Riser separation system

Abstract

An apparatus includes a riser reactor within a reaction vessel. The riser reactor defines a longitudinal axis and includes a riser reactor inlet at one end and at least one riser reactor outlet at an opposite end. The apparatus includes a separation vessel including at least one separation chamber and at least one collection chamber distributed in an alternating fashion about the longitudinal axis. Each separation chamber includes two vertical side walls that also include walls of adjacent collection chambers of the at least one collection chamber. A lateral separation chamber outlet is defined in at least one of the vertical side walls to provide fluid and particulate communication from the lateral separation chamber to one of the adjacent collection chambers of the at least one collection chamber. The separation vessel includes at least one collection chamber deflector positioned in the at least one collection chamber.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit of priority to U.S. Patent Application No. 17 / 330,354, filed May 25, 2021, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This disclosure relates to any steam-particle operation using a high-speed dilute phase riser (or riser reactor), such as a fluidized catalytic cracking (FCC) process. Background Technology

[0004] The FCC process is well-established in the petroleum refining industry, used to convert low-value, high-boiling-point petroleum fractions into high-value, low-boiling-point products, particularly gasoline, propylene, and other light olefins.

[0005] In the FCC process, finely divided solid catalyst particles promote the cracking reaction by providing heat and catalytic activity for the reaction. The finely divided form of the catalyst can behave like a fluid (hence the term fluid catalytic cracking), and it flows between the cracking zone (riseer reactor) and a separate regeneration zone connected to a delivery line (often called a riser or riser).

[0006] The reaction zone of an FCC unit typically consists of two parts: a riser reactor and a device known to those skilled in the art as a reaction or riser termination device (RTD) for the rapid separation of the catalyst and reaction products. For mechanical reasons, the RTD system is typically located at the outlet of the riser reactor and housed within a reactor vessel, which also contains other devices essential to the operation of the process. Once separated from the catalyst, the reaction products are discharged from the vessel for quenching and fractionation to the desired distillate.

[0007] In a riser reactor, the thermal catalyst comes into contact with the liquid oil feed, causing it to evaporate and allowing the desired gas-phase cracking reaction to occur, forming various hydrocarbon products and solid coke deposits on the catalyst. At the end of the riser reactor, rapid separation of the catalyst from the hydrocarbon products is required to control the reaction time and avoid over-cracking of the hydrocarbon vapors. It is desirable to confine the hydrocarbon conversion time within the riser reactor, as this zone is designed to ensure close mixing of the vapor and solid catalyst. Once the mixture leaves the riser reactor, less close contact can occur in the containment / separation vessel, and undesirable thermal cracking reactions can occur, resulting in the loss of valuable products and the generation of low-value byproducts. Enclosing the hydrocarbon vapors within the RTD and directing them out of the system as directly as possible minimizes the residence time at the high temperatures that lead to thermal degradation. Rapid and complete separation of the hydrocarbon vapors from the catalyst is also desired to conclude the catalytic cracking reaction. Two stages of vapor-catalyst separation are required to achieve very high catalyst recovery; the RTD is considered the primary separation stage, and the secondary separation step consists of multiple high-efficiency cyclone separators. In the primary separation process, hydrocarbon vapors are separated from most of the catalyst and leave the RTD through a gas outlet pipe directly connected to the secondary separation step. The separated catalyst flows downwards into the stripping bed through another chamber located at the lower end of the primary separator (called the immersion tube). As the catalyst flows downwards along the immersion tube, it carries some hydrocarbon vapors. The catalyst and the entrained hydrocarbons leave the RTD and flow into the stripping zone, where they are further separated. As the catalyst passes through the stripping zone, hydrocarbon vapors between and within the particles are removed by the countercurrent flow of stripping steam. The catalyst, free of gaseous hydrocarbons but contaminated with solid hydrocarbon coke, leaves the stripping zone and enters the regeneration zone.

[0008] After primary gas catalyst separation, the catalyst flows into a stripping bed below the RTD, where it comes into countercurrent contact with the stripping gas to remove any residual volatile hydrocarbons entrained in the catalyst. The hydrocarbon-stripped catalyst containing solid coke deposits (commonly referred to as spent catalyst) is passed into a catalyst regeneration zone, where the coke is burned off and catalytic activity is restored. The regeneration step releases energy and raises the catalyst temperature; after the coke deposits are burned off, the thermally regenerated catalyst flows back into the reaction zone. The hydrocarbon vapors separated from the catalyst flow to a downstream distillation system for fractionation into several products. The FCC unit, including the riser reactor regenerator assembly, is self-heating because the heat generated by burning coke in the regenerator matches the heat required for feed evaporation and the heat used for the cracking reaction.

[0009] Existing riser separation systems typically have two separation chambers, each with an accompanying inlet tube and a successive number of gas collection chambers for separating gases and catalyst material. U.S. Patent No. 6,296,812 to Gauthier et al. provides an apparatus for separating a mixture of gases and particles, having a shroud comprising separation chambers and circulation (e.g., gas collection) chambers distributed in association with the riser separation system. Each separation chamber has an upper inlet opening communicating with the riser reactor, an intermediate zone for rotating the mixture in a vertical plane, and a lower zone, referred to as the inlet tube, for collecting separated catalyst particles. Each separation chamber includes two sidewalls (which are also walls of the circulation chamber), at least one of the walls of each chamber including a lateral outlet opening for mixing the gas and particles into the adjacent circulation chamber. The gas collection chamber has two additional openings: one at the top connected to a gas outlet tube, which further connects to a secondary separator; and a lower opening communicating with a so-called rarefaction connection to a reactor vessel above the stripping bed below. The equipment is used for fluidized catalytic cracking of hydrocarbons in risers, but it can also be applied to other similar processes.

[0010] The apparatus of Gauthier et al. has multiple separation chambers and a circulation chamber, with each separation chamber having its own immersion tube including a particle outlet opening communicating with the stripping bed below the separation chamber. In Gauthier et al.'s apparatus, the riser steam and catalyst mixture is forced to change direction before entering the separation chamber through a window in the top of the riser, making a quarter (1 / 4) turn before separating from each other. The steam then turns another 180° below the deflector in the separation chamber before entering the collection chamber. The catalyst flows downward along the separation chamber into the immersion tube, which is designed for low mass flux to maximize gas removal. The apparatus is primarily used as a primary separation unit for catalyst and steam contained within an internal riser system within a reactor / stripper vessel. Stripped gas and hydrocarbon vapors carried away from the immersion tube in the separation chamber enter the reactor, pass through a lower conduit into the collection chamber, mix with the riser steam from the separation chamber before entering the gas outlet pipe / collector, and then flow into a cyclone separator-secondary separator for final gas / catalyst separation. The Gauthier apparatus addresses the separation and transport objectives; however, solids collection efficiency is lower than expected. The inlet of the separation chamber makes a sharp 90° turn from the top of the riser, and only provides a quarter turn for separating the gas and catalyst, which is insufficient to cleanly separate the gas and catalyst from each other. The abrupt 90° change in direction creates turbulent catalyst flow at the inlet, leaving insufficient time for the necessary flow structure to form for good separation of cracked gas from solid catalyst particles in the subsequent quarter turn. The lack of connection between the separation chambers creates the potential for uneven pressure distribution, leading to uneven loading in each chamber and consequently low separation efficiency.

[0011] Another type of riser separation system, such as U.S. Patent No. 10,731,086 to Marchant et al., includes an RTD design with additional features in the separation chamber that provide improved gas-solid separation and gas containment. These features include a corrugated riser top and a single (common) immersion tube for the separation chamber, the corrugated riser top providing a smooth 180° turn to the gas catalyst flow to minimize flow turbulence at the riser top and promote gas catalyst separation. Marchant et al. also provided a more compact design that reduces overall volume and residence time after the riser, and the balanced flow distribution per separation window improves operational stability. Marchant et al. also described a disc-shaped or annular baffle above the catalyst bed in the immersion tube of the separation chamber to deflect the momentum of the separated catalyst particles and reduce re-entrainment of the separated catalyst.

[0012] Another type of riser separation system, such as U.S. Patent 4,664,888 to Leonce F. Castagnos, includes a deflector device. Castagnos' patent relates to a coarse catalyst-vapor separator for a fluidized bed catalytic cracking riser, located at the riser outlet and causing the oil-catalyst mixture to undergo a sharp 180° downward turn. The centrifugal separator is equivalent to a semi-circular turn within a cyclone separator, causing most of the catalyst to move to the wall. Most of the hydrocarbon vapor is expelled from the wall. At the end of the separator is a scraper positioned to separate the vast majority of the catalyst phase from the vast majority of the hydrocarbon vapor phase. The scraper conducts the catalyst phase away from the center of the vessel and deposits it near the vessel wall, where it continues to flow downward under gravity. The vapor phase continues to flow downward for a period, but then must undergo a 180° turn and flow upward to exit the vessel through a series of conventional cyclone separators. However, the second 180° turn of the oil vapor can entrain the separated catalyst again, thus negating the initial gas-solid separation.

[0013] Castagnos also discloses an open, semi-annular deflector device in which the gas / catalyst mixture exiting the riser impinges on the surface of the deflector, where catalyst particles are compressed, and the separated gas phase is to enter an open region below the edge of the deflector. As the gas separates from the particulate phase, the solids tend to decelerate, and gravity counteracts the initial separation achieved. Any remaining compressed particulate phase flows onto the collection surface, then flows downwards and exits the surface toward the container wall. The separated gas is to flow upwards along the conduit without contacting the particulate phase again. Therefore, the pressure below the impact surface and the collection surface is higher than the pressure above them. This pressure difference forces the gas not only through the conduit but also through the open region below the edge of the deflector and the collection surface, further counteracting the achieved separation. Subsequently, the separated gas is "unrestricted" as it enters the container and undergoes a considerable residence time and significant cracking after the riser.

[0014] Conventional techniques have been considered to fulfill their intended purpose. However, there is a need for an apparatus to improve the separation of the catalyst and vapor phases at the outlet of a riser reactor. This disclosure provides a solution to this need. The inventors have discovered a method and apparatus for achieving improved catalyst and vapor phase separation and improved gas collection efficiency using a riser separation system with a novel design, thereby providing improved flow characteristics that facilitate gas-solid separation and improve operational stability. Summary of the Invention

[0015] An apparatus for separating a gas mixture from a particulate stream, the particulate stream entering from a riser reactor for cracking hydrocarbon feed through the particulate stream, the apparatus comprising a reaction vessel including a lower stripping bed region and an upper secondary separator region. The apparatus includes a riser reactor within the reaction vessel. The riser reactor defines a longitudinal axis and includes a riser reactor inlet at one end and at least one riser reactor outlet at the opposite end, the riser reactor inlet for receiving the hydrocarbon feed and the particulate stream, and the at least one riser reactor outlet for discharging a mixture of cracked gas and solid particles. The apparatus includes a separation vessel defined adjacent to the at least one riser reactor outlet. The separation vessel includes at least one separation chamber and at least one collection chamber distributed alternately around the longitudinal axis. Each separation chamber includes two vertical sidewalls, which also include walls of adjacent collection chambers of the at least one collection chamber. The at least one separation chamber includes a separation chamber inlet in an upper region communicating with the riser reactor. The lateral separation chamber outlet is defined in at least one vertical sidewall of the vertical sidewall to provide fluid and particle communication from the lateral separation chamber to an adjacent collection chamber of the at least one collection chamber. The separation container includes at least one collection chamber deflector positioned within the at least one collection chamber.

[0016] In some embodiments, the at least one separation chamber includes two separation chambers. One of the at least one collection chambers is located between the two separation chambers. The at least one collection chamber deflector extends between one of the two vertical sidewalls of the first separation chamber and one of the two vertical sidewalls of the second separation chamber. Each collection chamber may include an outer collection chamber wall including a stripping gas inlet window to allow stripping gas from at least one stripping gas injector near the lower stripping bed region to enter the collection chamber. Each collection chamber may include a collection chamber floor plate defining the collection chamber together with the outer collection chamber wall, the vertical sidewalls, and the riser reactor. The at least one collection chamber deflector may include a concave surface facing the collection chamber floor plate. The collection chamber deflector may include a downwardly pointing tip portion. The tip portion may be centrally located between the two vertical sidewalls.

[0017] In some embodiments, the collection chamber deflector includes a partition baffle extending from a concave surface of the collection chamber deflector. The partition baffle extends beyond the lower edge of the deflector in a direction parallel to the longitudinal axis. The device includes at least one collection chamber conduit in the upper region of the collection chamber for discharging the cracked gas and a small portion of the solid particles from the collection chamber to a gas outlet collector. The at least one collection chamber conduit may extend downward through the collection chamber deflector. Each collection chamber may include an outer collection chamber wall extending from the lateral separation chamber outlet into the lower stripping bed region. Each collection chamber may include a collection chamber floor. The collection chamber floor, the outer collection chamber wall, the vertical sidewall, and the riser reactor together define the collection chamber. The outer collection chamber wall may be a common outer collection chamber wall extending circumferentially toward the lower stripping bed around the riser reactor. The outer collection chamber wall may include an inclined section toward the riser reactor and a vertical wall located below the inclined section.

[0018] In some embodiments, each separation chamber may further include an outer wall extending from the separation chamber inlet toward the lower stripping bed region. The outer wall of the separation chamber and the outer wall of the collection chamber may terminate at the same vertical position relative to the longitudinal axis. The diameter of the outer wall of the collection chamber may be equal to or smaller than the diameter of the outer wall of the separation chamber. At least one of the at least one separation chamber may include a separation chamber deflector, which is at least partially positioned above the lateral separation chamber outlet. The separation chamber deflector may be integrally formed with the collection chamber deflector. The collection chamber deflector is at least partially positioned above the lateral separation chamber outlet.

[0019] According to another aspect, an apparatus for separating a gas mixture from a particulate stream, the particulate stream entering from a riser reactor for cracking hydrocarbon feed through the particulate stream, the apparatus comprising a reaction vessel including a lower stripping bed region and an upper secondary separator region. The apparatus includes a riser reactor within the reaction vessel. The riser reactor defines a longitudinal axis and includes a central riser reactor inlet at one end and at least one riser reactor outlet at the opposite end, the central riser reactor inlet for receiving the hydrocarbon feed and the particulate stream, and the at least one riser reactor outlet for discharging a mixture of cracked gas and solid particles. The apparatus includes a separation vessel defined adjacent to the at least one riser reactor outlet. The separation vessel includes at least one separation chamber and at least one collection chamber distributed alternately around the longitudinal axis. Each separation chamber includes two vertical sidewalls, which also include walls of an adjacent collection chamber. The separation chamber includes a separation chamber inlet in the upper region of the separation chamber communicating with the riser reactor. The lateral separation chamber outlet is defined in at least one vertical sidewall of the vertical sidewall to provide fluid and particle communication from the separation chamber to an adjacent collection chamber of the at least one collection chamber. Each collection chamber includes an outer collection chamber outer wall that extends from the lateral separation chamber outlet into the lower stripping bed region.

[0020] In some embodiments, the outer wall of the collection chamber is a common collection chamber outer wall that extends circumferentially around the riser reactor toward the lower stripping bed. This outer wall of the collection chamber may be similar to the one described above.

[0021] In some embodiments, the device is expected to include at least one collection chamber deflector positioned within an adjacent gas collection chamber, which is at least partially located above the outlet of the lateral separation chamber. The at least one collection chamber deflector may include a concave surface facing the lower stripping bed region. The at least one collection chamber deflector may be at least partially located above the outlet of the lateral separation chamber. The at least one separation chamber may be two separation chambers. One of the at least one collection chambers is located between the two separation chambers. The at least one collection chamber deflector extends between one of the two vertical sidewalls of the first separation chamber and one of the two vertical sidewalls of the second separation chamber. The at least one collection chamber deflector may be the same as the collection chamber deflector described above. The collection chamber deflector may include a partition baffle similar to the partition baffle described above. The device may include at least one collection chamber conduit similar to the collection chamber conduit described above. At least one of the at least one separation chamber may include a separation chamber deflector, which is at least partially positioned above the outlet of the lateral separation chamber. The separation chamber deflector may be integrally formed with the collection chamber deflector.

[0022] These and other features of the systems and methods disclosed herein will become more apparent to those skilled in the art from the following detailed description of preferred embodiments in conjunction with the accompanying drawings. Attached Figure Description

[0023] Therefore, those skilled in the art to which this subject matter pertains will readily understand how to manufacture and use the apparatus and methods disclosed herein without excessive experimentation. Preferred embodiments of this subject matter will be described in detail below with reference to certain accompanying drawings, in which:

[0024] Figure 1 This is a schematic perspective view of an apparatus constructed according to the present disclosure for separating a gas mixture from a particulate stream that enters from a riser reactor for cracked hydrocarbon feed. The schematic perspective view shows a separation vessel having alternating separation and collection chambers.

[0025] Figure 2A yes Figure 1 A schematic cross-sectional side plan view of the device, showing two separation chambers spaced ninety degrees apart;

[0026] Figure 2B yes Figure 1 A schematic cross-sectional side plan view of the device shows two collection chambers, each with a collection chamber deflector below which the gas from the separation chamber must make a 180° turn before leaving via the outlet pipe.

[0027] Figure 3A This is a schematic cross-sectional side plan view of another embodiment of an apparatus constructed according to the present disclosure for separating a gas mixture from a particulate stream that enters from a riser reactor for cracking hydrocarbon feed. The schematic cross-sectional side plan view shows two separation chambers spaced 90 degrees apart, each of which includes a riser having a concave deflector at the riser outlet for providing a smooth 180° turn to the gas and catalyst particles leaving the riser reactor and entering the RTD.

[0028] Figure 3B yes Figure 3A A schematic cross-sectional side plan view of the embodiment shows two collection chambers, each with a collection chamber deflector, below which the gas from the separation chamber must make a 180° turn before leaving via the outlet pipe;

[0029] Figure 4A This is a schematic cross-sectional side plan view of another embodiment of an apparatus constructed according to the present disclosure for separating a gas mixture from a particulate stream that enters from a riser reactor for cracking hydrocarbon feed. The schematic cross-sectional side plan view shows two separation chambers spaced 90 degrees apart, each of which includes a riser having a concave deflector at its outlet to provide a smooth 180° turn to the gas and catalyst particles leaving the riser reactor and entering the RTD. The outer wall of a common separation chamber is shown, which terminates at a stripping catalyst bed, such as a separation chamber immersion tube.

[0030] Figure 4B yes Figure 4A A schematic cross-sectional side plan view of the embodiment shows two collection chambers, each with a collection chamber deflector below which the gas from the separation chamber must make a 180° turn before leaving via an outlet pipe, and shows a collection chamber with a common collection chamber outer wall terminating at a stripping catalyst bed, such as a collection chamber inlet pipe, which surrounds the separation chamber inlet pipe;

[0031] Figure 5 This is a schematic perspective cross-sectional view of an apparatus constructed according to the present disclosure for separating a gas mixture from a particulate stream that enters from a riser reactor for cracking hydrocarbon feed. The schematic perspective cross-sectional view shows a separation vessel having alternating separation and collection chambers, wherein one of the collection chamber outer walls is shown in a translucent manner, and one of the separation chamber outer walls is shown in a partially cut-out manner.

[0032] Figure 6 yes Figure 5 A schematic perspective view of the device shows a collection chamber deflector extending from a separation chamber deflector and a partition baffle positioned below the collection chamber deflector.

[0033] Figure 7 yes Figure 5 A schematic top plan view of the equipment, showing the fluid / particle flow from the riser reactor to the separation chamber and then to the collection chamber;

[0034] Figure 8 This is a schematic perspective view of another embodiment of an apparatus constructed according to the present disclosure for separating a gas mixture from a particulate stream that enters from a riser reactor for cracking hydrocarbon feed. The schematic perspective view shows a deflector in a collection chamber with a central tip.

[0035] Figure 9 This is a schematic perspective view of another embodiment of an apparatus constructed according to the present disclosure for separating a gas mixture from a particulate stream that enters from a central riser reactor for cracking hydrocarbon feed. The schematic perspective view shows a conduit passing through an overflow baffle in a collection chamber as a means of directly conveying gas to a gas outlet pipe; and

[0036] Figure 10 This is a schematic cross-sectional side plan view of another embodiment of an apparatus constructed according to the present disclosure for separating a gas mixture from a particulate stream that enters from a riser reactor for cracking hydrocarbon feed. The schematic cross-sectional side plan view shows the outer wall of a collection chamber including a stripping gas inlet duct and an exhaust duct. Detailed Implementation

[0037] Reference will now be made to the accompanying drawings, wherein the same reference numerals identify similar structural features or aspects disclosed in this subject matter. For purposes of explanation and illustration, and not limitation, Figure 1 A partial view of an embodiment of an apparatus according to this disclosure is shown, which is used to separate a gas mixture from a particulate stream that enters from a central riser reactor, and the apparatus is generally indicated by reference numeral 500. Other embodiments of systems according to this disclosure or aspects thereof are provided in Figures 2 through 11, as will be described. The systems and methods described herein may provide a separation vessel, such as an RTD, wherein a gas collection chamber is modified by constructing an immersion tube extending into the catalyst bed, and / or wherein the gas collection chamber includes deflection baffles.

[0038] like Figures 1 to 2BAs shown, an apparatus 500 for separating a gas mixture from a particulate stream includes a reaction vessel 534 from which the particulate stream enters through a central riser reactor 501 for passing through the particulate stream as a cracked hydrocarbon feed. The reaction vessel includes a lower stripping bed region 10 and an upper secondary separator region 12. The riser reactor 501 is centrally located within the reaction vessel 534. The riser reactor 501 defines a longitudinal axis A and includes a riser reactor inlet 502 at one end and at least one riser reactor outlet 504 at the opposite end. The riser reactor inlet receives the hydrocarbon feed and the particulate stream (schematically indicated by arrows, e.g., flow arrow 591), and the at least one riser reactor outlet discharges a mixture of cracked gas and solid particles to a separation chamber 508. The apparatus 500 includes a separation vessel 506 defined near the riser reactor outlet 504. The separation vessel 506 includes separation chambers 508 and gas collection chambers 510 distributed alternately around the longitudinal axis A. Equipment 500 includes multiple separation chambers 519 (in Figure 1 (Seen semi-transparently in the middle), the outer wall of each separator chamber 508 extends from its respective separator chamber inlet 514 in the upper region 516 into the lower stripping bed region 10. Each separator chamber 508 includes its own outer wall 519 (in the middle). Figure 1 (Seen semi-transparently in the middle). Device 500 includes an outer wall 524 of the collection chamber 510 for each gas collection chamber 510 (in... Figure 1 (Seen semi-transparently in the middle), the outer wall of the collecting chamber extends from the lateral separation chamber outlet 518 toward the lower stripping bed region 10 and enters the lower stripping bed region. The outer walls of the collecting chamber immersion pipe region 524 and the separation chamber immersion pipe region 531, respectively, are submerged in the lower stripping bed region 10.

[0039] Continue to refer to Figures 1 to 2BEach collection chamber outer wall 524 includes an inclined section 528 converging toward the riser reactor 501 and a generally vertical wall, such as an inlet pipe, below the inclined section 528. Each vertical wall 530 forms a separate inlet pipe region 531 for each gas collection chamber 510. The generally vertical wall 530 of the collection chamber outer wall 524 terminates in the lower stripping bed region 10. The vertical walls 530 of each separator chamber outer wall 519 and the collection chamber outer wall 524 terminate at the same vertical position relative to the longitudinal axis A. The collection chamber outer wall 524 has the same or smaller diameter as the separator chamber outer wall 519. Because the vertical walls 530 of the collection chamber outer wall 524 are submerged in the lower stripping bed region 10, the apparatus 500 includes an open slip unit vent 548 to provide a flow path for stripped gas and entrained hydrocarbons to escape from the reactor to the gas outlet pipe 546 to the second-stage separator. The immersion tubes (e.g., the vertical wall portions of the outer wall 524 of the collection chamber and the outer wall 519 of the separation chamber extending into the catalyst bed) ensure that all hydrocarbons are contained in the RTD and that no hydrocarbon vapors leak into the reactor, resulting in maximum gas containment and potentially eliminating the chance of reactor coking.

[0040] Continue to refer to Figure 2A and Figure 2B Each separation chamber 508 includes two generally vertical vertical sidewalls 512, which also include the wall of the adjacent gas collection chamber 510. Separation chambers 508 (where two separation chambers are located in...) Figure 2A (Shown in) The separation chamber inlet 514, located in the upper region 516 of the separation chamber 508 communicating with the riser reactor 501, includes a gas / particle (schematically shown by flow arrow 591) from the riser reactor 501. The gas / particles from the riser reactor 501 first make an initial 90° turn (e.g., a 90° turn from axis A) and then another 90° turn around the separation chamber deflector 527. The gas and entrained catalyst (schematically shown by flow arrow 591a) then make another 180° turn below the separation chamber deflector 527, while catalyst particles (schematically indicated by flow region 591b) separate from the gas and descend into the catalyst bed. The device 500 includes a lateral separation chamber outlet 518 defined in each of the vertical sidewalls 512 to provide fluid and particle communication from the lateral separation chamber 508 to the adjacent gas collection chamber 510. The device 500 includes at least one collection chamber deflector 520, which is positioned in the gas collection chamber 510 at least partially above the lateral separation chamber outlet 518. Each collection chamber deflector 520 extends between two vertical sidewalls of the vertical sidewall 512 (to interact with...). Figure 5(Similar to the collection chamber deflector 120 in the reactor). The collection chamber deflector 520 is used to further enhance gas catalyst separation and ensure that there is no direct path for hydrocarbon vapors and entrained catalyst in the riser to reach the RTD outlet via the gas outlet pipe. The gas collection chamber inlet pipe, submerged in the stripping catalyst bed, ensures that no hydrocarbon vapors in the riser can escape through the gas collection chamber outlet 523 leading to the reactor. The collection chamber inlet pipe also ensures that fine particles returning from the cyclone separator inlet pipe 515 cannot be directly entrained again through the gas collection chamber outlet 525.

[0041] like Figures 2A to 2B As shown, the collection chamber deflector 520 is used to add another stage of separation in each gas collection chamber 510. The current RTD has the possibility of allowing the gas-solid flow to flow directly from the separation chamber outlet 518 to the main outlet duct that connects the RTD to the inlet of the cyclone separator. In an embodiment of this disclosure, the collection chamber deflector 520 forces the gas entering laterally towards the separation chamber outlet 518 to make another 180° turn, i.e., redirecting the flow, as schematically indicated by flow arrow 537, similar to the separation chamber deflector 527 used in separation chamber 508. This difference in momentum between the gas and the catalyst will result in further separation and a lower load on the cyclone separator. This contributes to improved overall system separation efficiency. Figure 2A and Figure 2B In one embodiment, the collection chamber deflector 520 and the separation chamber deflector 527 terminate at the same vertical position. The concave surface 526 of the collection chamber deflector 520 faces the catalyst bed.

[0042] like Figures 3A to 3B As shown, another embodiment of device 600 is illustrated, which is used to separate a gas mixture from a particulate stream that enters from a central riser reactor 601. Separation chamber 608 (where two separation chambers are located in...) Figure 3A(Shown in the diagram) Each separation chamber 600 includes a separation chamber inlet 614 in the upper region 616 of a separation chamber 608 communicating with a riser reactor 601. Gas / particles from the riser reactor 601 (schematically shown by flow arrow 691) first make an initial 90° turn from the riser reactor 601, and then make another 90° turn around the separation chamber deflector 627. Then, the gas and entrained catalyst (schematically shown by flow arrow 691a) make another 180° turn below the separation chamber deflector 627, while the catalyst particles (schematically indicated by flow arrow 691b) separate from the gas and descend into the catalyst bed. Device 600 is similar to device 500 because the outer wall 624 of the collection chamber 610 of each collection chamber extends from the lateral separation chamber outlet 618 toward and into the lower stripping bed region 10. Because the outer wall 624 of the collecting chamber is submerged in the lower stripping bed region 10, the apparatus 600 includes an open slip unit vent 648 to provide a flow path for stripped gas and entrained hydrocarbons to escape from the reactor to the gas outlet pipe 646. The apparatus 600 differs from the apparatus 500 in that the riser reactor 601 includes a parabolic concave cone deflector 653 at the riser outlet 604. The apex of the deflector 653 faces downward toward the riser inlet 602. The apparatus 600 also includes a baffle 607 in the separation chamber 608. The baffle 607 may be, for example, an annular segment positioned around the riser reactor 601.

[0043] like Figures 4A to 4BAs shown, another embodiment of device 700 is illustrated for separating a gas mixture from a particulate stream that enters from a central riser reactor 701. Device 700 is similar to device 600, except that the outer wall 724 of the collection chamber includes an inclined section 728 converging toward the riser reactor 701 and a generally vertical cylindrical wall 730 forming a common immersion tube region 731 below the inclined section 728. The generally vertical cylindrical wall 730, or skirt, below the inclined section 728 is a continuous cylinder forming an annular common immersion tube region 731 surrounding the riser reactor 701, such that the stripped gas outlet window 750 for each collection chamber 710 is in fluid communication with the common immersion tube region 731. The generally vertical cylindrical wall 730 extends toward and into a lower stripping bed region. Gas / particles from riser reactor 701 (schematically shown by flow arrow 791) first make an initial 90° turn from riser reactor 701, then make another 90° turn around separation chamber deflector 727. The gas and entrained catalyst (schematically shown by flow arrow 791a) then make another 180° turn below separation chamber deflector 727, while catalyst particles (schematically indicated by flow arrow 791b) separate from the gas and descend into the catalyst bed. Device 700 is similar to device 100, except that, in addition to the outer wall 724 of the collection chamber stopping above each stripped gas outlet window 750, a single, generally vertical cylindrical wall 730 begins at the lower edge of each inclined section 728 and extends downward into the catalyst bed, just as the outer wall 124 of the collection chamber and their equivalent inclined sections stop above each stripped gas outlet window 150.

[0044] Continue to refer to Figures 4A to 4B The apparatus 700 includes an outer wall 719 of the separation chamber, which extends from the lateral separation chamber outlet 718 toward and into the lower stripping bed region 10. The outer wall 719 is a common outer wall 719 for each separation chamber 708, such that the separation chamber immersion tube region 709 extends continuously circumferentially about the longitudinal axis A. An outer wall 724 of the collection chamber is concentric with the outer wall 719 of the separation chamber. A generally vertical cylindrical wall 730 has a diameter D1 larger than the diameter D2 of the lower portion 719a of the outer wall 719, which defines the separation chamber immersion tube region 709. The apparatus 700 includes an open sliding unit exhaust port 748 to provide a flow path for stripping gas and steam to escape from the reactor to a gas outlet pipe 746, where the collection chamber 710 is closed at the bottom via the generally vertical cylindrical wall 730.

[0045] like Figures 5 to 7As shown, an apparatus 100 for separating a gas mixture from a particulate stream includes a reaction vessel 134 from which the particulate stream enters through a central riser reactor 101 for passing through the particulate stream as a cracked hydrocarbon feed. The reaction vessel includes a lower stripping bed region 10 and an upper secondary separator region 12. The riser reactor 101 is positioned within the reaction vessel 134. The riser reactor 101 defines a longitudinal axis A and includes a riser reactor inlet 102 at one end and at least one riser reactor outlet 104 at the opposite end. The riser reactor inlet receives the hydrocarbon feed and the particulate stream, and the at least one riser reactor outlet discharges a mixture of cracked gas and solid particles. The apparatus 100 includes a separation vessel 106 defined adjacent to the riser reactor outlet 104. The separation vessel 106 includes separation chambers 108 and gas collection chambers 110 distributed alternately around the longitudinal axis A.

[0046] Continue to refer to Figures 5 to 7 Each separation chamber 108 includes two generally vertical sidewalls 112, which also include the wall of an adjacent gas collection chamber 110. The separation chamber 108 includes a separation chamber inlet 114 in an upper region 116 of the separation chamber 108 communicating with the riser reactor 101. Each separation chamber 108 includes an outer separation chamber 119 extending downward into the catalyst bed. The outer separation chamber 119 includes a vertically extending skirt 173 forming a common immersion tube region 109 for each separation chamber in the separation chambers 108. The common immersion tube region 109 is in fluid communication with each separation chamber in the separation chambers 108. The common immersion tube region 109 of the separation chambers extends continuously circumferentially about a longitudinal axis A. Lateral separation chamber outlets 118 are defined in each vertical sidewall of the vertical sidewalls 112 to provide fluid and particulate communication from the lateral separation chamber 108 to the adjacent gas collection chamber 110. The apparatus 100 includes at least one collection chamber deflector 120 positioned within the gas collection chamber 110, at least partially above the lateral separation chamber outlet 118. Each collection chamber deflector 120 extends between two vertical sidewalls of the vertical sidewall 112. The collection chamber deflectors 120 are used to further enhance gas catalyst separation and ensure that there is no direct path for hydrocarbon vapors in the riser to reach the gas collection chamber outlet 125.

[0047] like Figure 6As shown, the collection chamber deflector 120 is used to add another stage of separation in each gas collection chamber 110. This separation chamber includes a deflector “bent plate,” commonly referred to as the separation chamber deflector 27. Lateral separation chamber outlets 118 are located below the separation chamber deflector 27, with one outlet at each end, connecting to the gas collection chamber 110. The separation chamber deflector 27 and the collection chamber deflector 120 are connected to each other, integrally formed, etc., such that the separation chamber deflector 27 and the collection chamber deflector 120 form a ring around the riser reactor 101. Like the collection chamber deflector 120, the separation chamber deflector 27 extends into the gas collection chamber 110, allowing the gas and catalyst particles to make additional turns, thereby promoting the separation of gas particles in this gas collection chamber. The current RTD has the possibility of allowing the gas-solid flow to flow directly from the separation chamber outlet 118 to the main outlet duct that connects the RTD to the inlet of the cyclone separator. In embodiments of this disclosure, the collection chamber deflector 120 forces the gas entering from the side of the separation chamber outlet 118 to make another 180° turn, i.e., redirecting the flow, as schematically indicated by flow arrow 137, similar to the separation chamber deflector 27 used in separation chamber 108. This difference in momentum between the gas and the catalyst results in further separation and a lower load on the cyclone separator. This contributes to improved overall system separation efficiency. The collection chamber deflector 120 may include a partition baffle 136 extending from a concave surface 126 for the collection chamber deflector. Figures 5 to 7 In one embodiment, the partition baffle 136 does not extend beyond the lower edge 138 of the collection chamber deflector 120 in a direction parallel to the longitudinal axis A. Those skilled in the art will readily understand that the partition baffle 136 may also extend to a vertical position below the lower edge 138.

[0048] Continue to refer to Figures 5 to 7 The difference between the implementation of device 100 and the implementation of device 700 is that the outer wall 124 of the collection chamber does not extend downward into the catalyst bed like the outer wall 724 of the collection chamber and the generally vertical cylindrical wall 730 extending therefrom, but instead the outer wall 124 of the collection chamber stops in front of the catalyst bed. Figure 5The forward-facing outer wall 124 of the collection chamber is shown translucently, allowing easy visibility of the collection chamber deflector 120. In the apparatus 100, each gas collection chamber 110 includes a collection chamber base plate 122, which, together with the outer wall 124, vertical sidewalls 112, and central riser reactor 101, defines the gas collection chamber 110. A stripped gas outlet window 150, such as a collection chamber window, is disposed between the outer wall 124 and the collection chamber base plate 122 to allow stripped gas and entrained hydrocarbons to exit from the stripping section of the reactor and reach the gas collection chamber 110, and then to the chamber outlet 125. The concave surface 126 of the collection chamber deflector 120 faces the collection chamber base plate 122. The collection chamber deflector 120 is shown with an extended wall 142 (compared to the separation chamber deflector 27 in separation chamber 108), but those skilled in the art will readily understand that various lengths of the wall 142 can be used.

[0049] like Figure 8 As shown, another embodiment of device 200 is illustrated for separating a gas mixture from a particulate stream that enters from a central riser reactor 201. Device 200 is identical to device 100, except that device 200 includes another embodiment of a collection chamber deflector 220, as shown. The collection chamber deflector 220 is identical to collection chamber deflector 120, except that collection chamber deflector 220 includes a downward-pointing tip portion 221 at the intersection of two deflector portions 220a and 220b, instead of being open or including a separating baffle. The tip portion 221 is centrally located between two vertical sidewalls 212. Each deflector portion 220a and 220b provides its own independent semi-circular deflection for the gas-solid fluid entering from the separation chamber, as shown. Figure 8 The flow arrow 242 is schematically shown in the diagram. The downward sloping shape of each deflector section 220a and 220b makes it possible to eliminate the need for separators (e.g., separator baffles 136).

[0050] Now for reference Figure 9 Another embodiment of device 800 is shown, which is used to separate a gas mixture from a particulate stream that enters from a central riser reactor 801. Device 800 is similar to device 100, except that device 800 includes a collection chamber conduit 844 in the upper region 843 of each collection chamber 810 for discharging the cracked gas and a small portion of the solid particles from the collection chamber 810 to a gas outlet pipe (shown as 146 in Figure 4). Each collection chamber conduit 844 extends downward through a collection chamber deflector 820, which is similar to collection chamber deflector 120. The outer wall 824 of the collection chamber and the outer wall 819 of the separation chamber are shown as partially removed to show the interior of the collection chamber 810 and the separation chamber 808. Collection chamber 810 is similar to Figure 5Gas collection chamber 110. Each collection chamber includes a separate stripping gas outlet window 850, similar to stripping gas outlet window 150. Separation chamber 808 includes a common immersion tube area, similar to common immersion tube area 109.

[0051] Now for reference Figure 10 Another embodiment of device 400 is shown, which is used to separate a gas mixture from a particulate stream that enters from a central riser reactor 401. Device 400 is generally the same as device 500. Device 400 includes a plurality of separation chambers 408 and collection chambers 410. The outer wall 424 of the collection chamber 410 extends from the lateral separation chamber outlet 418 toward the lower stripping bed region 10 (e.g., a catalyst bed) and is immersed in the catalyst bed. Device 400 includes a stripping gas conduit 417, which is configured and adapted to provide an additional flow path through the outer wall 424 for the stripping gas to exit the reactor device 400 via a gas outlet pipe 446 to reach one or more cyclone separators.

[0052] As described above and as shown in the accompanying drawings, the methods and systems of this disclosure provide enhanced gas catalyst separation by utilizing a gas collection chamber to further separate gases from the catalyst. While the apparatus and methods disclosed herein have been shown and described with reference to preferred embodiments, those skilled in the art will readily understand that changes and / or modifications can be made thereto without departing from the scope of this disclosure.

Claims

1. An apparatus for separating a gas mixture from a particulate stream, the particulate stream entering from a riser reactor for passing the particulate stream as a cracked hydrocarbon feed, the apparatus comprising: The reaction vessel includes a lower stripping bed region and an upper secondary separator region; The riser reactor within the reaction vessel defines a longitudinal axis and includes a riser reactor inlet at one end and at least one riser reactor outlet at the opposite end. The riser reactor inlet is used to receive the hydrocarbon feed and the particulate stream, and the at least one riser reactor outlet is used to discharge a mixture of cracked gas and solid particles. Separation container, defined as being adjacent to the outlet of the at least one riser reactor, the separation container comprising: At least one separation chamber and at least one collection chamber are distributed alternately around the longitudinal axis. Each separation chamber includes two vertical sidewalls, which also include the wall of an adjacent collection chamber of the at least one collection chamber. The at least one separation chamber includes a separation chamber inlet in the upper region of the separation chamber in communication with the riser reactor. A lateral separation chamber outlet is defined in at least one vertical sidewall of the vertical sidewalls to provide fluid and particle communication from the separation chamber to an adjacent collection chamber of the at least one collection chamber. and At least one collection chamber deflector, located within the at least one collection chamber, ensures that there is no direct path for hydrocarbon vapors and entrained catalyst in the riser to reach the RTD outlet of the riser termination device via the gas outlet pipe.

2. The device of claim 1, wherein the at least one separation chamber comprises two separation chambers, one of the at least one collection chambers is located between the two separation chambers, and wherein the at least one collection chamber deflector extends between one of the two vertical sidewalls of the first separation chamber of the two separation chambers and one of the two vertical sidewalls of the second separation chamber of the two separation chambers.

3. The apparatus of claim 1, wherein each collection chamber includes an outer wall of the collection chamber, the outer wall of the collection chamber including a stripping gas inlet window to allow stripping gas from at least one stripping gas injector near the lower stripping bed region to enter the collection chamber.

4. The apparatus of claim 3, wherein each collection chamber includes a collection chamber floor plate, the collection chamber floor plate defining the collection chamber together with the outer wall of the collection chamber, the vertical side wall and the riser reactor.

5. The device of claim 4, wherein the at least one collection chamber deflector includes a concave surface facing the bottom plate of the collection chamber.

6. The device of claim 1, wherein the at least one collection chamber deflector includes a downwardly pointing tip portion.

7. The device of claim 6, wherein the tip portion is centrally located between two vertical sidewalls of the vertical sidewalls.

8. The device of claim 1, wherein the collection chamber deflector includes a partition baffle extending from a concave surface of the collection chamber deflector.

9. The device of claim 8, wherein the partition baffle extends beyond the lower edge of the collection chamber deflector in a direction parallel to the longitudinal axis.

10. The apparatus of claim 1, further comprising at least one collection chamber conduit in the upper region of the collection chamber for discharging the cracked gas and a small portion of the solid particles from the collection chamber to a gas outlet pipe.

11. The device of claim 10, wherein the at least one collection chamber conduit extends downward through the collection chamber deflector.

12. The apparatus of claim 1, wherein each collection chamber includes an outer wall extending from the lateral separation chamber outlet into the lower stripping bed region.

13. The apparatus of claim 12, wherein each collection chamber includes a collection chamber floor plate, wherein the collection chamber floor plate, the outer wall of the collection chamber, the vertical side wall and the riser reactor together define the collection chamber.

14. The apparatus of claim 12, wherein the outer wall of each collection chamber extends to form a single common immersion tube, the single common immersion tube extending in a continuous circumferential direction into the lower stripping bed region around the riser reactor.

15. The apparatus of claim 12, wherein the outer wall of each collection chamber extends to form a corresponding immersion tube, the corresponding immersion tube extending into the lower stripping bed region.

16. The apparatus of claim 1, wherein each collection chamber is surrounded by a common collection chamber floor plate, wherein the common collection chamber floor plate, the outer wall of the collection chamber, the vertical sidewall, and the riser reactor together define the collection chamber.

17. The apparatus of claim 1, wherein at least one of the at least one separation chamber further comprises a separation chamber deflector, the separation chamber deflector being at least partially positioned above the lateral separation chamber outlet.

18. The apparatus of claim 17, wherein the separation chamber deflector is integrally formed with the collection chamber deflector.

19. The apparatus of claim 1, wherein the at least one collection chamber deflector is at least partially positioned above the outlet of the lateral separation chamber.

20. The apparatus of claim 1, wherein the riser reactor includes a parabolic concave cone riser deflector at the outlet of the at least one riser reactor.

21. An apparatus for separating a gas mixture from a particulate stream, the particulate stream entering from a riser reactor for passing the particulate stream as a cracked hydrocarbon feed, the apparatus comprising: The reaction vessel includes a lower stripping bed region and an upper secondary separator region; The riser reactor within the reaction vessel defines a longitudinal axis and includes a riser reactor inlet at one end and at least one riser reactor outlet at the opposite end. The riser reactor inlet is used to receive the hydrocarbon feed and the particulate stream, and the at least one riser reactor outlet is used to discharge a mixture of cracked gas and solid particles. A separation container, defined near the outlet of the at least one riser reactor, comprising at least one separation chamber and at least one collection chamber arranged alternately around the longitudinal axis, each separation chamber comprising two vertical sidewalls, the two vertical sidewalls further comprising the wall of an adjacent collection chamber, the separation chamber comprising a separation chamber inlet in the upper region of the separation chamber in communication with the riser reactor; and A lateral separation chamber outlet is defined in at least one vertical sidewall of the vertical sidewall to provide fluid and particle communication from the separation chamber to an adjacent collection chamber of the at least one collection chamber, wherein each collection chamber includes an outer collection chamber outer wall extending from the lateral separation chamber outlet into the lower stripping bed region, and wherein each separation chamber also includes an outer separation chamber outer wall extending from the separation chamber inlet into the lower stripping bed region.

22. The apparatus of claim 21, wherein the outer wall of the collection chamber is a common outer wall of the collection chamber, which extends in a continuous circumferential direction toward the lower stripping bed region around the riser reactor.

23. The apparatus of claim 21, wherein the outer wall of the collection chamber comprises an inclined section toward the riser reactor and a vertical wall located below the inclined section.

24. The device of claim 21, wherein the diameter of the outer wall of the collecting chamber is equal to or less than the diameter of the outer wall of the separating chamber.

25. The apparatus of claim 21, wherein the apparatus further comprises at least one collection chamber deflector positioned in an adjacent gas collection chamber, the adjacent gas collection chamber being at least partially located above the outlet of the lateral separation chamber.

26. The apparatus of claim 25, wherein the at least one collection chamber deflector is at least partially positioned above the outlet of the lateral separation chamber.

27. The apparatus of claim 25, wherein the at least one collection chamber deflector includes a concave surface facing the lower stripping bed region.

28. The device of claim 25, wherein the at least one separation chamber is two separation chambers, and wherein the at least one collection chamber deflector extends between one of the two vertical sidewalls of the first separation chamber of the two separation chambers and one of the two vertical sidewalls of the second separation chamber of the two separation chambers.

29. The device of claim 25, wherein the at least one collection chamber deflector includes a downwardly pointing tip portion.

30. The device of claim 29, wherein the tip portion is centrally located between two vertical sidewalls of the vertical sidewalls.

31. The device of claim 25, wherein the collection chamber deflector includes a partition baffle extending from a concave surface of the collection chamber deflector.

32. The device of claim 31, wherein the partition baffle extends beyond the lower edge of the collection chamber deflector in a direction parallel to the longitudinal axis.

33. The apparatus of claim 25, wherein the apparatus further comprises at least one collection chamber conduit in the upper region of the collection chamber for discharging the cracked gas and a small portion of the solid particles from the collection chamber to a gas outlet pipe.

34. The device of claim 33, wherein the at least one collection chamber conduit extends downward through the collection chamber deflector.

35. The apparatus of claim 25, wherein at least one of the at least one separation chamber further comprises a separation chamber deflector, the separation chamber deflector being positioned at least partially above the lateral separation chamber outlet.

36. The apparatus of claim 35, wherein the separation chamber deflector is integrally formed with the collection chamber deflector.

37. The apparatus of claim 21, wherein the riser reactor includes a parabolic concave cone riser deflector at the outlet of the at least one riser reactor.

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