Heavy oil catalytic apparatus and method

Abstract

The application provides a heavy oil catalytic device and method. The first aspect of the application provides a heavy oil catalytic device, which comprises a reaction unit, a settler and a regeneration unit, wherein the reaction unit is a variable-diameter riser, which comprises a pre-lifting section, a first reaction zone, a second reaction zone and a third reaction zone, and the second reaction zone is provided with a first inner member and a second inner member. By arranging the first inner member and the second inner member inside the second reaction zone, the flow state of the gas and the catalyst is changed, the range of the gas superficial velocity in the second reaction zone is widened, the reaction oil gas flow rate that can be borne by the reaction unit is adjusted or fluctuated in a larger range, and the processing capacity of the catalytic device is improved.

Description

Technical Field

[0001] This invention relates to a heavy oil catalytic device and method, and relates to the field of catalytic technology. Background Technology

[0002] Catalytic reaction is one of the main methods of secondary petroleum processing. It refers to the process of converting heavy feedstocks into cracked gas, gasoline, and diesel fuel under high temperature and the action of a catalyst. Early catalytic reactions used aluminosilicate microspheres as catalysts and dense-phase bed reactors. With the advent of highly active and selective zeolite catalysts, the reaction rate between petroleum and the catalyst has been greatly accelerated, and riser reactors have been adopted, which is beneficial for improving the yield and selectivity of liquid products.

[0003] Riser reactors represent a significant advancement over dense-bed reactors in both structure and operation. Due to their superior flexibility and adaptability, riser reactors emphasize primary cracking of heavy oil, achieving ideal yields and selectivity for light oils. This type of reactor remains highly viable. With further technological advancements, adding an expansion section in the middle of the riser—a variable-diameter riser—allows for both primary cracking of heavy oil and secondary conversion of gasoline within the same reactor.

[0004] The ideal state for the flow and mixing of oil, gas, and catalyst within a variable-diameter riser is rapid and uniform contact and mixing. However, in practical applications, the two are not uniformly distributed, or their distribution patterns are not well-matched. By incorporating internal components within the variable-diameter riser, especially in the expansion section, the contact and mixing of the oil and catalyst can be improved to some extent. Therefore, seeking more optimized and rationally designed internal components remains a hot topic of ongoing interest for those skilled in the art. Summary of the Invention

[0005] This invention provides a catalytic device for heavy oil. By setting a first internal component and a second internal component inside the second reaction zone, the flow state of gas and catalyst is changed, the range of apparent gas velocity in the second reaction zone is widened, and the reaction unit can withstand a wider range of adjustment or fluctuation of the reaction oil flow rate, thereby improving the processing capacity of the catalytic device.

[0006] The present invention also provides a catalytic method for heavy feedstocks, using the above-described catalytic apparatus.

[0007] The first aspect of this invention provides a heavy oil catalytic device, the catalytic device comprising a reaction unit, a settling tank, and a regeneration unit; the reaction unit is a variable diameter riser, the variable diameter riser comprising a pre-lifting section, a first reaction zone, a second reaction zone, and a third reaction zone connected sequentially in the axial direction, the inner diameter of the second reaction zone being larger than the inner diameters of the first and third reaction zones; the inlet of the settling tank is connected to the outlet of the third reaction zone, the inlet of the regeneration unit is connected to the outlet of the settling tank's catalyst to be recycled, and the outlet of the regeneration unit is connected to the pre-lifting section;

[0008] The second reaction zone is provided with a first internal component and a second internal component. The first internal component is a first conveying pipe with the same diameter as the inner diameter of the third reaction zone. The first conveying pipe is connected to the inlet of the third reaction zone. The pipe wall of the first conveying pipe is provided with a plurality of first openings.

[0009] The second internal component is a distribution plate or a cap-type distributor.

[0010] Furthermore, the ratio of the height of the first internal component to the height of the second reaction zone is 0.15 to 0.8:1.

[0011] Furthermore, the distance between the bottom port of the first internal component and the bottom of the second reaction zone is 2 to 8 m, and the height of the first internal component is 2 to 7 m.

[0012] Furthermore, the distance between the first opening and the inlet of the third reaction zone is no greater than 0.5 to 2 m; the total area of ​​the first opening is 5% to 30% of the cross-sectional area of ​​the first internal component.

[0013] Furthermore, the diameter ratio of the first reaction zone, the second reaction zone, and the third reaction zone is 1:2 to 5:0.7 to 1.5, and the height ratio of the first reaction zone, the second reaction zone, and the third reaction zone is 1:0.3 to 2:0.5 to 2.

[0014] Furthermore, when the second internal component is a distribution plate, the distribution plate is one of an arched distribution plate, an irregularly shaped distribution plate, or a concave distribution plate.

[0015] Furthermore, when the second internal component is a cap-type distributor, the cap-type distributor includes a cap and a second conveying pipe, the second conveying pipe is connected to the outlet of the first reaction zone, and the cap is disposed on the side of the second conveying pipe near the outlet of the second reaction zone;

[0016] The cap has several second openings, and the wall of the second conveying pipe has several third openings. The wall of the third opening extends outward to form a gas channel.

[0017] Furthermore, the total area of ​​the second opening is 8% to 15% of the vertical projected area of ​​the cap, and the total area of ​​the third opening is 60% to 400% of the cross-sectional area of ​​the first reaction zone.

[0018] Furthermore, taking the plane formed by the axial and radial directions of the second reaction zone as the projection plane, the orthogonal projection of the gas channel on the projection plane includes a first straight line and a second straight line parallel to the radial direction. The first straight line is located on the side closer to the third reaction zone, and the second straight line is located on the side closer to the first reaction zone. The length of the first straight line is greater than the length of the second straight line.

[0019] A second aspect of the present invention provides a catalytic method for heavy oil, using any of the catalytic devices described above, comprising the following steps:

[0020] The steam-atomized heavy oil and the regenerated catalyst are fed into the first reaction zone through the pre-lift section of the reaction unit. The mixed oil and gas and the regenerated catalyst rise in the reaction unit and enter the settling tank after passing through the first reaction zone, the second reaction zone and the third reaction zone.

[0021] The settler separates the mixed reactants output from the third reaction zone to obtain reaction products and a catalyst to be generated; the catalyst to be generated is fed into the regeneration unit for regeneration to obtain a regenerated catalyst, which is then returned to the reaction unit for recycling.

[0022] This invention provides a catalytic device that, by setting a first internal component and a second internal component inside the second reaction zone, changes the flow state of the gas and the catalyst, widens the range of apparent gas velocity in the second reaction zone, and allows the reaction unit to withstand a wider range of adjustment or fluctuation in the reaction oil and gas flow rate, thereby improving the processing capacity of the catalytic device.

[0023] Using the device provided by this invention for the catalysis of heavy oil, by changing the catalyst and adjusting the operating conditions, it is possible to switch between two production modes: producing ultra-low olefin gasoline and producing more cracked gas, thereby achieving flexible control over product properties and product distribution. Attached Figure Description

[0024] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0025] Figure 1 This is a schematic diagram of the structure of a catalytic device provided in an embodiment of the present invention;

[0026] Figure 2 This is a schematic diagram of the structure of the first internal component provided in an embodiment of the present invention;

[0027] Figure 3 This is a schematic diagram of the structure of the second internal component provided in an embodiment of the present invention;

[0028] Figure 4 This is a structural schematic diagram of the second internal component provided in another embodiment of the present invention.

[0029] Explanation of reference numerals in the attached figures:

[0030] 1-Reaction unit; 1a-First reaction zone; 1b-Second reaction zone; 1c-Third reaction zone; 2-Settler; 3-Regeneration unit; 4-Heat extractor; 5-Catalyst delivery pipe; 6-First regenerated catalyst delivery pipe; 7-Second regenerated catalyst delivery pipe; 8-First internal component; 9-Second internal component;

[0031] 10-Pre-lift gas; 11-Heavy oil; 12-Quick coolant; 13-Reaction product; 14-Stripping steam; 15-Low-temperature steam; 16-High-temperature steam; 17-Regenerated air; 18-Regenerated flue gas. Detailed Implementation

[0032] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions in the embodiments of this invention will be clearly and completely described below in conjunction with the embodiments of this invention. Obviously, the described embodiments are only some embodiments of this invention, not all embodiments. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0033] Early variable-diameter risers did not consider adjusting the gas-solid fluidization state through internal components. However, industrial catalytic converters are meter-sized, and without internal components, it is difficult to achieve stable gas-solid fluidization in the lower part of the expansion section due to factors such as the high-speed fluid jet entering the expansion section from the lower riser, making it difficult to form a stable dense phase region of solid particles. With technological advancements, by installing a distribution plate at the bottom of the expansion section, the high-speed oil and gas exiting from the lower part of the variable-diameter riser and the catalyst can form a sufficiently uniform steady-state fluidization in the bottom region of the expansion section, with some catalyst forming a stable fluidized bed in this area. However, studies on the catalyst particle distribution in variable-diameter risers, especially in the expansion section, have revealed that, from an axial distribution perspective, the axial density of catalyst particles in the expansion section exhibits an "S-shaped" distribution, with a thinner upper section and a denser lower section. Although the height of the dense phase section is affected by gas velocity and particle delivery rate, it is still concentrated in the bottom section, below 60% of the expansion section height. From the radial distribution, at any cross section of the reactor, the maximum value of the catalyst particle velocity is at the center of the riser. The particle velocity maintains a relatively large and constant value in the central region. The descent from the center to the pipe wall is relatively slow. After r / R (r represents the distance from the central axis and R is the pipe radius) reaches a certain value, the particle velocity suddenly decreases and becomes almost zero near the side wall. The sidewall effect exists throughout the variable-diameter riser. In the lower pneumatic conveying riser, where the gas velocity is above 10 m / s and r / R < 0.8, the axial velocity of the catalyst particles is relatively high. However, in the expansion section, where the apparent gas velocity is between 1.5 and 3 m / s, the sidewall effect is more pronounced. In the lower part of the expansion section, where r / R < 0.7, the catalyst particle velocity is relatively high, but the axial velocity of the catalyst particles near the sidewall is zero or even negative. In the upper part of the expansion section, where r / R < 0.6, the catalyst particle velocity is relatively high, but the velocity of the catalyst particles near the sidewall remains near zero. This means that a large portion of the catalyst is suspended in this section, and this portion of the catalyst may remain in the expansion section for too long, affecting the optimal process effect.

[0034] Based on the above research findings, the present invention provides a catalytic device. Figure 1 This is a schematic diagram of the structure of a catalytic device provided in an embodiment of the present invention, as shown below. Figure 1 As shown, the device includes a reaction unit 1, a settling tank 2, and a regeneration unit 3. The following is a detailed description of each unit:

[0035] The reaction unit 1 is a variable diameter riser pipe, which includes a pre-lifting section, a first reaction zone 1a, a second reaction zone 1b and a third reaction zone 1c connected in sequence in the axial direction. The pre-lifting section is used to input pre-lifting gas 10, heavy oil 11 after steam atomization and regeneration catalyst output from regeneration unit 3. Under the action of pre-lifting gas 10, heavy oil 11 and regeneration catalyst rise and enter the first reaction zone 1a, and react in the first reaction zone 1a.

[0036] Heavy oil 11 and the regenerated catalyst continue to rise into the second reaction zone 1b, which is the expansion section, with an inner diameter larger than that of the first reaction zone 1a. The second reaction zone 1b includes a main zone and a connecting zone. The connecting zone is the transition area connecting the main zone with the first reaction zone 1a and the third reaction zone 1c. The main zone can be... Figure 1 The cylindrical shape shown can be a frustum of a cone that gradually expands in diameter from bottom to top, or a cylinder with two or three stages of diameter expansion, etc. The connecting area can be... Figure 1 The shape shown is frustum-shaped, or it could be dome-shaped, etc. The connecting zone is mainly used to rapidly reduce the high-speed gas-solid particles transported from the first reaction zone 1a to the gas-solid fluidization state required by the second reaction zone.

[0037] A first internal component 8 is provided at the outlet of the second reaction zone 1b, such as... Figure 2 As shown, the first internal component 8 is a first conveying pipe with the same diameter as the inner diameter of the third reaction zone 1c. The first internal component 8 is arranged parallel to the axial direction of the second reaction zone 1b and is connected to the inlet of the third reaction zone 1c, so that the oil and gas and catalyst in the second reaction zone 1b enter the third reaction zone 1c through the first internal component 8.

[0038] The first internal component 8 provided by the present invention can produce the following two effects: (1) When the apparent gas velocity in the expansion section decreases and a turbulent bed is formed, when the upper interface of the turbulent bed submerges the bottom port of the first internal component 8, the catalyst at the top of the turbulent bed can be drawn away, thus controlling the height of the turbulent bed in the expansion section and avoiding excessive bed pressure caused by an excessively high turbulent bed height. (2) The upper part of the expansion section, which is coaxial with the first internal component and at the same height, can serve as the dilute phase section of the turbulent bed. Gas carries a large amount of particulate solids and throws them into the dilute phase section above the turbulent bed. As the gas flow velocity decreases, a free space for solid particles to settle is formed. The catalyst particles carried up by the turbulent bed will fall back into the lower part of the expansion section, increasing the catalyst density at the bottom of the expansion section and strengthening gas-solid mixing and contact. Since a considerable amount of gas is stored in the free space, it can provide a buffer space for gas pulsation in the reactor. The above two effects can, to a certain extent, avoid the rapid and drastic increase and fluctuation of gas pressure and the large amount of catalyst in the variable diameter riser, thus broadening the range of apparent gas velocity for optimal operation in the expansion section. Specifically, in conventional MIP-CGP reactors, if the apparent gas velocity in the expansion section is too low, it is insufficient to carry the catalyst to the third reaction zone, which can easily lead to choking or even catalyst accumulation in the expansion section, causing equipment accidents. If the apparent gas velocity is too high, a dense phase section of catalyst cannot be formed in the expansion section, failing to meet process requirements. Therefore, the apparent gas velocity in the expansion section of conventional MIP-CGP is 1.4–2.8 m / s, and in industrial operation, it is generally preferred to be 1.5–2.0 m / s. However, the apparent gas velocity in the expansion section provided by this invention can achieve 0.7–3.5 m / s, and further 0.9–2.5 m / s, while meeting process requirements.

[0039] Furthermore, the height of the first internal component 8 is H1, and the height of the second reaction zone 1b is H2, with H1 / H2 = (0.15~0.8):1; even further, H1 / H2 = (0.2~0.6):1, and the height of the second reaction zone 1b is the sum of the heights of the main body zone and the connecting zone.

[0040] When the apparent gas velocity in the expansion section is low, the expansion section is prone to forming a turbulent bed. Therefore, it is necessary to appropriately increase the height of the first internal component 8. Specifically, the ratio of the height of the first internal component 8 to that of the second reaction zone 1b is (0.3~0.8):1, which helps to improve the gas-solid contact efficiency.

[0041] Furthermore, the distance H3 between the bottom port of the first internal component 8 and the bottom of the second reaction zone 1b is 2-8m, and the height H1 of the first internal component 8 is 2-7m; even further, the distance H3 between the bottom port of the first internal component 8 and the bottom of the second reaction zone 1b is 3-6m, and the height H1 of the first internal component 8 is 3-5m.

[0042] In addition, the tube wall of the first internal component 8 is provided with a number of first openings, through which the gas in the upper part of the second reaction zone 1b and the gas inside the first internal component 8 can flow to each other, so as to prevent the appearance of a dead zone without gas flow in the upper part of the second reaction zone 1b.

[0043] The inner wall of the first opening is provided with a ceramic wear-resistant layer to improve wear resistance.

[0044] Furthermore, the distance between the first opening and the entrance of the third reaction zone 1c is no greater than 0.5 to 2m, that is, the first opening is located within a 0.5 to 2m range of the first internal component 8 near the upper part of the third reaction zone 1c.

[0045] Furthermore, the total area of ​​the plurality of first openings is 5% to 30% of the cross-sectional area of ​​the first inner component 8.

[0046] The second reaction zone 1b is equipped with a second internal component 9 near the entrance. The second internal component 9 is a distribution plate or a cap-shaped distributor.

[0047] When the second inner component 9 is a cap-type distributor, it can be used as follows: Figure 3 The conical cap distributor shown or such Figure 4 The umbrella-shaped cap distributor shown includes a cap and a second delivery pipe below the cap, wherein the cap is a central axis rotationally symmetric body with a shape similar to a cone or umbrella cap.

[0048] The cap has several second openings. The axial direction of the second openings is parallel to the axial direction of the second reaction zone 1b, that is, the second openings are set vertically, and the total area of ​​the second openings is 8% to 15% of the total vertical projection area of ​​the cap. The second openings can make the gas above the cap flow smoothly and prevent the catalyst from accumulating on the cap.

[0049] Furthermore, the ratio of the vertical projected area of ​​the cap to the cross-sectional area of ​​the second reaction zone 1b is 0.7 to 0.85:1, and the gas velocity at the edge of the cap is controlled to be above 2.5 m / s, preferably above 3.5 m / s, to ensure that catalyst accumulation does not occur at the bottom of the second reaction zone 1b or even in the transition section, thus preventing equipment operation accidents.

[0050] The second delivery pipe is located on the side of the cap near the entrance of the second reaction zone and is connected to the outlet of the first reaction zone 1a, so that the oil and gas and catalyst output from the first reaction zone 1a enter the second reaction zone 1b through the second delivery pipe; the pipe wall of the second delivery pipe is provided with several third openings, and the walls of the third openings extend outward to form gas channels.

[0051] Furthermore, the third opening is rectangular or elliptical in shape, and the total area of ​​the third opening is 60% to 400% of the cross-sectional area of ​​the first reaction zone 1a. The wall of the third opening is provided with a ceramic wear-resistant layer.

[0052] Furthermore, such as Figure 3 As shown, the plane formed by the axial and radial directions of the second reaction zone 1b is the projection plane. The orthogonal projection of the gas channel on this projection plane includes a first straight line and a second straight line parallel to the radial direction. The first straight line is located on the side closer to the third reaction zone 1c, and the second straight line is located on the side closer to the first reaction zone 1a. The length of the first straight line is greater than the length of the second straight line. That is, the end face of the gas channel is inclined downward, and the extension direction of the end face has a certain angle with the axial direction of the second reaction zone 1b, so as to avoid the outlet of the gas channel being blocked by the catalyst as much as possible and ensure the smoothness of the outlet.

[0053] When the second inner component 9 is a distribution plate, the distribution plate is one of an arched distribution plate, an irregular distribution plate, or a concave distribution plate; a number of fourth openings are uniformly arranged on the distribution plate, and the total area of ​​the fourth openings is 15% to 25% of the vertical projection area of ​​the distribution plate, and a ceramic wear-resistant layer is arranged in the channel of the fourth opening.

[0054] Furthermore, the diameter of the fourth opening is 8–80 mm, and further, 10–50 mm.

[0055] The third reaction zone 1c is located above the second reaction zone 1b. Its inlet is connected to the outlet of the first internal component 8, and its inner diameter is smaller than that of the second reaction zone 1b. By reducing the inner diameter, the gas and catalyst in the second reaction zone 1b will be rapidly extracted to the settler 2.

[0056] The arrangement of the first internal component 8 and the second internal component 9 helps to broaden the range of apparent gas velocity in the second reaction zone 1b, making the diameter ratio of the second reaction zone 1b to other reaction zones wider. Specifically, the diameter ratio of the first reaction zone, the second reaction zone and the third reaction zone is 1:2 to 5:0.7 to 1.5, and the height ratio of the first reaction zone, the second reaction zone and the third reaction zone is 1:0.3 to 2:0.5 to 2.

[0057] Furthermore, the diameter ratio of the first reaction zone, the second reaction zone, and the third reaction zone is 1:2.5 to 4:0.7 to 1.5.

[0058] The settling device 2 is located above the reaction unit 1 in the axial direction, and its inlet is connected to the outlet of the third reaction zone 1c. It is used to perform gas-solid separation on the mixed reactants output from the third reaction zone 1c to inhibit the continued reaction. The settling device 2 specifically includes a cyclone separator and a stripping section below the cyclone separator. The specific structure can be set according to conventional technical means in this field.

[0059] The cyclone separator is used to separate the reaction product 13 and the catalyst to be generated in the mixed reactants. The separated reaction product 13 is output through the upper outlet, while the catalyst to be generated settles and enters the lower stripping section to remove the oil and gas adsorbed on the catalyst to replace the oil and gas between the catalyst particles, thereby reducing oil and gas loss and coking load of the subsequent regeneration unit. Therefore, the settler 2 is also provided with a stripping steam inlet for inputting stripping steam 14.

[0060] The regeneration unit 3 is located on one side of the reaction unit 1 and the settling tank 2. The inlet of the regeneration unit 3 is connected to the bottom outlet of the settling tank through the catalyst delivery pipe 5. The regeneration unit 3 includes a regeneration air inlet and a regeneration flue gas outlet. Regeneration air 17 is delivered into the regeneration unit 3 through the regeneration air inlet, so that the regeneration air 17 comes into contact with the catalyst to be generated and undergoes an oxidation reaction to regenerate the catalyst. The regenerated catalyst enters the bottom inlet of the reaction unit 1 through the first regeneration catalyst delivery pipe 6 and the second regeneration catalyst delivery pipe 7. A heat exchanger 4 is connected between the first regeneration catalyst delivery pipe 6 and the second regeneration catalyst delivery pipe 7. Low-temperature water vapor 15 is injected into the heat exchanger 4 to cool the regenerated catalyst. After heat exchange, the low-temperature water vapor 15 generates high-temperature water vapor 16 and is discharged from the outlet of the heat exchanger 4. The regeneration flue gas 18 is output from the top of the regeneration unit 3 through the regeneration flue gas outlet and enters the flue gas turbine for further energy recovery and treatment.

[0061] The apparatus provided by the present invention further includes a raw material feeding unit and a quench agent feeding unit. The raw material feeding unit is connected to the bottom of the reaction unit 1 and is used to deliver the steam-atomized heavy oil 11 into the reaction unit 1. The quench agent feeding unit is connected to the bottom of the second reaction zone 1b and is used to inject the quench agent 12 into the second reaction zone 1b to reduce the temperature in the second reaction zone 1b, promote the occurrence of hydrogen transfer reaction, and prevent coking. The specific configuration can be made according to conventional technical means in the art.

[0062] In summary, the present invention provides a catalytic device that, by setting a first internal component and a second internal component inside the second reaction zone, changes the flow state of the gas and the catalyst, widens the range of apparent gas velocity in the second reaction zone, and allows the reaction unit to withstand a wider range of adjustment or fluctuation in the reaction oil and gas flow rate, thereby improving the processing capacity of the catalytic device.

[0063] A second aspect of the present invention provides a catalytic method for heavy oil, using any of the catalytic devices described above, comprising the following steps:

[0064] The steam-atomized heavy oil and the regenerated catalyst are fed into the first reaction zone through the pre-lift section of the reaction unit. The mixed oil and gas and the regenerated catalyst rise in the reaction unit and enter the settling tank after passing through the first reaction zone, the second reaction zone and the third reaction zone.

[0065] The settler separates the mixed reactants output from the third reaction zone to obtain reaction product 13 and the catalyst to be generated; the catalyst to be generated is fed into the regeneration unit for regeneration to obtain the regenerated catalyst, which is then returned to the reaction unit for recycling.

[0066] In one specific embodiment, the heavy oil in this invention includes petroleum hydrocarbons and / or other mineral oils, wherein the petroleum hydrocarbons are selected from one or more of vacuum gas oil (VGO), atmospheric gas oil (AGO), coking gas oil (CGO), deasphalted oil (DAO), vacuum residue (VR), atmospheric residue (AR), and hydrotreated heavy oil, and the petroleum hydrocarbons can be unhydrogenated full fractions or partial fractions, or hydrogenated full fractions or partial fractions; the other mineral oils are selected from one or more of coal liquefaction oil, oil sands oil, and shale oil.

[0067] In this invention, the catalyst is a catalyst suitable for catalytic cracking or catalytic pyrolysis, and its active component is selected from one or more of the following: amorphous silica-alumina catalyst, Y or HY type zeolite with or without rare earth elements, ultra-stable Y type zeolite with or without rare earth elements, ZSM-5 series zeolite, or high-silica zeolite with a five-membered ring structure prepared by other methods; the temperature of the regenerated catalyst transported from the second regenerated catalyst transport pipe 7 is 660℃~760℃.

[0068] In the specific catalytic process, pre-lift gas 10 is introduced from the bottom inlet of reaction unit 1, and at the same time, steam-atomized heavy oil 11 and regenerated catalyst are introduced into the pre-lift section. Under the action of pre-lift gas 10, steam-atomized heavy oil 11 and regenerated catalyst enter the first reaction zone 1a for contact reaction and continue to rise. The rising oil and gas and catalyst enter the second reaction zone 1b through the first reaction zone 1a and the second internal component 9, and are fully mixed and contacted in the second reaction zone 1b. The contact between the oil and the catalyst is enhanced by the arrangement of the first internal component 8 and the second internal component 9.

[0069] Oil and gas, along with the catalyst, enter the third reaction zone 1c through the first internal component 8, and then proceed into the settler 2 for gas-solid separation.

[0070] Furthermore, the apparent residence times of oil and gas in the first reaction zone 1a, the second reaction zone 1b, and the third reaction zone 1c are 0.8–2 seconds, 5–15 seconds, and 0.5–1.5 seconds, respectively.

[0071] Due to the narrowing of the third reaction zone 1c, the oil and gas and catalyst quickly enter the settling tank 2. The mixed oil and gas and the spent catalyst are separated by a cyclone separator. The separated reaction product 13 is discharged through a pipeline. The spent catalyst with carbon is sent to the bottom stripping section through the settling tank below. After being stripped by stripping steam 14, it enters the regeneration unit 3 through the spent catalyst conveying pipe 5. By introducing regeneration air 17 into the regeneration unit 3, the spent catalyst comes into contact with the regeneration air 17 and undergoes an oxidation reaction to obtain the regenerated catalyst. The regenerated catalyst enters the heat exchanger 4 through the first regenerated catalyst conveying pipe 6. After being cooled by low-temperature steam 15, it returns to the reaction unit 1 for recycling through the second regenerated catalyst conveying pipe 7. The low-temperature steam 15 is converted into high-temperature steam 16 after heat exchange and discharged. The regenerated flue gas 18 is output from the top of the regeneration unit 3 and enters the flue gas turbine for further energy recovery and treatment.

[0072] In addition, to control the reaction temperature, a quenching agent 12 can be injected into the connecting area between the first reaction zone 1a and the second reaction zone 1b; further, it can be injected into the top of the first reaction zone 1a or the bottom of the second reaction zone 1b. The quenching agent 12 includes one or more of water, recycled oil, gasoline, diesel, and sludge, and the injection amount is 1 to 10 wt% of the heavy oil. The temperature of the quenching agent is room temperature to 200°C.

[0073] Regenerated catalyst, cooled regenerated catalyst, or catalyst with a carbon content of <0.5% can be injected into the upper part of the first reaction zone 1a or the middle and lower part of the second reaction zone 1b to supplement the catalyst activity in the second reaction zone 1b.

[0074] By changing the catalyst and adjusting the operating conditions, the catalytic device provided by this invention can switch between two operating modes: 1. Ultra-low olefin gasoline production mode: controlling the temperature at the inlet of the first internal component 8 to 510℃~540℃, further to 515℃~530℃; controlling the temperature of the regenerated catalyst or the catalyst to be generated injected into the upper part of the first reaction zone 1a or the middle and lower part of the second reaction zone 1b to 560℃~660℃; 2. High-crack gas production mode: controlling the temperature at the inlet of the first internal component 8 to 550℃~640℃, further to 560℃~600℃; controlling the temperature of the regenerated catalyst or the catalyst to be generated injected into the upper part of the first reaction zone 1a or the middle and lower part of the second reaction zone 1b to 580℃~680℃.

[0075] In summary, by using the device provided by this invention for the catalysis of heavy oil, the production modes of ultra-low olefin gasoline and high-volume cracked gas production can be switched by changing the catalyst and adjusting the operating conditions, thus achieving flexible control over product properties and product distribution.

[0076] The following examples will further illustrate the present invention, but are not intended to limit the invention. The properties of the catalytic feedstock and catalyst used in the examples and comparative examples are listed in Tables 1 and 2, respectively. The catalysts shown in Table 2 were produced by Lanzhou Catalyst Plant of China National Petroleum Corporation.

[0077] Example 1

[0078] The catalytic device provided in this embodiment has Figure 1 The structure shown includes a reaction unit 1 comprising a pre-lifting section, a first reaction zone 1a, a second reaction zone 1b, and a third reaction zone 1c, with a total height of 18 meters. The pre-lifting section has a diameter of 0.25 meters and a height of 1.5 meters. The first reaction zone 1a has a diameter of 0.30 meters and a height of 4 meters. The second reaction zone 1b has a diameter of 1.2 meters and a height of 7.6 meters. The third reaction zone 1c has a diameter of 0.30 meters and a height of 4 meters. The longitudinal section of the connection area between the first reaction zone 1a / third reaction zone 1c and the second reaction zone 1b is an isosceles trapezoid, with the lateral line of the isosceles trapezoid making an angle of 45° with the axis, and the height of the isosceles trapezoid is 0.45 meters.

[0079] The second reaction zone 1b is provided with a first internal component 8 and a second internal component 9. The diameter of the first internal component 8 is 0.30 meters and the height is 2.5 meters. Several first openings are provided above the first internal component 8. The first openings are concentrated in the range of 0.5 to 2 meters above the first internal component 8. The total area of ​​the first openings is 10% of the cross-sectional area of ​​the first internal component.

[0080] The second internal component 9 is a conical cap distributor, the structure of which is as follows: Figure 3As shown, the system includes a cap and a second conveying pipe located below the cap. The cap is a cone with an isosceles triangle cross-section, and the base angle of the isosceles triangle is 15°. A second opening parallel to the axial direction of the second reaction zone is provided on the cap. The diameter of the second opening is 0.01–0.05 m, and the total area of ​​the second opening accounts for 10% of the total vertical projection area of ​​the cap. The ratio of the vertical projection area of ​​the cap to the cross-sectional area of ​​the second reaction zone 1b is 0.8:1. The second conveying pipe has a height of 3 m and an inner diameter identical to that of the first reaction zone 1a. A third opening is provided on the second conveying pipe, and the total area of ​​the third opening is 150% of the cross-sectional area of ​​the first reaction zone 1a.

[0081] Based on the above-mentioned apparatus, ultra-low olefin gasoline was produced using the heavy oil shown in Table 1 and catalyst A shown in Table 2. The production conditions, product distribution, and main properties of the gasoline are shown in Table 3.

[0082] Example 2

[0083] The catalytic device and catalytic process provided in this embodiment are similar to those in Embodiment 1, except that the second internal component is an umbrella-shaped distributor, with the structure as follows: Figure 4 As shown, catalyst B from Table 2 was used, and the operating conditions, product distribution, and main properties of gasoline are shown in Table 3.

[0084] Comparative Example 1

[0085] The catalytic device provided in this comparative example can be referred to in Example 1, except that the second reaction zone does not include the first internal component, and the diameter of the second reaction zone is 0.9 meters.

[0086] Using the above-described apparatus, ultra-low olefin gasoline was produced with the same raw materials and catalyst A as in Example 1. The operating conditions, product distribution, and main properties of the gasoline are shown in Table 3.

[0087] Comparative Example 2

[0088] Using the same apparatus as Comparative Example 1, and with the same feedstock and catalyst B as in Example 2, a multi-product cracked gas operation mode was performed. The operating conditions, product distribution, and main properties of gasoline are shown in Table 3.

[0089] Table 1 Properties of Heavy Oil Feedstock

[0090]

[0091] Table 2 Catalyst Properties

[0092]

[0093] Table 3 Operating Conditions and Product Distribution

[0094]

[0095] As shown in Table 3, compared with Comparative Examples 1-2, Examples 1-2 have a higher diameter ratio; furthermore, the olefin content of gasoline in Example 1 is 2.5 percentage points lower than that in Comparative Example 1, the liquefied petroleum gas yield in Example 2 is 4.1 percentage points higher than that in Comparative Example 2, and the propylene yield is also 3 percentage points higher than that in Comparative Example 2. This indicates that the catalytic device provided by the present invention has a strong catalytic processing capability, realizes the switching between two production modes of ultra-low olefin gasoline and high-yield cracked gas, and achieves flexible control of product properties and product distribution.

[0096] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A heavy oil catalytic converter, characterized in that, The catalytic device includes a reaction unit, a settling tank, and a regeneration unit. The reaction unit is a variable-diameter riser, which includes a pre-lifting section, a first reaction zone, a second reaction zone, and a third reaction zone connected sequentially in the axial direction. The inner diameter of the second reaction zone is larger than the inner diameters of the first and third reaction zones. The inlet of the settling tank is connected to the outlet of the third reaction zone. The inlet of the regeneration unit is connected to the outlet of the catalyst to be generated in the settling tank, and the outlet of the regeneration unit is connected to the pre-lifting section. The second reaction zone is provided with a first internal component and a second internal component. The first internal component is a first conveying pipe with the same diameter as the inner diameter of the third reaction zone. The first conveying pipe is connected to the inlet of the third reaction zone. The pipe wall of the first conveying pipe is provided with a plurality of first openings. The second internal component is located near the inlet of the second reaction zone. The second internal component is a distribution plate or a cap-type distributor.

2. The catalytic device according to claim 1, characterized in that, The height ratio of the first internal component to the height of the second reaction zone is 0.15 to 0.8:

1.

3. The catalytic device according to claim 1 or 2, characterized in that, The distance between the bottom port of the first internal component and the bottom of the second reaction zone is 2 to 8 m, and the height of the first internal component is 2 to 7 m.

4. The catalytic device according to claim 1, characterized in that, The distance between the first opening and the entrance to the third reaction zone is no greater than 0.5 to 2 m; the total area of ​​the first opening is 5% to 30% of the cross-sectional area of ​​the first internal component.

5. The catalytic device according to any one of claims 1 to 4, characterized in that, The diameter ratio of the first reaction zone, the second reaction zone, and the third reaction zone is 1:2 to 5:0.7 to 1.5, and the height ratio of the first reaction zone, the second reaction zone, and the third reaction zone is 1:0.3 to 2:0.5 to 2.

6. The catalytic device according to any one of claims 1 to 4, characterized in that, When the second internal component is a distribution plate, the distribution plate is one of an arched distribution plate, an irregularly shaped distribution plate, or a concave distribution plate.

7. The catalytic device according to any one of claims 1 to 4, characterized in that, When the second internal component is a cap-type distributor, the cap-type distributor includes a cap and a second conveying pipe, the second conveying pipe is connected to the outlet of the first reaction zone, and the cap is disposed on the side of the second conveying pipe near the outlet of the second reaction zone; The cap has several second openings, and the wall of the second conveying pipe has several third openings. The wall of the third opening extends outward to form a gas channel.

8. The catalytic device according to claim 7, characterized in that, The total area of ​​the second opening is 8% to 15% of the vertical projected area of ​​the cap, and the total area of ​​the third opening is 60% to 400% of the cross-sectional area of ​​the first reaction zone.

9. The catalytic device according to claim 7, characterized in that, Using the plane formed by the axial and radial directions of the second reaction zone as the projection plane, the orthogonal projection of the gas channel onto the projection plane includes a first straight line and a second straight line parallel to the radial direction. The first straight line is located on the side closer to the third reaction zone, and the second straight line is located on the side closer to the first reaction zone. The length of the first straight line is greater than the length of the second straight line.

10. A catalytic method for heavy oil, characterized in that, The process, performed using the catalytic apparatus according to any one of claims 1 to 9, includes the following steps: The steam-atomized heavy oil and the regenerated catalyst are fed into the first reaction zone through the pre-lift section of the reaction unit. The mixed oil and gas and the regenerated catalyst rise in the reaction unit and enter the settling tank after passing through the first reaction zone, the second reaction zone and the third reaction zone. The settler separates the mixed reactants output from the third reaction zone to obtain reaction products and a catalyst to be generated; the catalyst to be generated is fed into the regeneration unit for regeneration to obtain a regenerated catalyst, which is then returned to the reaction unit for recycling.

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