Compact quench zone reactor internals

Abstract

The present invention discloses a method of reducing the height of the internal components of a hydroprocessing reactor by placing a mixing chamber above a collecting tray. The mixing chamber has an overflow port (top overflow port) at the top of the mixing chamber and an overflow port (side overflow port) at the side of the mixing chamber for fluid entry. The design of the overflow port has a significant effect on the pressure drop. Without affecting the mixing performance, the pressure drop is reduced by having a wide shallow overflow port instead of a narrow deep overflow port. By both the side overflow port and the top overflow port, the height of the mixing chamber can be significantly reduced with minimal impact on fluid mixing and pressure drop.

Description

[0001] Priority declaration

[0002] This application claims the benefit of U.S. Provisional Patent Application Serial No. 63 / 014,796, filed on April 24, 2020, which is incorporated herein by reference in its entirety. Background Art

[0003] A variety of processes use co-current reactors in which one or more fluids flow through a solid bed of particulate material to provide contact between the fluids and the solid particles. In the reactor, the solids may comprise a catalytic material on which the fluids react to form products. The fluids may be liquids, vapors, or a mixture of liquids and vapors, and the fluids react to form liquids, vapors, or a mixture of liquids and vapors. These processes cover a range of processes including hydrocarbon conversion, hydrocracking, and hydrotreating.

[0004] Co-current reactors with fixed beds are configured so that the reactor allows fluid to flow through the catalyst bed. When the fluid is a liquid, a vapor, or a liquid and vapor mixture, the fluid is usually directed downwardly through the reactor. Multi-bed reactors are also often used, in which the reactor beds are stacked on top of each other in a reactor housing. Typically, they are stacked together in a manner that leaves some space between the beds.

[0005] The inter-bed spaces are typically formed to provide for intermediate processing of the process fluids, such as cooling, heating, mixing, and redistribution.

[0006] In exothermic catalytic reactions, it is important to control the temperature and distribution of fluids. The temperature and composition of the fluids from the upper catalyst bed and the outside of the reactor should be fully mixed before being distributed to the lower catalyst bed. As the process fluid moves downward along the reactor, the initial poor fluid mixing and distribution at the top of the catalyst bed will continue or grow. Hot spots can form and cause rapid deactivation of the catalyst and shorten the reactor operating cycle length. The space between the catalyst beds is used to inject quenching gas or liquid, and for fluid mixing and distribution. In hydrocarbon processing, the quenching gas is usually a cold hydrogen / hydrocarbon stream. However, cooling the fluid without controlling mixing and distribution will lead to uneven reactions and uneven temperature distribution in subsequent reactor beds. And complex mixing and distribution systems take up valuable space in the reaction chamber that accommodates multiple catalyst beds.

[0007] It has always been desirable to minimize the space between catalyst beds for the introduction of quenching fluids and for mixing vapors and liquids with the quenching fluids. Specifically, for existing hydroprocessing reactors, it is often desirable to reduce the space between catalyst beds to increase catalyst loading so that reactor throughput can be increased or operating cycle time can be increased, or both. Even for new reactors, it is often desirable to reduce the overall size of the reactor to reduce capital expenditures and the appearance of the reactor in the processing plant. Therefore, it is desirable to provide good mixing and distribution of fluids between adjacent catalyst beds in a relatively small inter-bed space.

[0008] The design of reactor internals that overcome these limitations can greatly save valuable space within the reactor to maximize catalyst loading. In addition, it is often desirable to modify existing reactors to improve processes by taking advantage of reduced quench zone space between catalyst beds. New reactor internals that improve space utilization within the reactor housing can provide significant cost savings and allow modification of existing reactors to meet new operating and regulatory requirements. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 FIG. 4 is a cross-section of one embodiment of the hydroprocessing reactor internals of the present invention.

[0010] Figure 2 A top view of one embodiment of the collection tray, mixing chamber and annular quench distributor of the present invention.

[0011] Figure 3 FIG. 4 is a cross-section of another embodiment of the hydroprocessing reactor internals of the present invention. DETAILED DESCRIPTION

[0012] In improvements to existing reactors, minimizing the height of the hydroprocessing reactor internals (HRI) and maximizing the catalyst loading helps to increase productivity and / or increase the operating cycle length, thereby improving the economics of the process. In this design, the reduction in HRI height is achieved by placing the mixing chamber above the collection tray. The pressure drop is reduced using a special overflow design. The mixing chamber has an overflow located at the top of the mixing chamber (top overflow) and an overflow located on the side of the mixing chamber (side overflow) for fluid entry. The fluid leaves the mixing chamber through a central opening in the collection tray. Computational fluid dynamics (CFD) found that the design of the overflow has a significant effect on the pressure drop, and the pressure drop is reduced by having a wide shallow overflow instead of a narrow deep overflow without affecting the mixing performance. By having both side overflows and top overflows, it was surprisingly found that the height of the mixing chamber can be significantly reduced with minimal impact on fluid mixing and pressure drop.

[0013] The internal components of the quench zone of these hydroprocessing reactors include collecting trays, mixing chambers, annular distributors, crude liquid distribution trays and gas-liquid distribution trays. Fluid mixing mainly occurs in the mixing chamber.

[0014] A collecting tray is a tray with a central opening.

[0015] The mixing chamber is located above the collecting tray and around the central opening for downward liquid flow, or steam flow, or both steam flow and liquid flow. The mixing chamber has an outer wall and a top plate attached to the outer wall. There is at least one overflow port in the top plate of the mixing chamber, and at least one overflow port in the outer wall to allow fluid to flow through. Typically, the overflow ports in the top plate are evenly spaced around the circular top plate; the overflow ports in the outer wall are also usually evenly spaced around the outer wall. The same number of overflow ports are usually present in the top plate and in the outer wall. Typically, the overflow ports in the top plate and the overflow ports in the outer wall are located at the same position around the wall. However, for a specific embodiment, the number of top overflow ports and side overflow ports may be different, and they may be offset from each other. The overflow ports in the top plate are positioned close to the outer wall to maximize their distance from the central opening, thereby increasing the fluid residence time and improving mixing.

[0016] An annular quench distributor is located around the fluid collection tray between the mixing chamber and the reactor shell to eliminate the vertical space occupied by the distributor. An injector attached to the annular quench distributor manifold is positioned above the ceiling of the mixing chamber and is oriented tangentially to the annular manifold for injecting quench fluid while avoiding liquid from entering the distributor. Most of the vapor and a portion of the liquid enter the mixing chamber tangentially through an overflow port at the top of the mixing chamber, while the remaining liquid and vapor enter the mixing chamber tangentially through openings in the sides of the mixing chamber with directional guide plates. The mixing chamber has a central opening for fluid outflow.

[0017] The coarse liquid distribution plate has a central flat plate for receiving vapor and liquid from the mixing chamber. The details of the coarse liquid distribution plate are not important; any suitable coarse liquid distribution plate can be used. In one embodiment as shown in US 5,837,208, the plate has perforations on the bottom plate outside the central flat plate for liquid to flow into the gas-liquid distribution plate below, and an annular opening area between the outer edge of the plate and the reactor shell for vapor to flow into the gas-liquid distribution plate. In another embodiment as shown in US 9,295,959, the coarse liquid distribution plate may have a pie-shaped channel extending from the central flat plate to the outer edge of the plate for vapor to flow around into the gas-liquid distribution plate, so that the space required between the coarse liquid distribution plate and the gas-liquid distribution plate is reduced. In another embodiment, the coarse liquid distribution plate includes a plurality of fluid distribution grooves attached to the central flat plate, the plurality of fluid distribution grooves extending radially outward, and their outer ends are close to the reactor shell. The bottom of the fluid distribution groove has holes for liquid to flow to the gas-liquid distribution plate below. The fluid distribution trough has side walls and end walls that slope from the central flat plate toward the outer ends of the fluid distribution trough for holding liquid in the fluid distribution trough for liquid distribution. Vapor and liquid flow horizontally from the central flat plate to the distribution trough. Vapor leaves the fluid distribution trough from the top of these walls and flows downward to the gas-liquid distribution plate through the open space between the fluid distribution troughs and between the fluid distribution troughs and the reactor shell.

[0018] The rough liquid distribution plate helps the gas-liquid distribution plate to evenly distribute the fluid to the lower catalyst bed.

[0019] Any suitable gas-liquid distribution tray may be used. In one embodiment as shown in US 6,769,672, the tray has a plurality of distributors, and each distributor has a fluid path with a different resistance to fluid flow. In another embodiment as shown in US 7,506,861, the tray has a plurality of distributors, and each distributor has a liquid conduit attached to a downcomer for introducing liquid, and an orifice at the top of the downcomer for the entry of vapor. The liquid mixes with the downwardly flowing vapor in the downcomer. The downcomer has an orifice located inside for enhancing gas-liquid mixing, and a plate located below for diffusing the liquid.

[0020] The new design of the quench zone HRI reduces the space between catalyst beds by 12 inches to 24 inches compared to the conventional design of the HRI.

[0021] One aspect of the present invention is an apparatus for mixing and distributing fluids between catalyst beds. In one embodiment, the apparatus includes a collection tray having a central opening, the collection tray being in fluid communication with the bottom of the upper catalyst bed. A mixing chamber, the mixing chamber being located above the collection tray, the mixing chamber being located around the central opening, the mixing chamber having an outer wall located at a position inside the reactor wall and a top plate attached to the outer wall, the outer wall having at least one side overflow port to allow fluid to pass therethrough, and the top plate having at least one top overflow port to allow fluid to pass therethrough, the top plate being in fluid communication with the bottom of the upper catalyst bed; an annular quench distributor, the annular quench distributor including an ejector for injecting quench fluid into the space between the reactor wall and the outer wall above the collection tray; a coarse liquid distribution tray, the coarse liquid distribution tray including a central flat tray in fluid communication with the central opening of the collection tray; and a gas-liquid distribution tray, the gas-liquid distribution tray being in fluid communication with the coarse liquid distribution tray and with the top of the lower catalyst bed.

[0022] In some embodiments, the at least one top overflow is aligned with the at least one side overflow.

[0023] In some embodiments, there are at least four top overflows and at least four side overflows.

[0024] In some embodiments, the at least four top overflows are aligned with the at least four side overflows, and wherein the at least four top overflows and the at least four side overflows are equally spaced around the mixing chamber.

[0025] In some embodiments, the apparatus further comprises a directional guide plate located at at least one side overflow outlet.

[0026] In some embodiments, the directional baffle extends inwardly into the mixing chamber.

[0027] In some embodiments, the directional baffles extend outwardly into the space between the reactor wall and the outer wall.

[0028] In some embodiments, the directional guide plate forms an angle of less than 30° relative to a tangent line to the outer wall.

[0029] In some embodiments, the outer wall has a height, and wherein the height of the at least one side overflow is equal to the height of the outer wall.

[0030] In some embodiments, the bottom plate of the collection tray outside the mixing chamber is at an angle relative to the bottom plate of the collection tray inside the mixing chamber.

[0031] In some embodiments, the injector is positioned above the ceiling of the mixing chamber.

[0032] In some embodiments, the mixing chamber has a plurality of internal vertical support plates oriented tangentially to one or more concentric circles to support the top plate and promote rotational fluid flow within the mixing chamber.

[0033] Another aspect of the invention is an apparatus for mixing and distributing fluids between catalyst beds. In one embodiment, the apparatus comprises a collection tray having a central opening in fluid communication with the bottom of an upper catalyst bed. a mixing chamber located above the collection tray, the mixing chamber located about the central opening, the mixing chamber having an outer wall located at a position interior to the reactor wall and a top plate attached to the outer wall, the outer wall having at least two side overflows to allow fluid to pass therethrough, and the top plate having at least two top overflows to allow fluid to pass therethrough, the at least two top overflows being aligned with the at least two side overflows, and wherein the at least two top overflows and the at least two side overflows are equally spaced about the mixing chamber, the top plate being in fluid communication with the bottom of the upper catalyst bed; an annular quench distributor including an ejector for injecting quench fluid into the space between the reactor wall and the outer wall above the collection tray; a rough liquid distribution tray including a central flat tray in fluid communication with the central opening of the collection tray; and a gas-liquid distribution tray in fluid communication with the rough liquid distribution tray and with the top of the lower catalyst bed.

[0034] In some embodiments, there are at least four top overflows and at least four side overflows.

[0035] In some embodiments, the apparatus further comprises a directional guide plate located at at least one side overflow outlet.

[0036] In some embodiments, the directional guide plate extends inwardly into the mixing chamber or the directional guide plate extends outwardly into the space between the reactor wall and the outer wall; and wherein the directional guide plate forms an angle of less than 30° relative to a tangent to the outer wall.

[0037] In some embodiments, the outer wall has a height, and wherein the height of at least two side overflows is equal to the height of the outer wall.

[0038] In some embodiments, the bottom plate of the collection tray outside the mixing chamber is at an angle relative to the bottom plate of the collection tray inside the mixing chamber.

[0039] In some embodiments, the injector is positioned above the ceiling of the mixing chamber.

[0040] In some embodiments, the mixing chamber has a plurality of internal vertical support plates oriented tangentially to one or more concentric circles to support the top plate and promote rotational fluid flow within the mixing chamber.

[0041] like Figure 1 and Figure 2 As shown, the quench zone HRI 100 is between the bottom of the upper catalyst bed 105 and the top of the lower catalyst bed 110. There is a support system at the bottom of the upper catalyst bed 105 for supporting the bed. The HRI 100 includes a collection tray 115, a crude liquid distribution tray 120, and a gas-liquid distribution tray 125.

[0042] In some embodiments, the mixing chamber 130 has an inner wall 135, an outer wall 140, and a top plate 145. The top plate 145 is generally located on top of the outer wall 140. The inner wall 135 does not extend all the way to the top plate 145. In some embodiments, there is no inner wall 135.

[0043] In other embodiments, the mixing chamber 130 has a plurality of internal vertical support plates 147 between the top plate 145 and the collection tray 115 , which are oriented tangentially to one or more concentric circles to support the top plate and promote rotating fluid flow within the mixing chamber 130 .

[0044] The outer wall 140 has a side overflow 150 to allow fluid to enter the mixing chamber 130. There may be a directional guide plate 155 at the side overflow 150, which extends from the outer wall 140 into the mixing chamber 130. The side overflow 150 generally extends from the collection tray 115 to the top plate 145. There is also a top overflow 160 in the top plate 145. The total opening area of ​​the top overflow 160 for fluid to enter the mixing chamber 130 is larger than the total opening area of ​​the side overflow 150 for fluid to enter to reduce pressure drop.

[0045] The annular region 165 between the outer wall 140 and the reactor shell 210 is determined by the space required to mount the annular quench distributor 170 and is sized to maximize the diameter of the mixing chamber 130. The top overflow ports 160 are located close to the outer wall 140 to maximize their distance from the central opening 190, thereby increasing fluid residence time and improving mixing.

[0046] Downflow process vapors and liquids from the upper catalyst bed 105 fall onto the top plate 145 and onto the annular region 165 between the mixing chamber 130 and the reactor shell 210. The quench fluid is primarily injected into the annular region 165. Most of the vapor and some of the liquid enter the mixing chamber 130 through the top overflow port 160 in the top plate 145. The remaining liquid and vapor flow into the mixing chamber 130 through the side overflow ports 150 in the outer wall 140. This arrangement allows the height of the mixing chamber to be reduced with minimal impact on fluid mixing and pressure drop.

[0047] The injectors 167 for the quench fluid are generally oriented tangentially to the annular quench distributor 170 .

[0048] In some embodiments, there may be an intermediate wall between top overflow 160 and interior wall 135, with overflow and directional baffles similar to side overflow 150 and directional baffles 155 on the side walls. Alternatively, there may be a gap between the top of the intermediate wall and the ceiling.

[0049] exist Figure 3 In the embodiment of FIG. 1 , the collection tray 115 located outside the mixing chamber 130 is raised so that there is more space below the collection tray 115 for vapor expansion and the quality of the rough liquid distribution is improved due to the reduced fluid velocity around the rough liquid distribution tray 120. In this embodiment, the annular quench distributor 170 is mainly located below the collection tray 115, with only the ejector 167 extending above the collection tray 115 for quench fluid distribution.

[0050] The rough liquid distribution plate 120 includes a central flat plate 180 and a fluid distribution groove 185 .

[0051] All fluids flow toward the center of the collection tray 115 in a swirling pattern to mix and flow downward through the center opening 190 in the collection tray 115, as shown in FIG. Figure 1 and Figure 3 shown.

[0052] like Figure 1 and Figure 3 As shown, the mixed fluid then enters the center flat plate 180 and then enters the fluid distribution groove 185 attached to the center flat plate 180 for distribution. The liquid flows down to the gas-liquid distribution plate 125 through the holes in the perforated bottom plate 195 of the fluid distribution groove 185, and the vapor (gas) flows through the top of the side wall 200 and the end wall 205, and then flows into the space between the fluid distribution groove 185 and flows into the gas-liquid distribution plate 125 below.

[0053] The fluid distribution slots 185 can be any suitable size and shape. The number, size and shape of the slots can be designed to accommodate various reactor sizes and vapor and liquid flow rates. Narrow fluid distribution slots 185 (e.g., less than 30 inches) can be designed to pass through manholes in the reactor to facilitate installation with minimal required sealing. Multiple narrow fluid distribution slots 185 also reduce the velocity of vapor leaving the fluid distribution slots 185 through gaps above the sidewalls 200 and end walls 205 of the fluid distribution slots 185 to improve the quality of fluid distribution to the gas-liquid distribution plate 125 below.

[0054] In one embodiment, the fluid distribution trough 185 is constructed with a perforated bottom plate 195, a sloped sidewall 200, and an end wall 205. The end of the trough attached to the center flat plate 180 is open so that fluid can enter the trough. The sidewall 200 slopes from a height close to the spacing between the rough liquid distribution tray 120 and the collection tray 115 attached to the side of the center flat plate 180 to 1 inch at the end wall 205 adjacent to the reactor shell 210. Typically, the height of the end wall 205 of the fluid distribution trough 185 is the same as the height of the sidewall 200 where they meet.

[0055] Descriptions of the processes and apparatus of the prior art and the present invention are presented with reference to the accompanying drawings. The drawings are simplified diagrams of various embodiments of the prior art and the present invention and are not intended to unduly limit the general broad scope of the description provided herein and the appended claims. Mechanical supports and hardware for attaching HRI components to supports have been omitted as they are not necessary for a clear understanding of the present invention.

[0056] 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.

[0057] 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.

[0058] Those of ordinary skill in the art will recognize and appreciate that various other components, such as beams, supports, hardware, etc., are not shown in the accompanying drawings because it is believed that their details are well within the knowledge of those of ordinary skill in the art and their description is not necessary for the practice or understanding of the embodiments of the present invention.

[0059] 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.

[0060] Specific implementation plan

[0061] 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.

[0062] A first embodiment of the present invention is an apparatus for mixing and distributing fluids between catalyst beds, the apparatus comprising: a collecting tray including a central opening, the collecting tray being in fluid communication with the bottom of an upper catalyst bed; a mixing chamber located above the collecting tray, the mixing chamber being located around the central opening, the mixing chamber having an outer wall located at a position interior to a reactor wall and a top plate attached to the outer wall, the outer wall having at least one side overflow port to allow fluid to pass therethrough, and the top plate having at least one top overflow port to allow fluid to pass therethrough, the top plate being in fluid communication with the bottom of the upper catalyst bed; an annular quench distributor including an ejector for injecting quench fluid into a space above the collecting tray between the reactor wall and the outer wall; a rough liquid distribution tray including a central flat tray in fluid communication with the central opening of the collecting tray; and a gas-liquid distribution tray in fluid communication with the rough liquid distribution tray and with the top of a lower catalyst bed. One embodiment of the present invention is one, any or all embodiments from the first embodiment in this paragraph to the previous embodiments in this paragraph, wherein the at least one top overflow is aligned with the at least one side overflow. One embodiment of the present invention is one, any or all embodiments from the first embodiment in this paragraph to the previous embodiments in this paragraph, wherein there are at least four top overflows and at least four side overflows. One embodiment of the present invention is one, any or all embodiments from the first embodiment in this paragraph to the previous embodiments in this paragraph, wherein the at least four top overflows are aligned with the at least four side overflows, and wherein the at least four top overflows and the at least four side overflows are equally spaced around the mixing chamber. One embodiment of the present invention is one, any or all embodiments from the first embodiment in this paragraph to the previous embodiments in this paragraph, further comprising a directional guide plate at at least one side overflow. One embodiment of the present invention is one, any or all embodiments from the first embodiment in this paragraph to the previous embodiments in this paragraph, wherein the guide plate extends inwardly into the mixing chamber. One embodiment of the present invention is one, any or all of the embodiments from the first embodiment in this paragraph to the previous embodiments in this paragraph, wherein the guide plate extends outwardly into the space between the reactor wall and the outer wall. One embodiment of the present invention is one, any or all of the embodiments from the first embodiment in this paragraph to the previous embodiments in this paragraph, wherein the directional guide plate forms an angle of less than 30° relative to the tangent of the outer wall. One embodiment of the present invention is one, any or all of the embodiments from the first embodiment in this paragraph to the previous embodiments in this paragraph, wherein the outer wall has a height, and wherein the height of the at least one side overflow port is equal to the height of the outer wall.One embodiment of the present invention is one, any or all of the first embodiment in this paragraph to the previous embodiments in this paragraph, wherein the bottom plate of the collection tray located outside the mixing chamber forms an angle relative to the bottom plate of the collection tray located inside the mixing chamber. One embodiment of the present invention is one, any or all of the first embodiment in this paragraph to the previous embodiments in this paragraph, wherein the injector is located above the top plate of the mixing chamber. One embodiment of the present invention is one, any or all of the first embodiment in this paragraph to the previous embodiments in this paragraph, wherein the mixing chamber has a plurality of internal vertical support plates, which are oriented tangentially to one or more concentric circles to support the top plate and promote rotating fluid flow inside the mixing chamber.

[0063] A second embodiment of the present invention is an apparatus for mixing and distributing fluids between catalyst beds, the apparatus comprising: a collecting tray including a central opening, the collecting tray being in fluid communication with the bottom of the upper catalyst bed; a mixing chamber located above the collecting tray, the mixing chamber being located around the central opening, the mixing chamber having an outer wall located at a position interior to the reactor wall and a top plate attached to the outer wall, the outer wall having at least two side overflows to allow fluid to pass therethrough, and the top plate having at least two top overflows to allow fluid to pass therethrough, the at least two top overflows being connected to the at least Two side overflows are aligned, and wherein the at least two top overflows and the at least two side overflows are equally spaced around the mixing chamber, the top plate is in fluid communication with the bottom of the upper catalyst bed; an annular quench distributor, the annular quench distributor comprising an ejector for injecting quench fluid into the space between the reactor wall and the outer wall above the collection tray; a coarse liquid distribution tray, the coarse liquid distribution tray comprising a central flat tray in fluid communication with the central opening of the collection tray; and a gas-liquid distribution tray, the gas-liquid distribution tray being in fluid communication with the coarse liquid distribution tray and with the top of the lower catalyst bed. One embodiment of the present invention is one, any or all of the embodiments from the second embodiment in this paragraph to the previous embodiments in this paragraph, wherein there are at least four top overflows and at least four side overflows. One embodiment of the present invention is one, any or all of the embodiments from the second embodiment in this paragraph to the previous embodiments in this paragraph, further comprising a directional guide plate at at least one side overflow. One embodiment of the present invention is one, any or all of the embodiments from the second embodiment in this paragraph to the previous embodiments in this paragraph, wherein the guide plate extends inwardly into the mixing chamber or wherein the guide plate extends outwardly into the space between the reactor wall and the outer wall; and wherein the directional guide plate forms an angle of less than 30° relative to the tangent of the outer wall. One embodiment of the present invention is one, any or all of the embodiments from the second embodiment in this paragraph to the previous embodiments in this paragraph, wherein the outer wall has a height, and wherein the height of the at least two side overflow ports is equal to the height of the outer wall. One embodiment of the present invention is one, any or all of the embodiments from the second embodiment in this paragraph to the previous embodiments in this paragraph, wherein the bottom plate of the collection tray located outside the mixing chamber forms an angle relative to the bottom plate of the collection tray located inside the mixing chamber. One embodiment of the present invention is one, any or all of the embodiments from the second embodiment in this paragraph to the previous embodiments in this paragraph, wherein the ejector is located above the top plate of the mixing chamber.One embodiment of the present invention is one, any or all of the embodiments from the second embodiment in this paragraph to the previous embodiments in this paragraph, wherein the mixing chamber has a plurality of internal vertical support plates, which are oriented tangentially to one or more concentric circles to support the top plate and promote rotating fluid flow inside the mixing chamber.

[0064] 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.

[0065] In the foregoing, all temperatures are set forth in degrees Celsius and all parts and percentages are by weight unless otherwise indicated.

Claims

1. An apparatus for mixing and distributing fluids between catalyst beds, comprising: a collection tray (115) comprising a central opening (190), the collection tray (115) being in fluid communication with the bottom of the upper catalyst bed (105); a mixing chamber (130) located above the collection tray (115), the mixing chamber (130) being located about the central opening (190), the mixing chamber (130) having an outer wall (140) located at a position interior to the reactor wall (210) and a top plate (145) attached to the outer wall (140), the outer wall having at least one side weir (150) to allow fluid to pass therethrough, and the top plate (145) having at least one top weir (160) to allow fluid to pass therethrough, the top plate (145) being in fluid communication with the bottom of the upper catalyst bed (105), wherein the top weir (160) is positioned proximate the outer wall (140) to maximize their distance from the central opening (190) to increase fluid residence time and improve mixing; an annular quench distributor (170) comprising an injector (167) for injecting a quench fluid into the space between the reactor wall (210) and the outer wall (140) above the collection tray (115); a coarse liquid distribution pan (120) comprising a central flat pan (180) in fluid communication with the central opening (190) of the collection pan (115); and a gas-liquid distribution plate (125) in fluid communication with the crude liquid distribution plate (120) and with the top of the lower catalyst bed (110); The total opening area of ​​the top overflow port (160) for fluid to enter the mixing chamber (130) is greater than the total opening area of ​​the side overflow port (150) for fluid to enter.

2. The apparatus according to claim 1, wherein the at least one top overflow (160) is aligned with the at least one side overflow (150).

3. The apparatus according to claim 1 or 2, wherein there are at least four top overflows (160) and at least four side overflows (150), and wherein the at least four top overflows (160) are aligned with the at least four side overflows (150).

4. The apparatus according to claim 1 or 2, further comprising a directional guide plate (155) at the at least one side overflow outlet (150).

5. The apparatus according to claim 4, wherein the directional guide plate (155) extends inwardly into the mixing chamber (130) or outwardly into the space between the reactor wall (210) and the outer wall (140).

6. The apparatus according to claim 4, wherein the directional guide plate (155) forms an angle of less than 30° with respect to a tangent line of the outer wall (140).

7. The apparatus according to claim 1 or 2, wherein the outer wall (140) has a height, and wherein the height of the at least one side overflow (150) is equal to the height of the outer wall (140).

8. The apparatus according to claim 1 or 2, wherein a bottom plate of the collecting tray (115) outside the mixing chamber (130) forms an angle with respect to a bottom plate of the collecting tray (115) inside the mixing chamber (130).

9. The apparatus according to claim 1 or 2, wherein the injector (167) is positioned above the ceiling (145) of the mixing chamber (130).

10. An apparatus according to claim 1 or 2, wherein the mixing chamber (130) has a plurality of internal vertical support plates (147), which are oriented tangentially to one or more concentric circles to support the top plate (145) and promote rotating fluid flow inside the mixing chamber (130).

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