Hydroprocessing reactor internals with reduced height

Abstract

Hydrotreating reactor quench zone internals are disclosed that include a collection tray, a mixing chamber, an annular quench distributor, a rough liquid distribution tray, and a gas-liquid distribution tray. The rough liquid distribution tray has a central flat tray for receiving vapor and liquid exiting the mixing chamber and a plurality of fluid distribution slots attached to the central flat tray that extend radially outward with outer ends proximate the reactor shell. The fluid distribution slots can include at least one longitudinal baffle, or at least one transverse baffle, or both, and optionally end baffles. The baffles improve the flow of liquid and / or vapor in the rough liquid distribution tray.

Description

[0001] Priority Statement

[0002] This application claims priority to U.S. Application No. 17 / 038,049, filed on September 30, 2020, the entire contents of which are incorporated herein by reference. Background Technology

[0003] Many processes utilize co-current reactors, in which one or more fluids flow through a fixed bed of solid particulate material to provide contact between the fluid and the solid particles. Within the reactor, the solids may contain catalytic materials on which the fluid reacts to form products. The fluid can be a liquid, a vapor, or a mixture of liquids and vapors, and the fluid reacts to form a liquid, vapor, or a mixture of liquids and vapors. These processes encompass a range of technologies including hydrocarbon conversion, hydrocracking, and hydrotreatment.

[0004] Co-current reactors with fixed beds are configured to allow fluid to flow through the catalyst beds. When the fluid is a liquid, vapor, or a mixture of liquid and vapor, it is typically directed to flow downwards through the reactor. Multi-bed reactors are also frequently used, in which the catalyst beds are stacked on top of each other within the reactor shell. Typically, they are stacked together with some space between the beds.

[0005] Bed spaces are typically formed to provide intermediate treatment of process fluids, such as cooling, heating, mixing, and redistribution.

[0006] In exothermic catalytic reactions, controlling the temperature and distribution of the fluids is crucial. The temperature and composition of the fluids from the upper catalyst bed and outside the reactor must be adequately mixed before being distributed to the lower catalyst bed. As the process fluids move down the reactor, the initially poor temperature and composition distribution at the top of the catalyst bed can persist or worsen. Hot spots can form and lead to rapid catalyst deactivation and shorten the reactor operating cycle length. The space between the catalyst beds is used for injecting quench gas or liquid, as well as for fluid mixing and distribution. In hydrocarbon processing, the quench gas is typically a cold hydrogen / hydrocarbon stream. However, cooling the fluid without controlled mixing and distribution can lead to uneven reaction and temperature distribution in subsequent catalyst beds. Moreover, complex mixing and distribution systems occupy valuable space in the reaction chamber housing multiple catalyst beds.

[0007] Minimizing the space between catalyst beds is consistently desirable for introducing quench fluid, mixing vapor and liquid with the quench fluid, and distributing the fluid. Specifically, for existing hydrotreating reactors, reducing the space between catalyst beds is generally desirable to increase catalyst loading, thereby increasing reactor throughput or operating cycle time, or both. Even for newer reactors, reducing the overall reactor size is generally desirable to reduce capital expenditure and reactor profile within the treatment plant. Therefore, it is desirable to provide good mixing and distribution of fluids between adjacent catalyst beds within a relatively small interbed space.

[0008] Reactor designs that overcome these limitations can significantly save valuable space within the reactor to maximize catalyst loading. Furthermore, it is often desirable to improve existing reactors by utilizing the same or reduced quench zone space between catalyst beds to enhance the process. New reactor internals that improve space utilization within the reactor shell can significantly reduce costs and allow for improvements to existing reactors to meet new operational and regulatory requirements. Attached Figure Description

[0009] Figure 1 This is a cross-section of one embodiment of the internal components of the hydrogenation reactor of the present invention.

[0010] Figure 2 This is a top view of one embodiment of the coarse liquid distribution disc of the present invention. Detailed Implementation

[0011] In improvements to existing reactors, minimizing the height of the hydrotreatment 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.

[0012] The components within the quenching zone of these hydrotreating reactors include a collection tray, a mixing chamber, an annular quench distributor, a coarse liquid distribution tray, and a gas-liquid distribution tray. Fluid mixing primarily occurs in the mixing chamber.

[0013] The collecting tray is a tray with a central opening.

[0014] The mixing chamber is located above the collecting tray and surrounds a central opening for downward liquid flow, or vapor flow, or both vapor and liquid flow.

[0015] An annular quench distributor is located above 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 top plate of the mixing chamber and oriented tangentially to the annular manifold for injecting the quench fluid while preventing 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 tangentially through openings with directional guide vanes in the side of the mixing chamber.

[0016] The coarse liquid distribution plate has a central flat plate for receiving vapor and liquid exiting the mixing chamber and multiple fluid distribution channels (e.g., 3 to 12) attached to the central flat plate, the multiple fluid distribution channels extending radially outward, with their outer ends close to (e.g., less than 12 inches) the reactor shell. The bottom of the fluid distribution channel can be solid or have openings (e.g., orifices or slots) for liquid flow to the gas-liquid distribution plate below. The fluid distribution channel has sidewalls sloping downward from the central flat plate to the outer ends of the fluid distribution channel. When the channel bottom has openings, the outer ends of the channel may have walls for retaining liquid within the fluid distribution channel for liquid distribution. Vapor and liquid flow radially from the central flat plate to the distribution channels. Vapor exits the fluid distribution channel at the top of the sloping walls and in the open space between the fluid distribution channel and the reactor shell.

[0017] The coarse liquid distribution plate helps the gas-liquid distribution plate to evenly distribute the fluid to the lower catalyst bed.

[0018] In some cases, it has been found that the momentum of the vortex fluid flow induced from the mixing chamber is carried over to the liquid distribution channel in the coarse liquid distribution plate. This causes the liquid to slosh to one side of the distribution channel. By adding a longitudinal baffle to the inlet of the distribution channel in the coarse liquid distribution plate, the vortex fluid flow from the mixing chamber is disrupted, and the liquid is guided more evenly across the width of the distribution channel and distributed more evenly to the gas-liquid distribution plate below. This reduces flow turbulence on the gas-liquid distribution plate and improves fluid distribution to the catalyst bed below. The baffle is simple to manufacture and does not increase the number of parts or complicate the installation of the HRI.

[0019] There may be at least one longitudinal baffle extending from the central flat plate toward the outer end of the fluid distribution channel. The longitudinal baffle may be solid or perforated, and its length is typically between 10% and 50% of the length of the fluid distribution channel, or 20% to 30% of the channel length. In some embodiments, the longitudinal baffle may extend the entire length of the fluid distribution channel. The height of the baffle is typically 1 inch or greater and may extend to any height to the bottom of the collection tray. The number, height, and length can be adjusted to optimize the uniformity of the liquid across the width of the fluid distribution channel while attempting to minimize the amount of material in the baffle.

[0020] In some cases, the radial vapor flow along the fluid distribution channel is so strong that most of the vapor directly impacts the reactor wall. This creates a high static pressure zone near the reactor wall. As a result, the liquid level near the reactor wall is much lower than the liquid level in the inner region of the gas-liquid distribution plate. This will affect the uniformity of fluid distribution through the distributor near the reactor wall, especially when the vapor velocity is high and the liquid velocity is low. At least one transverse baffle extending between the sidewalls can be added to reduce the amount of vapor directly impacting the reactor wall, thereby making the liquid level in the gas-liquid distribution plate more uniform. The transverse baffle can be solid or perforated, gradually deflecting the vapor into the space between the fluid distribution channels along the circumference. The transverse baffle is perpendicular to the direction of the vapor flow (radial) in the fluid distribution channel and is positioned between 25% and 75% of the length of the fluid distribution channel. They are typically as wide as the fluid distribution channel, although they can be narrower or wider if needed. The transverse baffle can be positioned on the top of the sidewall and extend upwards to the bottom of the collection plate. The number of transverse baffles and the opening ratio of the perforations can be optimized. There are usually three or fewer lateral deflectors.

[0021] In some implementations, an end guide plate may be present between the outer end of the fluid distribution tank and the reactor wall. The end guide plate directs the liquid downwards to the lower gas-liquid distribution plate. The guide plate may have a horizontal lip at the top to prevent liquid splashing onto the reactor wall. The end guide plate may be attached to the fluid distribution tank, the gas-liquid distribution plate, or partially attached to both. Depending on the liquid volumetric flow rate and the fluid distribution tank design, the end guide plate is typically spaced 1 to 5 inches from the end of the fluid distribution tank. It may extend up to 3 inches above and below the end of the fluid distribution tank. The end guide plate may be straight or it may be curved to conform to the reactor shell. The width of the end guide plate is preferably wider than the fluid distribution tank, allowing the liquid to spread over a wider area on the gas-liquid distribution plate to minimize interference from liquid pooling on the gas-liquid distribution plate.

[0022] Longitudinal and end baffles improve liquid distribution across the distribution channels. Transverse baffles improve vapor distribution through the space between the fluid distribution channels, thus reducing the radial pressure drop in the gas-liquid distribution plate. These baffles reduce the local momentum of the fluid flow and improve fluid distribution to the lower gas-liquid distribution plate. This allows for uniform fluid distribution to the lower catalyst bed via distributors within the gas-liquid distribution plate.

[0023] One aspect of the 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 an upper catalyst bed; a coarse liquid distribution tray including a central flat plate in fluid communication with the central opening of the collection tray and a plurality of fluid distribution channels in fluid communication with and extending radially outward from the central flat plate, the fluid distribution channels including a bottom and sidewalls, each fluid distribution channel having at least one longitudinal guide plate extending from the central flat plate toward the outer end of the fluid distribution channel or at least one transverse guide plate extending between the sidewalls, or both, the outer end of the fluid distribution channel being spaced apart from a reactor wall; and a gas-liquid distribution tray in fluid communication with the coarse liquid distribution tray and with the top of a lower catalyst bed.

[0024] In some embodiments, the length of at least one longitudinal baffle is 10% to 50% of the length of the fluid distribution channel.

[0025] In some implementations, the coarse liquid distribution plate has 3 to 12 fluid distribution channels.

[0026] In some implementations, each fluid distribution slot has three longitudinal baffles.

[0027] In some implementations, at least one transverse baffle is positioned between 25% and 75% of the length of the fluid distribution channel.

[0028] In some implementations, each fluid distribution trough has three or fewer transverse baffles.

[0029] In some implementations, at least one longitudinal deflector is perforated or the at least one transverse deflector is perforated, or both.

[0030] In some implementations, the bottom of the fluid distribution tank has an opening through which it passes.

[0031] In some implementations, the bottom of the fluid distribution tank is solid.

[0032] In some implementations, the fluid distribution channel also includes an end wall connected to the sidewall.

[0033] In some implementations, the fluid distribution channel also includes an end guide plate positioned between the outer end of the fluid distribution channel and the reactor wall.

[0034] Another aspect of the 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 an upper catalyst bed; a coarse liquid distribution tray including a central flat plate in fluid communication with the central opening of the collection tray and a plurality of fluid distribution channels in fluid communication with and extending radially outward from the central flat plate, the fluid distribution channels including a bottom and sidewalls, each fluid distribution channel having at least one longitudinal guide plate extending from the central flat plate toward the outer end of the fluid distribution channel and at least one transverse guide plate extending between the sidewalls, the sidewalls sloping downward from the central flat plate toward the outer end, the outer end of the fluid distribution channel being spaced apart from the reactor wall; and a gas-liquid distribution tray in fluid communication with the coarse liquid distribution tray and with the top of a lower catalyst bed.

[0035] In some embodiments, the length of at least one longitudinal baffle is 10% to 50% of the length of the fluid distribution channel.

[0036] In some implementations, each fluid distribution slot has three longitudinal baffles.

[0037] In some implementations, at least one transverse baffle is positioned between 25% and 75% of the length of the fluid distribution channel.

[0038] In some implementations, each fluid distribution trough has three or fewer transverse baffles.

[0039] In some implementations, the bottom of the fluid distribution tank has an opening through which it passes.

[0040] In some implementations, the bottom of the fluid distribution tank is solid.

[0041] In some implementations, the fluid distribution channel has an end wall at its outer end.

[0042] Another aspect of the invention is an apparatus for mixing and distributing fluids between catalyst beds. In one embodiment, the device includes a collection tray with a central opening, the collection tray being in fluid communication with the bottom of an upper catalyst bed; a coarse liquid distribution tray including a central flat plate in fluid communication with the central opening of the collection tray and a plurality of fluid distribution channels in fluid communication with and extending radially outward from the central flat plate, the fluid distribution channels including a bottom and sidewalls, each fluid distribution channel having at least one of the following: at least one longitudinal guide plate extending from the central flat plate toward the outer end of the fluid distribution channel; at least one transverse guide plate extending between the sidewalls; and an end guide plate located between the outer end of the fluid distribution channel and the reactor wall; wherein the length of at least one longitudinal guide plate is 10% to 50% of the length of the fluid distribution channel, wherein at least one transverse guide plate is positioned between 25% and 75% of the length of the fluid distribution channel, the sidewalls sloping downward from the central flat plate toward the outer end of the fluid distribution channel, and the end of the fluid distribution channel spaced apart from the reactor wall; and a gas-liquid distribution tray in fluid communication with the coarse liquid distribution tray and the top of the lower catalyst bed.

[0043] like Figure 1 and Figure 2 As shown, the quench zone HRI 100 is located between the bottom of the upper catalyst bed 105 and the top of the lower catalyst bed 110. A support system (not shown) is present at the bottom of the upper catalyst bed 105 to support the bed. The quench zone HRI 100 includes a collection tray 115, a mixing chamber 130, an annular quench distributor 170, a coarse liquid distribution tray 120, and a gas-liquid distribution tray 125.

[0044] 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 typically located on top of the outer wall 140. The inner wall 135 does not extend to the top plate 145. In some embodiments, there is no inner wall 135.

[0045] The annular region 165 between the outer wall 140 and the reactor shell 210 is determined by the space required to install the annular quench distributor 170, and its size is set to maximize the diameter of the mixing chamber 130.

[0046] Downstream process vapors and liquids from the upper catalyst bed 105 fall onto the top plate 145 and the annular zone 165 between the mixing chamber 130 and the reactor shell 210. Quenching fluid is primarily injected into the annular zone 165. The injector 167 for the quenching fluid is typically oriented tangentially to the annular quench distributor 170.

[0047] The coarse liquid distribution plate 120 includes a central flat plate 180 and a fluid distribution channel 185. The fluid distribution channel 185 includes a base plate 195 and side walls 200. The fluid distribution channel 185 may also include one or more open truss mechanical support beams (not shown) that can be connected to the base plate 195.

[0048] All fluids flow in a vortex pattern toward the center of the collection tray 115 within the mixing chamber 130 for mixing, and flow downward through the central opening 190 in the collection tray 115.

[0049] like Figure 2 As shown, the mixed fluid enters the central plate 180 and then flows into the fluid distribution channel 185 attached to the central plate 180 for distribution. The diameter of the central plate 180 is larger than the diameter of the central opening 190.

[0050] A longitudinal baffle 300 extends from the central flat plate 180 toward the outer end 205 of the fluid distribution channel 185. The longitudinal baffle 300 may extend any suitable portion of the length of the fluid distribution channel 185, including its entire length. The longitudinal baffle 300 is typically 10% to 50% of the length of the fluid distribution channel 185, or 20% to 30% of the channel length. At least one longitudinal baffle 300 is present in each fluid distribution channel 185; typically, one, two, or three will be present. The height of the longitudinal baffles 300 is typically 1 inch or greater and may extend to any height to the bottom of the collection tray. They may be solid or perforated. The longitudinal baffles 300 may be attached in any suitable manner, including but not limited to welding to the base plate 195 of the fluid distribution channel 185.

[0051] Lateral guide vanes 305 may be present perpendicular to the radial fluid distribution channels 185. The lateral guide vanes 305 gradually deflect vapor into the space 315 between the fluid distribution channels 185 leading to the lower gas-liquid distribution plate 125. The lateral guide vanes 305 extend across the fluid distribution channels 185 between the sidewalls 200. The lateral guide vanes 305 may extend across the entire width of the fluid distribution channels 185, although they may be narrower or wider if desired. They are typically positioned between 25% and 75% of the length of the fluid distribution channels 185. There is at least one lateral guide vane 305 on each fluid distribution channel 185; there may be one, two, three, or more. The heights of the lateral guide vanes 305 may be the same or different. For example, the lateral guide vane 305 closest to the center plate 180 may be shorter than the next one, or they may have the same height. The lateral guide vanes 305 typically extend from the top of the sidewalls 200 to the bottom of the collection plate 115. They may be solid or perforated. The transverse baffle 305 can be attached in any suitable manner, including but not limited to welding.

[0052] In an embodiment with a perforated base plate 195, liquid flows downward through an opening (e.g., a hole or slot) in the base plate 195 of the fluid distribution channel 185 to the gas-liquid distribution plate 125. If the base plate 195 is solid, the fluid flows to the outer end 205 and downward to the gas-liquid distribution plate 125. Vapor (gas) flows through the top and outer end 205 of the sidewall 200, and the space 315 between the fluid distribution channel 185.

[0053] If there are any gaps between adjacent fluid distribution channels 185 at the end attached to the central plate 180, these gaps shall be sealed with a plate or other material so that fluid leaving the central plate 180 can only flow into the fluid distribution channels 185 for distribution to the gas-liquid distribution plate 125 below.

[0054] The fluid distribution channel 185 can be any suitable size and shape. The number, size, and shape of the fluid distribution channels 185 can be designed to accommodate various reactor sizes and steam and liquid flow rates. Narrow fluid distribution channels 185 (e.g., less than 30 inches) can be designed to pass through manholes in the reactor for easy installation with minimal required sealing. Multiple narrow fluid distribution channels 185 also reduce the velocity of steam leaving the fluid distribution channel 185 through gaps above the sidewalls 200 of the fluid distribution channel 185, thereby improving the uniformity of fluid distribution to the lower gas-liquid distribution plate 125.

[0055] Typically, the number of fluid distribution channels 185 is between 3 and 12, with a width ranging from 12 inches to 36 inches, and a length extending radially outward from the central plate 180 to a distance of less than 12 inches from the reactor shell 210. The sidewalls 200 are generally parallel. However, other shapes are possible. For example, in some embodiments, the width of the fluid distribution channel 185 at its outer end 205 may be less than the width of the fluid distribution channel 185 at the central plate 180. Alternatively, the width of the fluid distribution channel 185 at its outer end 205 may be greater than the width of the fluid distribution channel 185 at the central plate 180.

[0056] The fluid distribution tank 185 may be configured with a base plate 195 and sidewalls 200. In some embodiments, a wall (not shown) is present at the outer end 205, particularly when the base plate 195 has an opening. The end attached to the central platen 180 is open, allowing the fluid mixture to enter the fluid distribution tank 185. In some embodiments, the sidewalls 200 slope from the height of the distance between the coarse liquid distribution plate 120 and the collection plate 115 (e.g., if the distance between these plates is 6 inches, then the sidewalls 200 will be 6 inches or less) near the side of the central platen 180 attached to the outer end 205 of the reactor housing 210 to 1 to 3 inches. Typically, the height of the end wall of the fluid distribution tank 185 (if present) is the same as the height of the sidewalls 200 at their intersection.

[0057] like Figures 1 to 2 As shown, depending on the liquid volumetric flow rate and the design of the fluid distribution tank 185, the end guide plate 310 is typically 1 to 5 inches from the outer end 205 of the fluid distribution tank 185. It typically extends up to 3 inches above and below the end of the fluid distribution tank 185. The end guide plate 310 may be attached to the fluid distribution tank 185, the gas-liquid distribution plate 125, or both. The outer ends of the end guide plate 310 and the fluid distribution tank 185 may be straight, or they may be curved to conform to the reactor housing 210. The width of the end guide plate 310 is preferably wider than the fluid distribution tank 185, allowing the liquid to spread over a wider area on the gas-liquid distribution plate 125 to minimize interference from liquid pooling on the gas-liquid distribution plate 125.

[0058] The accompanying drawings illustrate the processes and apparatus of the prior art and the present invention. The drawings are simplified diagrams of the prior art and various embodiments of the invention, and are not intended to unduly limit the general broad scope of the description provided herein and the appended claims. Certain hardware, such as valves, pumps, compressors, heat exchangers, instruments, and controls, has been omitted because such hardware is not essential for a clear understanding of the invention. The use and application of such hardware is entirely within the scope of the art.

[0059] Any of the aforementioned pipelines, conduits, units, equipment, containers, surrounding environment, areas, or the like may be equipped with one or more monitoring components, including sensors, measuring devices, data acquisition devices, or data transmission devices. Signal, method, or condition measurements, as well as data from the monitoring components, can be used to monitor conditions within, around, and in connection with the method or equipment. Signals, measurements, and / or data generated or recorded by the monitoring components may be collected, processed, and / or transmitted through one or more networks or connections, which may be private or public, general or dedicated, direct or indirect, wired or wireless, encrypted or unencrypted, and / or combinations thereof; this specification is not intended to be limiting in this respect.

[0060] Signals, measurements, and / or data generated or recorded by monitoring components may be transmitted to one or more computing devices or systems. The computing devices or systems may include at least one processor and a memory storing computer-readable instructions that, when executed by the at least one processor, cause the 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 from one or more monitoring components related to at least one device associated with the method. 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 comprising one or more recommended adjustments to one or more parameters of one or more methods described herein.

[0061] Those skilled in the art should recognize and understand that various other components, such as valves, pumps, filters, coolers, etc., are not shown in the accompanying drawings because it is believed that their specific details are entirely within the knowledge of those skilled in the art and their description is not necessary for the implementation or understanding of the embodiments of the present invention.

[0062] While at least one exemplary embodiment has been presented in the foregoing detailed description of the invention, it should be understood that numerous variations exist. It should also be understood that one or more exemplary embodiments are merely examples and are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient roadmap for implementing exemplary embodiments of the invention, and it should be understood that various changes may be made to the function and arrangement of the elements described in the exemplary embodiments without departing from the scope of the invention as set forth in the appended claims and their legal equivalents.

[0063] Specific implementation plan

[0064] While the following description is presented in conjunction with specific embodiments, it should be understood that the description is intended to illustrate, and not limit, the scope of the foregoing description and the appended claims.

[0065] A first embodiment of the present invention is an apparatus for mixing and distributing fluids between catalyst beds, the apparatus comprising: a collection tray including a central opening, the collection tray being in fluid communication with the bottom of an upper catalyst bed; a coarse liquid distribution tray including a central flat plate in fluid communication with the central opening of the collection tray and a plurality of fluid distribution channels in fluid communication with and extending radially outward from the central flat plate, the fluid distribution channels including a bottom and sidewalls, each fluid distribution channel having at least one longitudinal guide plate extending from the central flat plate toward the outer end of the fluid distribution channel or at least one transverse guide plate extending between the sidewalls, or both, the outer end of the fluid distribution channel being spaced apart from a reactor wall; and a gas-liquid distribution tray in fluid communication with the coarse liquid distribution tray and with the top of a lower catalyst bed. One embodiment of the invention is one, any, or all of the previous embodiments described in this paragraph up to the first embodiment described in this paragraph, wherein the length of the at least one longitudinal guide plate is 10% to 50% of the length of the fluid distribution channel. One embodiment of the invention is one, any, or all of the previous embodiments from this paragraph up to the first embodiment in this paragraph, wherein the coarse liquid distribution disc has 3 to 12 fluid distribution channels. One embodiment of the invention is one, any, or all of the previous embodiments from this paragraph up to the first embodiment in this paragraph, wherein each fluid distribution channel has three longitudinal guide vanes. One embodiment of the invention is one, any, or all of the previous embodiments from this paragraph up to the first embodiment in this paragraph, wherein the at least one transverse guide vane is positioned between 25% and 75% of the length of the fluid distribution channel. One embodiment of the invention is one, any, or all of the previous embodiments from this paragraph up to the first embodiment in this paragraph, wherein each fluid distribution channel has three or fewer transverse guide vanes. One embodiment of the invention is one, any, or all of the previous embodiments from this paragraph up to the first embodiment in this paragraph, wherein the at least one longitudinal guide vane is perforated or the at least one transverse guide vane is perforated, or both. One embodiment of the invention is one, any, or all of the preceding embodiments from this paragraph up to the first embodiment in this paragraph, wherein the bottom of the fluid distribution tank has an opening therethrough. One embodiment of the invention is one, any, or all of the preceding embodiments from this paragraph up to the first embodiment in this paragraph, wherein the bottom of the fluid distribution tank is solid. One embodiment of the invention is one, any, or all of the preceding embodiments from this paragraph up to the first embodiment in this paragraph, wherein the fluid distribution tank further includes an end wall connected to a sidewall. One embodiment of the invention is one, any, or all of the preceding embodiments from this paragraph up to the first embodiment in this paragraph, wherein the fluid distribution tank further includes an end guide plate positioned between the outer end of the fluid distribution tank and the reactor wall.

[0066] A second embodiment of the invention is an apparatus for mixing and distributing fluids between catalyst beds, the apparatus comprising: a collection tray having a central opening and in fluid communication with the bottom of an upper catalyst bed; a coarse liquid distribution tray comprising a central plate in fluid communication with the central opening of the collection tray and a plurality of fluid distribution channels in fluid communication with and extending radially outward from the central plate, each fluid distribution channel comprising a bottom and sidewalls, each fluid distribution channel having at least one longitudinal guide plate extending from the central plate toward an outer end of the fluid distribution channel and at least one transverse guide plate extending between the sidewalls, the sidewalls sloping downward from the central plate toward an outer end, the outer end of the fluid distribution channel being spaced apart from a reactor wall; and a gas-liquid distribution tray in fluid communication with the coarse liquid distribution tray and with the top of a lower catalyst bed. One embodiment of the invention is one, any, or all of the preceding embodiments up to the second embodiment in this paragraph, wherein the length of the at least one longitudinal guide plate is 10% to 50% of the length of the fluid distribution channel. One embodiment of the invention is one, any, or all of the previous embodiments from the second embodiment in this paragraph, wherein each fluid distribution channel has three longitudinal guide vanes. One embodiment of the invention is one, any, or all of the previous embodiments from the second embodiment in this paragraph, wherein the at least one transverse guide vane is positioned between 25% and 75% of the length of the fluid distribution channel. One embodiment of the invention is one, any, or all of the previous embodiments from the second embodiment in this paragraph, wherein each fluid distribution channel has three or fewer transverse guide vanes. One embodiment of the invention is one, any, or all of the previous embodiments from the second embodiment in this paragraph, wherein the bottom of the fluid distribution channel has an opening therethrough. One embodiment of the invention is one, any, or all of the previous embodiments from the second embodiment in this paragraph, wherein the bottom of the fluid distribution channel is solid. One embodiment of the invention is one, any, or all of the previous embodiments from the second embodiment in this paragraph, wherein the fluid distribution channel has an end wall at its outer end.

[0067] A third embodiment of the present invention is an apparatus for mixing and distributing fluids between catalyst beds, the apparatus comprising: a collection tray having a central opening and in fluid communication with the bottom of an upper catalyst bed; and a coarse liquid distribution tray comprising a central plate in fluid communication with the central opening of the collection tray and a plurality of fluid distribution channels in fluid communication with the central plate and extending radially outward from the central plate, each fluid distribution channel comprising a bottom and sidewalls, each fluid distribution channel having at least one of the following: at least one longitudinal extension extending from the central plate toward the outer end of the fluid distribution channel. A flow guide plate; at least one transverse flow guide plate extending between the sidewalls; and an end flow guide plate located between the outer end of the fluid distribution channel and the reactor wall; wherein the length of at least one longitudinal flow guide plate is 10% to 50% of the length of the fluid distribution channel, and wherein at least one transverse flow guide plate is positioned between 25% and 75% of the length of the fluid distribution channel, the sidewalls sloping downward from the central plate toward the outer end of the fluid distribution channel, the end of the fluid distribution channel being spaced apart from the reactor wall; and a gas-liquid distribution plate in fluid communication with the coarse liquid distribution plate and the top of the lower catalyst bed.

[0068] Although no further detailed description has been provided, it is believed that those skilled in the art will be able to make full use of the invention by employing the foregoing description and will be able to readily identify the essential features of the invention without departing from its spirit and scope, and to make various changes and modifications to adapt it to various uses and situations. Therefore, the foregoing preferred embodiments should be understood as illustrative only and not as limiting the remainder of this disclosure in any way, and are intended to cover various modifications and equivalent arrangements included within the scope of the appended claims.

[0069] In the foregoing, all temperatures are expressed in degrees Celsius, and all portions and percentages are by weight unless otherwise specified.

Claims

1. An apparatus for mixing and distributing fluids between catalyst beds, comprising: A collection tray (115) including a central opening (190) and in fluid communication with the bottom of an upper catalyst bed (105); A coarse liquid distribution plate (120) includes a central flat plate (180) in fluid communication with the central opening (190) of the collection plate (115) and a plurality of fluid distribution channels (185) in fluid communication with and extending radially outward therefrom from the central flat plate (180). The fluid distribution channels (185) include a bottom plate (195) and sidewalls (200). Each fluid distribution channel (185) has at least one longitudinal guide plate (300) extending from the central flat plate (180) toward an outer end (205) of the fluid distribution channel (185) and at least one transverse guide plate (305) extending between the sidewalls (200). The outer end (205) of the fluid distribution channel (185) is spaced apart from the reactor shell (210). and Gas-liquid distribution plate (125), which is in fluid communication with the coarse liquid distribution plate and the top of the lower catalyst bed.

2. The device according to claim 1, wherein the length of the at least one longitudinal guide plate (300) is 10% to 50% of the length of the fluid distribution channel (185).

3. The device according to any one of claims 1 to 2, wherein the coarse liquid distribution plate (120) has 3 to 12 fluid distribution channels (185).

4. The device according to any one of claims 1 to 2, wherein each fluid distribution tank (185) has three longitudinal guide vanes (300).

5. The device according to any one of claims 1 to 2, wherein the at least one transverse guide plate (305) is positioned at a location between 25% and 75% of the length of the fluid distribution channel (185).

6. The device according to any one of claims 1 to 2, wherein each fluid distribution slot (185) has three or fewer transverse guide plates (305).

7. The device according to any one of claims 1 to 2, wherein the at least one longitudinal guide plate (300) is perforated, or the at least one transverse guide plate (305) is perforated, or both.

8. The device according to any one of claims 1 to 2, wherein the bottom plate (195) of the fluid distribution tank (185) has an opening therethrough.

9. The device of claim 8, wherein the fluid distribution channel (185) further comprises an end wall connected to the side wall (200).

10. The device according to any one of claims 1 to 2, wherein the fluid distribution tank (185) further comprises an end guide plate (310) located between the outer end (205) of the fluid distribution tank (185) and the reactor shell (210).

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