Chemical processing vessel having a plate grid distributor and method of operation thereof

Abstract

According to one or more embodiments, the chemical treatment vessel may include a sidewall, a bed, a catalyst outlet through the bed, and a plate grid distributor for distributing fluid. The plate may include a plurality of openings and a central opening extending through a thickness of the plate. The plate may include a catalyst transport passage extending from the central opening to the catalyst outlet. The catalyst transport passage may have a larger cross-sectional area at the central opening of the plate than at the catalyst outlet. According to one or more embodiments, a method of operating a chemical treatment vessel includes directing a fluid into the chemical treatment vessel, directing the fluid through the plate grid distributor, and directing catalyst from above the plate, through the catalyst transport passage, and out of the chemical treatment vessel through the catalyst outlet.

Description

[Technical field]

[0001] (CROSS REFERENCE TO RELATED APPLICATIONS) This application is a PCT application claiming priority to U.S. Provisional Patent Application No. 63 / 216,786, filed June 30, 2021, and entitled “CHEMICAL PROCESSING VESSELS HAVING PLATE GRID DISTRIBUTORS AND METHODS OF OPERATING THE SAME,” which is incorporated by reference in its entirety.

[0002] FIELD OF THE DISCLOSURE The present disclosure relates generally to chemical processing, and more particularly to systems and methods for distributing fluids through a distributor. [Background technology]

[0003] Gaseous chemicals may be delivered to reactors or other vessels through distributors. Distributors may be utilized to facilitate balanced distribution of fluids to such reactors or vessels. Such fluid distribution may promote favorable reactions and maintain mass transfer equilibrium in the chemical system. Summary of the Invention

[0004] In many chemical processes, fluid is delivered to a chemical processing vessel, such as a reactor or other vessel, through a plate grid distributor. In some chemical processes, catalyst may be simultaneously removed while fluid is being delivered to the chemical processing vessel. For example, such processes may occur in a catalyst treatment section of a reactor system, such as an oxygen submerged zone. Conventional plate grid distributors may require a hopper cone above the plates of the plate grid distributor. Any catalyst above the plates and below the hopper cone may be unnecessary and of little use. Furthermore, conventional plate grid distributors may require expansion joints. These conventional plate grid distributors may increase the required catalyst inventory and / or make it difficult to remove catalyst from the chemical processing vessel. Thus, there is a continuing need for improved plate grid distributors. It has been discovered that a plate grid distributor having catalyst transport passages, as described herein, may reduce the amount of catalyst required and / or provide an efficient means for removing catalyst from the chemical processing vessel. Embodiments of such plate grid distributors are described herein. The embodiments of the present disclosure meet this need by utilizing a catalyst transport passage that can align the top of the standpipe (i.e., the catalyst transport passage) with the top surface of the plate, which also avoids the need for a hopper cone.

[0005] According to one embodiment, the chemical treatment vessel may include a sidewall, a bed, a catalyst outlet through the bed, and a plate grid distributor for distributing fluid within the chemical treatment vessel. The plate grid distributor may include a plate having an upper surface and a lower surface opposite the upper surface and defining a thickness of the plate. The plate may include a plurality of openings extending through the thickness of the plate. The plate may include a central opening. The catalyst transport passage may extend from the central opening to the catalyst outlet to form a passage from a region above the plate to the catalyst outlet. The catalyst transport passage and the plate may be connected such that they form a unitary body. The catalyst transport passage may have a larger cross-sectional area at the central opening of the plate than at the catalyst outlet to allow gas bubbles to leave the fluidized catalyst.

[0006] According to another embodiment, a method of operating a chemical treatment vessel may include delivering a fluid into the chemical treatment vessel at reaction conditions through a gas supply conduit below a plate grid distributor and directing the fluid through a plate grid distributor in the chemical treatment vessel. The plate grid distributor may include a plate having an upper surface and a lower surface opposite the upper surface and defining a thickness of the plate. The plate may include a plurality of openings extending through the thickness of the plate. The plate may include a central opening. The catalyst transport passage may extend from the central opening to the catalyst outlet to form a passage from a region above the plate to the catalyst outlet. The catalyst transport passage and the plate may be connected such that they form a unitary body. The catalyst transport passage may have a larger cross-sectional area at the central opening of the plate than at the catalyst outlet. The method may include passing the catalyst from above the plate, through the catalyst transport passage and out of the chemical treatment vessel through the catalyst outlet.

[0007] Additional features and advantages are set forth in the Detailed Description below, and in part will be readily apparent to those skilled in the art from that description, or will be learned by practicing the embodiments described herein, including in the Detailed Description below, and in the claims.

[0008] It is to be understood that both the foregoing general description and the following detailed description are intended to provide an overview or framework for describing the various embodiments and understanding the nature and character of the claimed subject matter. [Brief description of the drawings]

[0009] [Figure 1] FIG. 2 is a schematic diagram of a cross-sectional view of a vessel and a plate grid distributor in accordance with one or more embodiments of the present disclosure. [Diagram 2] FIG. 2 is a schematic diagram of a perspective view of a plate grid distributor and catalyst transport passages according to one or more embodiments of the present disclosure. [Diagram 3] FIG. 1 is a schematic diagram of a reactor system according to one or more embodiments of the present disclosure. [Figure 4A] FIG. 1 is a schematic diagram of a sparger according to one or more embodiments of the present disclosure. [Figure 4B] FIG. 4B is a schematic diagram of a cross-sectional view of the sparger of FIG. 4A in accordance with one or more embodiments of the present disclosure.

[0010] Reference will now be made in more detail to various embodiments, some of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] The present disclosure is directed to a chemical processing vessel including a plate grid distributor and a method of operating a chemical processing vessel, according to one or more embodiments described herein. Generally, the plate grid distributor described herein may include a plate and a catalyst transport passage. The plate grid distributor described herein can be used to distribute fluids in a chemical processing vessel. Generally, the plate grid distributor described herein includes a catalyst transport passage that can aid in removing catalyst from the chemical processing vessel. The catalyst transport passage of the present disclosure can minimize catalyst inventory, can remove catalyst from the center of the fluidized bed, and can provide additional annular space around the plate grid distributor.

[0012] 1, a plate grid distributor 100 of the present disclosure may be disposed within a chemical treatment vessel 110. The chemical treatment vessel 110 may have a variety of configurations. The chemical treatment vessel 110 may include one or more polyhedrons, spheres, cylinders, cones, irregular shapes, combinations thereof, and / or portions thereof. For example, the chemical treatment vessel 110 may include a hollow right cylinder having a longitudinal axis. The chemical treatment vessel 110 may include a sidewall 111, a floor 116, a top 118, a catalyst outlet 120, and a gas supply conduit receiving passage 122. The sidewall 111, floor 116, and top 118 of the chemical treatment vessel 110 may include a refractory lined inner wall 112 and an outer wall 114.

[0013] According to one or more embodiments, a plate grid distributor 100 for distributing a fluid in a chemical treatment vessel 110 may include a plate 102. The plate 102 may include a top surface 104 and a bottom surface 106. The bottom surface 106 may be opposite the top surface 104 and may be spaced apart from the top surface 104. The distance between the top surface 104 and the bottom surface 106 may define a thickness of the plate 102. The plate 102 may include an outer surface 108. The outer surface 108 may have a portion perpendicular to the top surface 104 and the bottom surface 106. The outer surface 108 may be welded to the top surface 104. The plate 102 may have an average diameter of at least 5 feet (1.5 meters (m)) and at most 75 feet (22.9 m), for example, at least 10 feet (3.0 m) and at most 50 feet (15.2 m). The plate 102 may be substantially planar (i.e., the top surface 104 and the bottom surface 106 may be substantially parallel). In other embodiments, the plate 102 may be dished (i.e., non-planar). If the plate 102 is dished, the top surface 104 and the bottom surface 106 may not be flat (i.e., the outer surface 108 of the plate 102 may be higher than the top surface 104 or lower than the bottom surface 106).

[0014] The bottom surface 106, the top surface 104, or both of the plate 102 may be lined with a fire-resistant material. For example, FIG. 1 shows a fire-resistant material in the shaded area above the plate 102. Additionally or alternatively, other materials having insulating properties (e.g., insulating materials) may be disposed between the bottom surface 106 and the top surface 104 of the plate 102. The fire-resistant backing, the insulating material, or both, may help prevent the bottom surface 106 of the plate 102 from heating up.

[0015] The plate 102 may include a plurality of openings 130. The plurality of openings 130 may be in fluid communication with the bottom surface 106 of the plate 102 and the top surface 104 of the plate 102 via a first opening 132 and a second opening 134, respectively. The plurality of openings 130 may be flush with the top surface 104 and / or the bottom surface 106. Alternatively, the plurality of openings 130 may extend beyond (i.e., below) the bottom surface 106 and / or beyond (i.e., above) the top surface 104. That is, the plurality of openings 130 may include an enclosure that extends above the top surface 104 of the plate 102. The second opening 134 may have a larger cross-sectional area than the first opening 132.

[0016] The first opening 132 of the plate 102 can provide a pressure drop from the bottom surface 106 of the plate 102 to the top surface 104 of the plate 102 to ensure an even distribution of gas passing through the plate 102. The second opening 134 can reduce the velocity of the gas passing through the plate 102. If the velocity of the gas passing through the plate 102 is too high, the gas may wear down or damage the catalyst in the chemical treatment vessel 110 above the plate 102. The first opening 132 and the second opening 134 of the plate 102 can have a uniform or varying cross-sectional area to assist in an even distribution of gas passing through each of the multiple openings 130. For example, the openings 130 closer to the gas supply conduit 132 can have a higher pressure difference between the bottom surface 106 and the top surface 104 of the plate 102. Thus, the first openings 132 in the plate 102 closer to the gas supply conduit 123 may have a smaller cross-sectional area than the first openings 132 further away from the gas supply conduit 123 to assist in balancing the pressure difference across the plate 102.

[0017] As shown in FIG. 2, the plate 102 may include a bottom surface 106 and an outer surface 108. The bottom surface 106 may include a plurality of openings 130 formed by first openings 132 in the plate 102. The plurality of openings 130 may be arranged around the central opening 121B in a geometric pattern. The geometric pattern may vary for various applications. For example, the plurality of openings 130 may be arranged around the central opening 121B in a grid and / or concentric circles. The plate 102 may include 10-50 openings 130 per square meter, such as 20-35 openings per square meter. Other numbers of openings 130 per square meter are also contemplated.

[0018] 1, the ratio of the inner diameter of the first opening 132 of the plate 102 to the inner diameter of the second opening 134 of the plate 102 may be 0.13 to 0.8, for example, 0.34 to 0.51. The ratio of the inner diameter of the first opening 132 of the plate 102 to the inner diameter of the chemical treatment vessel 110 may be 0.003 to 0.014, for example, 0.008 to 0.012. The ratio of the inner diameter of the second opening 134 of the plate 102 to the inner diameter of the chemical treatment vessel 110 may be 0.008 to 0.163, for example, 0.026 to 0.087.

[0019] The plate grid distributor 100 may include an outer support 150. The outer support 150 may mount and support the plate 102 to the chemical treatment vessel 110 at or near the floor 116 of the chemical treatment vessel 110. The outer support 150 may extend down at or near the periphery of the plate 102. As used in this disclosure, "periphery of the plate" may refer to the outermost 25% (i.e., the portion closest to the inner wall of the refractory lining) of the plate 102. The outer support 150 may include a first end 152 and a second end 154. The first end 152 may be connected to the floor 116 of the chemical treatment vessel 110. The second end 154 may be connected to the plate 102. The first end 152 and the second end 154 may be spaced apart from one another. The space between the first end 152 and the second end 154 may define an outer plane 156. The outer plane 156 may be spaced apart from the inner plane 158. The outer plane 156 may be spaced apart from the refractory lined inner wall 112. The outer plane 156 may be connected to a portion of the inner plane 158 adjacent the second end 154 and spaced apart from the first end 152. In an embodiment, the filler (i.e., insulation) of the plate grid distributor may be disposed between the lower portion of the refractory lined inner wall 112 closer to where the refractory lined inner wall 112 is connected to the floor 116 of the chemical treatment vessel 110 and the outer surface 108 of the plate 102. The filler of the plate grid distributor may be ceramic wool insulation. In an embodiment, the outer support 150 may be at an angle. Alternatively, the outer support 150 may be vertical (i.e., perpendicular to the floor 116 or parallel to the sidewall 111).

[0020] 1 , the chemical treatment vessel 110 may include a gas supply conduit 123. The gas supply conduit 123 may be connected to a gas supply conduit receiving passage 122 that extends through the floor of the chemical treatment vessel 110. The chemical treatment vessel 110 may include multiple gas supply conduits 123. In an embodiment, the multiple gas supply conduits 123 may be connected to multiple gas supply conduit receiving passages 122. The multiple gas supply conduit receiving passages 122 may circumscribe a longitudinal axis of the chemical treatment vessel 110.

[0021] Gas supply conduit 123 may be mounted flush with or extend beyond refractory lined inner wall 112. The ratio of the inner diameter of gas supply conduit 112 to the inner diameter of chemical treatment vessel 110 may be between 0.02 and 0.4, such as between 0.20 and 0.23.

[0022] The plate grid distributor 100 may include a deflector plate 170 spaced from and operably connected to a portion of the bottom surface 106 of the plate 102 by a number of deflector plate connectors 172. The deflector plate 170 may deflect and / or reduce the velocity of the gas feed entering the chemical treatment vessel 110. The velocity deflection and / or redirection may cause the gas feed to be more evenly distributed through the number of openings 130.

[0023] 1, as previously described in this application, the chemical treatment vessel 110 may include a catalyst transport passage 121. In an embodiment, the catalyst transport passage 121 may include a truncated cone. As used in this disclosure, "frustum of a cone" may refer to a truncated cone shape created by cutting off the top of a cone (the cut is made parallel to the base). The catalyst transport passage 121 may extend from the central opening 121B to the catalyst outlet 120. The catalyst transport passage 121 may form a passage from an area above the plate 102 to the catalyst outlet 120. The catalyst transport passage 121 and the plate 102 may be connected such that they form a unitary body. As used herein, a unitary body may mean that two components (e.g., the catalyst transport passage 121 and the plate 102) are formed from a single structure. Without being bound to any particular theory, it is believed that a unitary body may be lighter and stiffer than a structure using separate parts. The plate 102 and the catalyst transport passage 121 may be operable to accommodate a catalyst below the plate 102 within the catalyst transport passage 121. It should be understood that the catalyst may be above the plate 102 as well as within the catalyst transport passage 121. The catalyst transport passage 121 may include a rounded transition 124 between the catalyst transport passage 121 and the plate 102. A "rounded transition" may refer to rounding an inner corner or an outer corner of a part design. The rounded geometry is a concave function line when at an inner corner, and a rounded geometry at an outer corner is a convex function line. The flat edge transition 124 may provide a smooth transition from the plate 102 to the catalyst transport passage 121. The refractory material may be in direct contact with and cover substantially all of the inner surface 126 of the catalyst transport passage 121.

[0024] The catalyst transport passage 121 does not have to extend above the plate 102. A flush transition 124 of the catalyst transport passage 121 can provide a flush transition from the catalyst transport passage 121 to the plate 102. That is, the top surface 128 of the catalyst transport passage 121 can be substantially flush with the top surface 104 of the plate 102. Such a design can minimize the catalyst inventory required for the chemical process performed in the chemical process vessel 110. Conventional plate grid distributors and catalyst collection standpipes may require a hopper cone above the conventional plate grid distributor. Any particulate solids above the plates and in the hopper cone of a conventional plate grid distributor may, in some embodiments, not be useful and may unnecessarily increase catalyst inventory costs.

[0025] The catalyst transport passage 121 may have a larger cross-sectional area at the central opening 121B of the plate 102 than at the catalyst outlet 120. In an embodiment, the catalyst transport passage 121 may be 2 to 6 times larger, for example 3.5 to 4.5 times larger, than the catalyst outlet 120. Thus, the cross-sectional area of ​​the catalyst transport passage 121 may be 2 to 6 times larger, for example 3.5 to 4.5 times larger, at the central opening 121B of the plate 102 than at the catalyst outlet 120.

[0026] During operation, particulate solids, such as catalyst particles, may be removed from chemical treatment vessel 110 via catalyst transport passageway 121. Catalyst transport passageway 121 may be connected to a standpipe (not shown) to deliver the particulate solids to another vessel or treatment unit. During operation, catalyst may be removed from chemical treatment vessel 110 at a rate of up to 50 lb / ft 2 -sec or more 400lb / ft 2 -sec or less, e.g. 100 lb / ft 2 -sec or more 300lb / ft 2 The catalyst may be withdrawn from vessel 110 at a catalyst flux of 0.1-sec or less and transferred to the standpipe. A gas supply conduit 123 may deliver gas into chemical treatment vessel 110 through plate grid distributor 100, while particulate solids may be removed via catalyst transport passage 121. Thus, catalyst transfer passage 121 forms a barrier between the catalyst and the ultimately distributed gas.

[0027] 1 and 4A-B, in an embodiment, the chemical treatment vessel 110 may include a sparger 160 in the catalyst transport passage 121 operable to direct gas above the plate 102 or toward the catalyst outlet 120. A sparger may be utilized to fluidize material passing through the catalyst transport passage 121, which in some embodiments may be defluidized without the use of a sparger due to the relatively large size of the catalyst transport passage 121. The sparger 160 may include a sparger body 162 and a number of sparger openings 164. In operation, fluid may be directed into the sparger body 162 and through the number of sparger openings 164 to assist in fluidizing the particulate solids from the chemical treatment vessel 110. The fluid may be directed downward toward the catalyst outlet 120 to assist in fluidizing the particulate solids passing from above the plate 102 through the catalyst transport passage 121 and out of the catalyst outlet 120. The fluid may be directed into the sparger body through a sparger supply pipe 166. The sparger 160 may deliver an oxygen-containing gas or an inert gas, such as nitrogen, into the chemical treatment vessel 110. In an embodiment, the chemical treatment vessel 110 may include multiple spargers 160, for example, two, three, five, or any number of spargers 160, which may be in a loop.

[0028] 4B, the sparger body 162 may include one or more sparger walls 426. The sparger 160 may include a reinforcing bar 432 rigidly connected to an exterior surface of the sparger wall 426. The plurality of sparger openings 164 may each include an orifice 437 at the beginning of each sparger opening 164 to create a pressure drop and evenly distribute the gas fed through the sparger 160. The plurality of sparger openings 164 may also include a diffuser 438 connected to the sparger wall 426 at each of the sparger openings 164. The diffuser 438 may slow the superficial gas velocity exiting the orifice 437 to reduce or prevent catalyst wear, damage to the internal structure of the chemical treatment vessel 110, damage to the plate grid distributor 100, or damage to the catalyst transport passages 121.

[0029] 4B, the sparger 160 may include a refractory material 436 lined on the outside of the sparger body 162 of the sparger 160. As used herein, a refractory material 136 is a material that may be resistant to degradation by heat, pressure, or chemical attack and may retain strength and shape at high temperatures. Oxides of aluminum, silicon, magnesium, and calcium may be common materials used in the manufacture of refractory materials.

[0030] 1 and 4A, the plate grid distributor 100 may include one or more loops 168. The one or more loops 168 may be secured to the plate 102 using any conventional or yet to be developed means, such as welding. The one or more loops 168 may provide mechanical support to the sparger 160.

[0031] Referring now to FIG. 3, an exemplary reactor system 300 in which the chemical processing vessel 110 of the present disclosure may reside is illustrated in schematic form. The reactor system 200 generally comprises multiple system units, such as a reactor section 400 and a regenerator section 500. As used herein in connection with FIG. 3, the reactor section 400 generally refers to the portion of the reactor system 300 where the primary process reaction occurs and where the particulate solids are separated from the product stream of the reaction. In one or more embodiments, the particulate solids may be spent, meaning that the particulate solids are at least partially inactivated. Also, as used herein, the regenerator section 500 generally refers to the portion of the reactor system 300 where the particulate solids are regenerated, such as by combustion, and where the regenerated particulate solids are separated from other process materials, such as gases generated from materials previously combusted on the spent particulate solids or from auxiliary fuels. The reactor section 400 generally comprises a reaction vessel 450, a riser 430 including an outer riser segment 432 and an inner riser segment 434, and a particulate solids separation section 410. The regenerator section 500 generally includes a particulate solids processing vessel 550, a riser 530 including an outer riser segment 532 and an inner riser segment 534, and a particulate solids separation section 510. Generally, the particulate solids separation section 410 may be in fluid communication with the particulate solids processing vessel 550, for example, by a standpipe 526, and the particulate solids separation section 510 may be in fluid communication with the reaction vessel 450, for example, by a standpipe 324 and a transport riser 330.

[0032] In general, reactor system 300 may operate by feeding a hydrocarbon feed and fluidized particulate solids to reaction vessel 450 and reacting the hydrocarbon feed by contacting it with the fluidized particulate solids to produce products in reaction vessel 450 of reactor section 400. The products and particulate solids may exit reaction vessel 450 through riser 430 and enter gas / solids separation device 420 in particulate solids separation section 410 where the particulate solids may be separated from the products. The particulate solids may then exit particulate solids separation section 410 and be transported to particulate solids processing vessel 550 where the particulate solids may be regenerated by a chemical process. For example, spent particulate solids may be regenerated by one or more of oxidation of the particulate solids by contact with an oxygen-containing gas, burning of coke present on the particulate solids, and burning a supplemental fuel to heat the particulate solids. The particulate solids may then exit the particulate solids processing vessel 550 through the riser 530 and into the riser termination device 578 where the gas and particulate solids from the riser 530 are partially separated. The gas and residual particulate solids from the riser 530 are transported to the gas / solids separation device 520 in the particulate solids separation section 510 where the residual particulate solids are separated from the gas from the regeneration reaction. The particulate solids separated from the gas may reach the solid particle collection area 580, which may be structured as a plate grid distributor 100 of the chemical processing vessel 110 of the present disclosure (as further detailed in Figures 1-2). The separated particulate solids may then travel from the solid particle collection area 580 to the reaction vessel 450 where they are further utilized. Thus, the particulate solids may circulate between the reactor section 400 and the regenerator section 500.

[0033] The solid particle collection area 580 may also include an oxygen treatment zone. The oxygen treatment zone may be in fluid communication with the reactor section 450 (e.g., via the standpipe 324 and the transport riser 330) to supply treated catalyst from the catalyst treatment section 500 of the reactor system 300 back to the reactor section 400. The oxygen treatment zone may include an oxygen-containing gas inlet 328, such as the gas supply conduit 123 of the plate grid distributor 100 of the present disclosure, that may supply an oxygen-containing gas to the oxygen treatment zone for oxygen treatment of the catalyst.

[0034] Referring again to FIG. 1 , the present disclosure is also directed to a method of operating a chemical treatment vessel 110. The method may include delivering a fluid into the chemical treatment vessel 110 at reaction conditions through a gas supply conduit 123 below the plate grid distributor 100 and directing the fluid through the plate grid distributor 100 in the chemical treatment vessel 110. The plate grid distributor 100 may include a plate 100 having an upper surface 104 and a lower surface 106 opposite the upper surface that defines a thickness of the plate 100. The plate 100 may include a plurality of openings 130 extending through the thickness of the plate 100. The plate 100 may include a central opening 121B. The catalyst transport passage 121 may extend from the central opening 121B to the catalyst outlet 120 to form a passage from an area above the plate 100 to the catalyst outlet 120. The catalyst transport passage 121 and the plate 100 may be connected such that they form a unitary body. The catalyst transport passage 121 may have a larger cross-sectional area at the central opening 121B of the plate 100 than at the catalyst outlet 120. The method may include passing catalyst from above the plate 100, through the catalyst transport passage 121, and out of the chemical treatment vessel 110 through the catalyst outlet 120.

[0035] The chemical treatment vessel 110 may have any of the features discussed previously in this disclosure for the chemical treatment vessel 110. The plate grid distributor 100 may have any of the features discussed previously in this disclosure for the plate grid distributor 100. The catalyst transport passage 121 may have any of the features discussed previously in this disclosure for the catalyst transport passage 121.

[0036] One or more aspects of the disclosure are described herein. A first aspect may include a chemical processing vessel comprising a sidewall, a bed, a catalyst outlet through the bed, and a plate grid distributor for distributing fluid within the chemical processing vessel. The plate grid distributor may comprise a plate having an upper surface and a lower surface opposite the upper surface defining a thickness of the plate. The plate may comprise a plurality of openings extending through the thickness of the plate, the plate comprising a central opening. The catalyst transport passage may extend from the central opening to the catalyst outlet to form a passage from a region above the plate to the catalyst outlet. The catalyst transport passage and the plate may be connected such that they form a unitary body. The catalyst transport passage may have a larger cross-sectional area at the central opening of the plate than at the catalyst outlet.

[0037] A second aspect of the present disclosure may include the first aspect, wherein the plate is substantially planar.

[0038] A third aspect of the present disclosure may include any of the first or second aspects, wherein the plate has an average diameter of at least 5 feet (1.5 m) and not more than 75 feet (22.9 m).

[0039] A fourth aspect of the present disclosure may include any one of the first to third aspects, wherein the central opening is disposed in the center of the plate.

[0040] A fifth aspect of the present disclosure may include any one of the first to fourth aspects, wherein the central opening is 2 to 6 times larger than the catalyst outlet.

[0041] A sixth aspect of the present disclosure may include any one of the first to fifth aspects, wherein the central opening is 3.5 to 4.5 times larger than the catalyst outlet.

[0042] A seventh aspect of the present disclosure may include any one of the first to sixth aspects, further comprising an outer support extending downward from or near the outer periphery of the plate.

[0043] An eighth aspect of the present disclosure may include the seventh aspect, wherein the outer support is angled.

[0044] A ninth aspect of the present disclosure may include any one of the first to eighth aspects, wherein the plate and catalyst transport passage are operable to contain catalyst below the plate in the catalyst transport passage.

[0045] A tenth aspect of the present disclosure may include any one of the first to ninth aspects, in which the catalyst transport passage includes a fillet transition between the catalyst transport passage and the plate.

[0046] An eleventh aspect of the present disclosure may include any one of the first to tenth aspects, further comprising a fire-resistant material in direct contact with and covering substantially all of an upper surface of the plate.

[0047] A twelfth aspect of the present disclosure may include any one of the first to eleventh aspects, further comprising a fire-resistant material in direct contact with and covering substantially all of the inner surface of the catalyst transport passage.

[0048] A thirteenth aspect of the present disclosure may include any one of the first to twelfth aspects, further comprising a sparger in the catalyst transport passage operable to direct gas toward the catalyst outlet.

[0049] A fourteenth aspect of the present disclosure may include any one of the first to thirteenth aspects, wherein the plurality of openings includes an enclosure extending above the upper surface of the plate.

[0050] A fifteenth aspect of the present disclosure may include a method of operating a chemical processing vessel. The method may include delivering a fluid into the chemical processing vessel at reaction conditions through a gas supply conduit below a plate grid distributor and directing the fluid through a plate grid distributor in the chemical processing vessel. The plate grid distributor may include a plate having an upper surface and a lower surface opposite the upper surface and defining a thickness of the plate. The plate may include a plurality of openings extending through the thickness of the plate. The plate may include a central opening. The catalyst transport passage may extend from the central opening to the catalyst outlet to form a passage from a region above the plate to the catalyst outlet. The catalyst transport passage and the plate may be connected such that they form a unitary body. The catalyst transport passage may have a larger cross-sectional area at the central opening of the plate than at the catalyst outlet. The method may also include passing the catalyst from above the plate, through the catalyst transport passage, and out of the chemical processing vessel through the catalyst outlet.

[0051] Finally, it will be apparent to those skilled in the art that various modifications and variations can be made to the embodiments described herein without departing from the spirit and scope of the claimed subject matter. Accordingly, this specification is intended to cover such modifications and variations of the various embodiments described herein, provided such modifications and variations come within the scope of the appended claims and their equivalents.

Claims

1. A chemical treatment vessel comprising: a side wall, a floor, a catalyst outlet passing through the floor, and a plate grid distributor for distributing fluid within the chemical treatment vessel. The plate grid distributor comprises: a plate having an upper surface and a lower surface opposite the upper surface defining the thickness of the plate, the plate further comprising a plurality of openings extending through the thickness of the plate, the plate comprising a central opening, and a catalyst transport passage extending from the central opening to the catalyst outlet and forming a passage from a region above the plate to the catalyst outlet. The catalyst transport passage and the plate are connected such that the catalyst transport passage and the plate form a single unit, wherein the catalyst transport passage has a larger cross-sectional area at the central opening of the plate than at the catalyst outlet. A chemical treatment vessel.

2. The chemical treatment vessel according to claim 1, wherein the plate is substantially planar or dish-shaped.

3. The chemical treatment vessel according to claim 1, wherein the plate has an average diameter of 5 feet (1.5 m) or more and 75 feet (22.9 m) or less.

4. The chemical treatment vessel according to claim 1, wherein the central opening is disposed at the center of the plate.

5. The chemical treatment vessel according to claim 1, wherein the central opening is 2 to 6 times larger than the catalyst outlet.

6. The chemical treatment vessel according to claim 1, wherein the catalyst transport passage comprises a frustum of a cone.

7. The chemical treatment vessel according to claim 1, further comprising an outer support extending downward from the outer periphery of the plate or in the vicinity thereof.

8. The chemical treatment vessel according to claim 7, wherein the outer support is angled.

9. The chemical treatment vessel according to claim 1, wherein the plate and the catalyst transport passage are operable to contain catalyst below the plate within the catalyst transport passage.

10. The chemical treatment vessel according to claim 1, wherein the catalyst transport passage includes a rounded transition between the catalyst transport passage and the plate.

11. The chemical treatment vessel according to claim 1, further comprising a refractory material in direct contact with and covering substantially all of the upper surface of the plate.

12. The chemical treatment vessel according to claim 1, further comprising a refractory material in direct contact with and covering substantially all of the inner surface of the catalyst transport passage.

13. ​ ​ The chemical processing vessel according to claim 1, further comprising a sparger in the catalyst transport passage operable to direct gas toward the catalyst outlet.

14. The chemical processing vessel according to any one of claims 1 to 13, wherein the plurality of openings includes an enclosure extending above the upper surface of the plate.

15. A method of operating a chemical processing vessel, comprising: delivering a fluid to the chemical processing vessel under reaction conditions through a gas supply conduit below the plate grid distributor; directing the fluid through a plate grid distributor in the chemical processing vessel, wherein the plate grid distributor comprises: a plate having an upper surface and a lower surface opposite the upper surface that defines the thickness of the plate, the plate further comprising a plurality of openings extending through the thickness of the plate, the plate having a central opening; and a catalyst transport passage extending from the central opening to the catalyst outlet and forming a passage from a region above the plate to the catalyst outlet; wherein the catalyst transport passage and the plate are connected such that the catalyst transport passage and the plate form a single body, and the catalyst transport passage has a larger cross-sectional area at the central opening of the plate than at the catalyst outlet; and passing a catalyst from above the plate through the catalyst transport passage and out of the chemical processing vessel through the catalyst outlet. A method comprising: ​

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