi) or 350 kPa to 4,250 kPa (51 psi to 616 psi). It is believed that particularly good results can be obtained at low pressures, i.e., absolute pressures of 350 kPa to 2,500 kPa (51 psi to 363 psi). The reforming conditions include temperatures within the range of 315°C to 600°C (599°F to 1112°F) or 425°C to 565°C (797°F to 1049°F). As is well known to those skilled in the art of reforming, the temperature within this wide range is initially selected primarily based on the desired octane of the product reformate, taking into account the characteristics of the feed stream and the catalyst.

[0021] The reforming conditions in the present invention also generally include sufficient hydrogen to provide an amount of from 1 to 20 moles of hydrogen per mole of hydrocarbon feed entering the reforming zone, wherein similarly enhanced results are obtained when 2 to 10 moles of hydrogen are used per mole of hydrocarbon feed. The liquid hourly space velocity (LHSV) used in the reforming is selected from 0.1 to 10 hr -1 or 1 to 5 hours -1 range.

[0022] In catalytic reforming, a multifunctional catalyst composite material is generally used, which contains a metal hydrogenation-dehydrogenation component on a porous inorganic oxide carrier to provide acid sites for cracking and isomerization. Most reforming catalysts are in the form of spheres or cylinders with an average particle size or average cross-sectional diameter of 1.59 mm to 4.76 mm (1 / 16 inch to 3 / 16 inch). Catalyst composite materials comprising platinum on high-purity alumina or zeolite carriers are particularly well known in the art. Metal modifiers (such as rhenium, iridium, tin and germanium) that improve product yield or catalyst life can also be incorporated into the catalyst.

[0023] like Figure 1 As shown, the reforming reactor 8 includes a series of four reaction zones 30, 40, 50, 70 arranged vertically in the reforming reactor 8. This is only one configuration and is not intended to be limiting, and other configurations can be used to practice the present invention. Catalyst particles enter the top of the reforming reactor 8 through the catalyst delivery line 9 and pass through the series of reaction zones 30, 40, 50, 70 under gravity flow. After passing through all reaction zones 30, 40, 50, 70, the catalyst particles are extracted from the bottom of the reforming reactor 8 through one or more catalyst extraction lines 11. The catalyst extracted through the catalyst extraction line 11 can be regenerated by oxidation and removal of coke deposits in a regeneration zone (not shown). After regeneration, the catalyst particles can be returned to the process and the reforming reactor 8 again through the catalyst delivery line 9.

[0024] After heating the feed stream 12 in the feed heater 10, the heated feed 14 can be transferred to the first reaction zone 30. Since the reforming reaction is endothermic, a heater is used to add heat to drive the catalyst reaction to advance toward the desired product. Therefore, the first reactor effluent 32 is transferred to the first heater 20 to produce the second reactor feed 22 of heating. The second reactor effluent 42 is transferred to another heater 60 to produce the third reactor feed 62 of heating. The third reactor effluent 52 is transferred to another heater 80 to produce the fourth reactor feed 82. The fourth reactor effluent 72 contains the reformate product, which can be recovered from the reactor 8 and further processed as known. In fixed bed and continuous catalyst regeneration reforming processes, a heater is generally used to heat the feed streams 14, 22, 62, 82 to an elevated temperature and catalyzed by a metal-based catalyst in the catalyst reaction zone to meet product quality specifications, such as product octane, aromatic compound product yield, and hydrogen product yield.

[0025] like Figure 1 As shown, the introduction of heated feed streams 14, 22, 62, 82 and the withdrawal of effluent streams 32, 42, 52, 72 occur in non-reaction zones 31, 41, 51, 71. It can be seen that some non-reaction zones 31, 41, 51, 71 are separated between consecutive reaction zones 30, 40, 50, 70, and the first non-reaction zone 31 is arranged between the first reaction zone 30 and the catalyst introduction zone 90. The catalyst introduction zone 90 may include a reduction zone. In the reduction zone, the oxidation catalyst from the catalyst regeneration section (not shown) is reduced to a reduced state to obtain optimal performance. Alternatively, the catalyst introduction zone 90 may include a catalyst surge zone that provides catalyst surge capability.

[0026] The non-reaction zones 31, 41, 51, 71 are usually used as rough distribution zones where there is substantially no catalyst. In these non-reaction zones 31, 41, 51, 71, there are important pipes and fittings that cause flow imbalance, turbulence and impact. In addition, the upper section of the non-reaction zone usually has a large vortex in which the process gas accumulates turbulence. This undesirable turbulence can lead to uneven distribution and higher pressure drop in the reaction zone, so the reaction yield and conversion rate will be affected.

[0027] Typical fixed bed reforming processes or continuous regeneration processes operate at temperatures approaching or above 480°C (950°F). This non-catalytic molecular weight reduction shift phenomenon is well understood in fixed bed reforming processes and continuous catalyst regeneration processes. Non-catalytic molecular weight reduction shifts prior to entering reaction zones 30, 40, 50, 70 produce lower C5+ hydrocarbon yields, lower product aromatic compound yields, and lower hydrogen yields. The severity and amount of hydrocarbons that undergo this undesirable non-catalytic molecular weight reduction shift prior to entering reaction zones 30, 40, 50, 70 depends on many factors, including the operating temperature, the boiling point temperature of the hydrocarbon species, the type of hydrocarbon species, and the residence time of the hydrocarbons in the elevated temperature environment.

[0028] The size or volume of non-reactive zone 31,41,51,71 is usually controlled by the personnel entry requirements and the actual space required for the internal components of the maintenance activities and the installation of the reactor internal components. In addition, as described below, the size of non-reactive zone 31,41,51,71 is also controlled by the system hydraulic pressure requirements for carrying out appropriate catalyst flow transportation between the container (such as catalyst introduction zone 90) or reaction zone 30,40,50 and another reaction zone 30,40,50,70 containing catalyst. These requirements usually control the dimensions of non-reactive zone 31,41,51,71, and the size is usually greater than the required size or volume for properly carrying out feed distribution to achieve uniform flow. Due to the internal equipment in this section, there is a significant amount of flow impact that causes flow imbalance. Usually, the volume of non-reactive zone 31,41,51,71 determines the residence time of heated feed stream 14,22,62,82 in non-reactive zone 31,41,51,71.

[0029] The present invention aims to efficiently and effectively distribute the process gas to the reaction zones 30, 40, 50, 70 uniformly through the non-reaction zones 31, 41, 51, 71 occupied by the feed (or intermediate effluent), and reduce the flow imbalance in the reaction zones 30, 40, 50, 70. By reducing the non-reaction volume contacted by the process gas, turbulence can be reduced and circumferential flow distribution can be improved.

[0030] Go to Figure 2 , shows a reactor unit 88, which includes a catalyst source area 100, a non-reaction area 102 and a reaction area 104. The catalyst source area 100 may include a catalyst introduction area 90 (from Figure 1 ) or reaction zones 30, 40, 50 (from Figure 1 ), which depends on the number of reaction zones and the type of reactor unit 88. Conduit 106 transports catalyst 109 from catalyst source zone 100 through non-reaction zone 102 and to reaction zone 104, so that catalyst 109 is separated from any reactants in non-reaction zone 102. An outlet 108 of conduit 106 is disposed in reaction zone 104.

[0031] According to the present disclosure, the non-reactive zone 102 is divided into two parts 110, 112 by a flow distributor 114, and the flow distributor can be a blade, a plate, a baffle or other such flow guiding structures. The first part 110 of the non-reactive zone 102 is the upper part, and the second part 112 of the non-reactive zone 102 is the lower part. The flow distributor 114 includes a first horizontal part 116, a second horizontal part 118 and at least a first vertical part 120. "Horizontal" means that the horizontal parts 116, 118 extend in the direction of forming an angle between 0 and 35 degrees with the horizon. For example, the first horizontal part 116 can be angled at 15 degrees, as depicted by the dotted line 116a. Similarly, "vertical" means that any vertical part (such as the first vertical part 120) extends in the direction of forming an angle between 0 and 30 degrees with a vertical line (such as the longitudinal axis of the reactor unit 88). In addition, the length of the upper horizontal part from the reactor shell toward the center of the reactor unit 88 can be between a radius (from the shell to the center) and a radius of 0.3.

[0032] The reaction zone 104 is separated from the non-reaction zone 102 by a plate 122. The reactor unit 88 also includes an inlet 124 for the hydrocarbon feed stream and an outlet 126 for the effluent stream. The outlet 126 communicates with the reaction zone 104 via, for example, a central tube 128. Both the inlet 124 and the outlet 126 are located in the non-reaction zone 102, and more specifically in the second portion 112 of the non-reaction zone 102.

[0033] Go to Figure 3 and Figure 4, when viewed from the top, the second horizontal portion 118 has a sector shape. The angle between the two ends of the sector shape of the second horizontal portion 118 may be between 60 degrees and 180 degrees, between 80 degrees and 120 degrees, or 100 degrees. The second horizontal portion 118 includes a plurality of sections 130a, 130b, 130c, 130d, 130e, each of which has a sector shape when viewed from the top. Use of sections 130a, 130b, 130c, 130d, 130e allows the flow distributor 114 to be installed in the reactor through passage 132. The diameter of a typical passage 132 is 0.6 meters (24 inches), however, the size of the passage 132 may be in the range between 0.46 meters and 1.22 meters (18 inches to 48 inches). The installation / removal of the segments 130a, 130b, 130c, 130d, 130e of the flow distributor 114 from the passage 132 simplifies the installation process because no interference with other reactor internal components is required, making it easy to manage during turnaround. In addition, the segments 130a, 130b, 130c, 130d, 130e themselves serve as passages, so that personnel can remove one of the segments 130a, 130b, 130c, 130d, 130e to enter the lower portion 112 of the non-reactive zone 102 from the upper section 110 of the non-reactive zone 102 without removing the entire flow distributor 106 and without removing other structures (such as the catalyst conduit 106).

[0034] The flow distributor 114 may be mounted to support lugs (not shown) that are welded to the wall of the reactor unit 88. Additionally, support rods (not shown) may extend from the center tube 128, and specifically from the elbow of the center tube 128. Other mounting structures may be used.

[0035] like Figure 3 As shown, there are holes 134 in the segments 130a, 130b, 130c, 130d, 130e to allow the catalyst delivery tube 106 to pass through the flow distributor 114. The joints 136 between the segments 130a, 130b, 130c, 130d, 130e strengthen the mechanical integrity of the flow distributor and seal the second portion 112 of the non-reaction zone 102 from the first portion 110. The joint 136 connection can utilize a wedge pin, bolt or weld connection. The flow distributor 114 allows space for personnel to enter during turnaround activities and can be used to support personnel entry during turnaround for inspection, maintenance and installation activities.

[0036] The first vertical flow distributor portion 120 is connected to the second vertical flow distributor portion 138, and the third vertical flow distributor portion 140 also extends between the upper horizontal flow distributor portion 116 and the lower horizontal flow distributor portion 118. When viewed from the top along their respective longitudinal axes, the second vertical flow distributor portion and the third vertical flow distributor portion 138, 140 each have a planar profile shape. In addition, both the second vertical flow distributor portion and the third vertical flow distributor portion 138, 140 are connected to the first vertical flow distributor portion 120.

[0037] return Figure 2 , a purge gas may be introduced into the first portion 110 of the non-reactive zone 102 via a purge gas inlet 142. The purge gas may be <1% of the total inlet process flow to the reactor unit 88 and is used to sweep the first portion 110 of the non-reactive zone 102 and prevent process gas from entering the upper portion 110 of the non-reactive zone 102 above the flow distributor 114. The purge gas exits the first portion 110 of the non-reactive zone 102 and is, for example, directed through a small vent hole 144 ( Figure 3 ), the enlarged holes 134 ( Figure 3 ) and / or the sections 130a, 130b, 130c, 130d, 130e are designed to be joined to the joint 136 ( Figure 3 ) to mix with the rest of the inlet gas flow. It may be desirable to use small mechanical fittings (such as guard plate gaskets) around the delivery tube 106 to reduce the amount of purge gas required while also providing mechanical flexibility during thermal expansion of the reactor unit 88.

[0038] The purge gas comprises a gas having a stable molecular weight at the operating temperature of the reactor unit 88, and may be, for example, an inert (non-reactive) gas such as a halide, nitrogen, or a hydrogen-rich gas containing more than 70% by volume of hydrogen, light hydrocarbon substances (C5-hydrocarbons), and less than 5% by volume of C6 hydrocarbons (preferably containing 80% by volume or more of hydrogen and less than 1% by volume of C6 hydrocarbons). Figure 1 As shown, it is contemplated that the purge gas for the non-reaction zones may include a portion of the effluent 32, 42, 52, 72 from the reaction zones 30, 40, 50, 70 (preferably the upstream reaction zone). Figure 1, a portion of the effluent 52 in line 52a from the third reaction zone 50 can be used as a purge gas in a non-reaction zone 71 associated with a fourth reaction zone 70. Using a portion of the effluent 32, 42, 52, 72 will minimize the need or use of external purge gas, which may be particularly beneficial in applications where the present invention is practiced by retrofitting an existing reformer.

[0039] To prevent the feed from diffusing into and occupying the first portion 110 of the non-reactive zone 102, the first portion 110 of the non-reactive zone 102 is preferably maintained at a higher pressure than the second portion 104 of the non-reactive zone 102 by a differential pressure controller and control valve (not shown). The differential pressure control valve continuously injects a sufficient amount of purge gas rate to maintain a positive differential pressure between the first portion 110 and the second portion 104, which is preferably between 1.24 kPag and 68.9 kPag (0.18 psi and 10 psi).

[0040] The combined gas (feed and purge) can be delivered to the reaction zone 104 through a conduit 146 (such as a fan). See, for example, U.S. Patent Nos. 5,366,704, 6,224,838 and 7,842,257. The conduit 146 typically includes a perforated plate or screen and distributes the feed axially to the reaction zone 104. Preferably, there is a positive pressure differential between the second portion 112 of the non-reactive zone 102 and the conduit 146 between 0.2 kPag and 24 kPag (0.03 psi to 3.5 psi). This pressure differential will allow the second portion 112 of the non-reactive zone 102 to serve as a distribution chamber for the feed entering through the feed inlet nozzle 124.

[0041] Thus, in operation, the reactor section 88 can be used in the process of reforming hydrocarbons. In an exemplary process, a hydrocarbon stream (feed or partially reformed effluent) is injected into the non-reactive zone 102 via a feed inlet nozzle 124. The non-reactive zone 102 is divided into an upper portion 110 and a lower portion 112 by a flow distributor 114. Hydrocarbons from the feed are transferred from the lower portion 112 of the non-reactive zone 102 to the reaction zone 104 of the reactor section 88 through a conduit 146. Catalyst particles are transferred to the reaction zone 104 via a catalyst delivery pipe 106. Catalyst particles discharged from the outlet 108 of the conduit 106 are retained in the catalyst section 148 in the reaction zone 104. Hydrocarbons enter and pass through the catalyst section 148 in a radial direction. In the depicted embodiment, this is inward, but it is also conceivable that the flow is reversed. The effluent from the reaction zone 104 can be recovered from the outlet nozzle 112, which is connected to the reaction zone 104 via a center pipe 128. The first portion 110 of the non-reactive zone 102 includes an inlet 142 for a purge gas. As described above, the purge gas will flow from the first portion 110 of the non-reactive zone 102 to the second portion 112 via holes 144, oversized conduit holes 134, junctions 136, combinations thereof, or via another means.

[0042] The flow distributor 114 includes two horizontal portions 116, 118 connected by at least one vertical portion 120, 138, 140. As described above, such a flow distributor 114 reduces the volume of the second portion 112 of the non-reactive zone 102 while maintaining or providing a suitable flow from the second portion 112 of the non-reactive zone 102 to the reactive zone 104 through the conduit 146. In practice, such a flow distributor 114 provides the second portion 112 of the non-reactive zone 102 with different heights. In addition, the shape of the second portion 112 of the non-reactive zone 102 is non-uniform. It was surprisingly found that such a non-uniformly shaped portion would allow for a suitable distribution of the feed.

[0043] It was calculated that a flow distributor with a flat upper horizontal section between the second and third vertical flow distributor sections that was 1000 mm long and had an angle of 100 degrees would reduce the volume of the non-reactive zone by 51.1% with only a 0.2 pressure drop. For the same design, but with a -10 degree angle for the upper horizontal section, the volume reduction was 51.0% with a .18 pressure drop.

[0044] It should be recognized and appreciated by those skilled in the art that various other components such as valves, pumps, compressors, instruments, filters, coolers, etc. are not shown in the accompanying drawings because it is believed that their details are well within the knowledge of those skilled in the art and their description is not necessary to practice or understand the embodiments of the present invention.

[0045] Any of the above-mentioned pipelines, conduits, units, equipment, containers, surrounding environments, zones, or the like may be equipped with one or more monitoring components, including sensors, measuring devices, data capture devices, or data transmission devices. Signals, process or state measurements and data from the monitoring components can be used to monitor conditions in, around, and related to the process equipment. The signals, measurements, and / or data generated or recorded by the monitoring components can be collected, processed, and / or transmitted via one or more networks or connections, which can be private or public, general or dedicated, direct or indirect, wired or wireless, encrypted or unencrypted, and / or combinations thereof; the present specification is not intended to be limiting in this regard.

[0046] The signals, measurements, and / or data generated or recorded by the monitoring components may be transmitted to one or more computing devices or systems. The computing device or system may include at least one processor and a memory storing computer-readable instructions that, when executed by at least one processor, cause one or more computing devices to perform a method that may include one or more steps. For example, one or more computing devices may be configured to receive data related to at least one piece of equipment associated with the method from one or more monitoring components. One or more computing devices or systems may be configured to analyze the data. Based on the data analysis, one or more computing devices or systems may be configured to determine one or more recommended adjustments to one or more parameters of one or more methods described herein. One or more computing devices or systems may be configured to transmit encrypted or unencrypted data, which includes one or more recommended adjustments to one or more parameters of one or more methods described herein.

[0047] Specific implementation plan

[0048] While the following is described in conjunction with specific embodiments, it should be understood that this description is intended to illustrate and not to limit the scope of the foregoing description and the appended claims.

[0049] The first embodiment of the present invention is a radial flow reactor, which includes: a non-reaction zone, which is divided into a first part and a second part by a flow distributor, wherein the flow distributor includes a first horizontal part, a second horizontal part, and a first vertical part connecting the first horizontal part and the second horizontal part, and wherein when viewed from the top, the second horizontal part includes a sector shape; a reaction zone, which is arranged below the non-reaction zone and is separated from the non-reaction zone by a plate; an inlet for a hydrocarbon feed stream in the non-reaction zone; and an outlet for an effluent stream in the non-reaction zone, the outlet being connected to the reaction zone fluid. The embodiment of the present invention is one, any or all of the first embodiment of this paragraph to the previous embodiment of this paragraph, wherein the inlet and the outlet are both arranged in the second part of the non-reaction zone. The embodiment of the present invention is one, any or all of the first embodiment of this paragraph to the previous embodiment of this paragraph, wherein the second horizontal part includes a plurality of sections, each section having a sector shape when viewed from the top. The embodiment of the present invention is one, any or all of the first embodiment of this paragraph to the previous embodiment of this paragraph, wherein the first horizontal part includes an upper horizontal part, and the second horizontal part includes a lower horizontal part. The embodiment of the present invention is one, any or all embodiments in the first embodiment of this paragraph to the previous embodiment of this paragraph, wherein the flow distributor also includes a second vertical portion, and wherein both the first vertical portion and the second vertical portion extend between the upper horizontal portion and the lower horizontal portion. The embodiment of the present invention is one, any or all embodiments in the first embodiment of this paragraph to the previous embodiment of this paragraph, wherein the first vertical portion is connected to the second vertical portion. The embodiment of the present invention is one, any or all embodiments in the first embodiment of this paragraph to the previous embodiment of this paragraph, wherein the flow distributor also includes a third vertical portion having a planar profile shape. The embodiment of the present invention is one, any or all embodiments in the first embodiment of this paragraph to the previous embodiment of this paragraph, wherein the first vertical portion is attached to both the third vertical portion and the second vertical portion. The embodiment of the present invention is one, any or all embodiments in the first embodiment of this paragraph to the previous embodiment of this paragraph, wherein the non-reaction zone includes a channel, and wherein the flow distributor is formed by a plurality of sections, and the size of each section is set to be removed through the channel and passed into and out of the reactor.

[0050] The second embodiment of the present invention is a radial flow reactor, which includes: a non-reaction zone, which is divided into a first part and a second part by a flow distributor, wherein the flow distributor includes a first horizontal part, a first vertical part and a second vertical part, wherein both the first vertical part and the second part are connected to the first horizontal part; a reaction zone arranged below the non-reaction zone, the reaction zone being a radial flow reaction zone; an inlet for a hydrocarbon feed stream in the lower part of the non-reaction zone; and an outlet for an effluent stream in the lower part of the non-reaction zone, the outlet being connected to the reaction zone fluid through a central tube. The embodiment of the present invention is one, any or all of the second embodiment of this paragraph to the previous embodiment of this paragraph, wherein when viewed from the top, the angle between the first vertical part and the second vertical part is between 60 degrees and 180 degrees. The embodiment of the present invention is one, any or all of the second embodiment of this paragraph to the previous embodiment of this paragraph, wherein the flow distributor also includes a second horizontal part. The embodiment of the present invention is one, any or all of the second embodiment of this paragraph to the previous embodiment of this paragraph, wherein the second horizontal part includes a plurality of sections, each of which has a sector shape when viewed from the top. The embodiment of the present invention is one, any or all of the second embodiment of this paragraph to the previous embodiment of this paragraph, wherein the angle of the first horizontal portion from the horizontal plane is 15 degrees. The embodiment of the present invention is one, any or all of the second embodiment of this paragraph to the previous embodiment of this paragraph, wherein the angle of the second horizontal portion from the horizontal plane is 0 degrees. The embodiment of the present invention is one, any or all of the second embodiment of this paragraph to the previous embodiment of this paragraph, wherein the non-reaction zone includes a channel, and wherein the flow distributor is formed by a plurality of sections, and the size of each section is set to be removed through the channel and transferred into and out of the reactor. The embodiment of the present invention is one, any or all of the second embodiment of this paragraph to the previous embodiment of this paragraph, wherein the flow distributor also includes a second horizontal portion and a third vertical portion, and wherein each of the vertical portions extends between the two horizontal portions.

[0051] The third embodiment of the present invention is a method for reforming hydrocarbons in a reactor, the method comprising: injecting a hydrocarbon stream into a non-reactive zone of the reactor via an inlet, wherein the non-reactive zone of the reactor is divided into a first portion and a second portion by a flow distributor, the flow distributor comprising an upper horizontal portion, a lower horizontal portion, and a first vertical portion; transferring hydrocarbons from the hydrocarbon stream from the first portion of the non-reactive zone to the reaction zone of the reactor; transferring catalyst particles to the reaction zone, wherein the catalyst particles are retained in a catalyst section within the reaction zone; transferring hydrocarbons in a radial direction through the catalyst section; and transferring effluent from the reaction zone to the outlet through the first portion of the non-reactive zone of the reactor. The embodiment of the present invention is one, any or all of the embodiments of the third embodiment of this paragraph to the previous embodiments of this paragraph, and further comprises injecting a purge gas stream into the second portion of the non-reactive zone of the reactor; and transferring a purge gas from the purge gas stream from the second portion of the non-reactive zone to the first portion. The embodiment of the present invention is one, any or all of the embodiments of the third embodiment of this paragraph to the previous embodiments of this paragraph, and further comprises forming a flow distributor by a plurality of sections, each section being sized to be removed through a channel and transferred into and out of the reactor.

[0052] Although there is no further detailed description, it is believed that those skilled in the art can utilize the present invention to the greatest extent by using the foregoing description and can easily determine the essential characteristics of the present invention without departing from the spirit and scope of the present invention to make various changes and modifications of the present invention and adapt it to various usages and conditions. Therefore, the aforementioned preferred specific embodiments should be understood as merely illustrative and not to limit the rest of the present disclosure in any way, and are intended to cover various modifications and equivalent arrangements included within the scope of the appended claims.

[0053] In the foregoing, all temperatures are set forth in degrees Celsius and all parts and percentages are by weight unless otherwise indicated.

[0054] Although at least one exemplary embodiment has been presented in the foregoing specific embodiments of the present invention, it should be understood that there are a large number of variations. It should also be understood that an exemplary embodiment or multiple exemplary embodiments are only examples and are not intended to limit the scope, applicability or configuration of the present invention in any way. On the contrary, the foregoing specific embodiments will provide a convenient roadmap for those skilled in the art to implement the exemplary embodiments of the present invention, and it should be understood that various changes can be made to the functions and arrangements of the elements described in the exemplary embodiments without departing from the scope of the present invention as set forth in the attached claims and their legal equivalents.

Claims

1. A radial flow reactor (8), comprising: a non-reactive zone (31, 41, 51, 71, 102), the non-reactive zone being divided into a first portion (110) and a second portion (112) by a flow distributor (114), wherein the flow distributor (114) comprises a first horizontal portion (116), a second horizontal portion (118), and a first vertical portion (120) connecting the first horizontal portion (116) and the second horizontal portion (118), wherein the second horizontal portion (118) comprises a sector shape when viewed from the top, and wherein the first portion (110) is located above the second portion (112); a reaction zone (30, 40, 50, 70, 104), the reaction zone being arranged below the non-reaction zone (31, 41, 51, 71, 102) and being separated from the non-reaction zone (31, 41, 51, 71, 102) by a plate (122); an inlet (124) for a hydrocarbon feed stream in the second portion (112) of the non-reactive zone (31, 41, 51, 71, 102); and, An outlet (126) for an effluent stream in the non-reactive zone (31, 41, 51, 71, 102), the outlet (126) being in fluid communication with the reactive zone (30, 40, 50, 70, 104).

2. The radial flow reactor (8) according to claim 1, wherein the inlet (124) and the outlet (126) are both arranged in the second part (112) of the non-reaction zone (31, 41, 51, 71, 102).

3. The radial flow reactor (8) according to claim 1, wherein the second horizontal portion (118) includes a plurality of segments (130a, 130b, 130c, 130d, 130e), each segment having a sector shape when viewed from the top.

4. The radial flow reactor (8) according to any one of claims 1 to 3, wherein the first horizontal portion (116) comprises an upper horizontal portion and the second horizontal portion (118) comprises a lower horizontal portion.

5. The radial flow reactor (8) according to claim 4, wherein the flow distributor further comprises a second vertical portion (138), and Wherein both the first vertical portion (120) and the second vertical portion (138) extend between the upper horizontal portion (116) and the lower horizontal portion (118).

6. The radial flow reactor (8) according to claim 5, wherein the first vertical section (120) is connected to the second vertical section (138).

7. The radial flow reactor (8) according to claim 6, wherein the flow distributor (114) further comprises a third vertical portion (140) having a planar profile shape.

8. The radial flow reactor (8) according to claim 7, wherein the first vertical portion (120) is attached to both the third vertical portion (140) and the second vertical portion (138).

9. The radial flow reactor (8) according to any one of claims 1 to 3, wherein the non-reactive zone (31, 41, 51, 71, 102) comprises a channel (132), and The flow distributor (114) is formed of a plurality of sections (130a, 130b, 130c, 130d, 130e), each section being sized to be removed through the passage (132) and to be passed into and out of the reactor (8).

10. A method for reforming hydrocarbons in a reactor (8), the method comprising: injecting a hydrocarbon stream into a non-reactive zone (31, 41, 51, 71, 102) of the reactor (8) via an inlet (124), wherein the non-reactive zone (31, 41, 51, 71, 102) of the reactor (8) is divided into a first portion (110) and a second portion (112) by a flow distributor (114), the flow distributor (114) comprising a first horizontal portion (116), a second horizontal portion (118) and a first vertical portion (120) connecting the first horizontal portion (116) and the second horizontal portion (118), and wherein the second horizontal portion (118) comprises a sector shape when viewed from the top, and wherein the first portion (110) is located above the second portion (112); transferring the second portion (112) of the hydrocarbon stream from the non-reactive zone (31, 41, 51, 71, 102) to the reactive zone (30, 40, 50, 70, 104) of the reactor (8); delivering catalyst particles to the reaction zone (30, 40, 50, 70, 104), wherein the catalyst particles are retained in a catalyst section (148) within the reaction zone (30, 40, 50, 70, 104); passing the hydrocarbons in a radial direction through the catalyst section (148); and, The effluent from the reaction zone (30, 40, 50, 70, 104) is passed through the second portion (112) of the non-reaction zone (31, 41, 51, 71, 102) of the reactor (8) to an outlet (126).

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