Plate grid distributor and method of using same

Abstract

According to one or more embodiments, a plate grid distributor for distributing a fluid within a vessel or a plenum for removing a fluid from a vessel may comprise a plate and a skirt. The skirt may be in direct contact with the plate and may comprise a first portion and a second portion. The first portion may be in direct contact with the plate and the second portion may be in direct contact with the first portion. The first portion may have a first allowable stress and the second portion may have a second allowable stress. According to one or more other embodiments, a method of distributing a fluid through a plate grid distributor in a vessel may include passing a fluid into the vessel and directing the fluid through the plate grid distributor.

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 / 216778, filed June 30, 2021, and entitled “PLATE GRID DISTRIBUTORS AND METHODS OF USING THE SAME,” the entire contents of which are incorporated herein by reference.

[0002] FIELD OF THEINVENTION 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 fed to reactors or other vessels through distributors. Distributors can be utilized to facilitate balanced distribution of feed chemical streams to such reactors or vessels. Such feed chemical distribution can promote desirable reactions and maintain mass transfer equilibrium in chemical systems. However, mechanical loads on distributors can be challenging, especially when distributors are made larger and in high temperature environments. Summary of the Invention

[0004] In many chemical processes, chemical feed streams are delivered to a high temperature environment, such as a reactor or other vessel, through a plate grid distributor. In other chemical processes, fluids are removed from a high temperature environment, such as a reactor or other vessel, through a plenum. As the size of the reactor or vessel increases, such as when the plate grid distributor or plenum is at least 20 ft, additional mechanical supports may be required to help support the plate grid distributor. Furthermore, these high temperature environments may increase the temperature of the plate grid distributor, such as the plates of the plate grid distributor. As the temperature of the plate grid distributor may increase, the plates may thermally expand outward toward the outer wall of the reactor or other vessel. This is particularly problematic in some fluidized bed vessels where the high temperature environment may cause the plates of the plate grid distributor to thermally expand and contract. The thermal expansion and contraction of the plates, in turn, may create difficulties in supporting the plates of the plate grid distributor. Thus, there is a continuing need for improved plate grid distributors.

[0005] It has been found that a plate grid distributor with a skirt having multiple distinct portions can provide adequate support for the plates of the plate grid distributor while meeting the need to support the plates during thermal expansion and contraction of the plates. An embodiment of such a plate grid distributor is described herein. An embodiment of the present disclosure meets this need by utilizing a skirt having portions that have a relatively high allowable cost at the high temperatures found during the reaction, which allows the skirt to flex without breaking as the plate grid expands. This design incorporates such materials with high allowable stresses in certain portions of the skirt that observe mechanical stresses, while using other materials in areas that are less susceptible to the maximum stresses, thereby reducing material costs. Such concepts can also be applied to other internal structures within the reactor, such as plenums, as described herein.

[0006] According to one embodiment, a plate grid distributor for distributing a fluid within a vessel may comprise a plate and a skirt. The plate may comprise a top surface, a bottom surface opposite the top surface, and a plurality of openings extending from the top surface to the bottom surface. The skirt may be in direct contact with the bottom surface of the plate at or near the periphery of the plate. The skirt may extend substantially vertically from the plate to a floor of the vessel. The skirt may comprise a first portion and a second portion. The first portion may be in direct contact with the plate and may have a first allowable stress. The second portion may be located below the first portion, in direct contact with the first portion, and may extend downwardly to a floor of the vessel. The material of the second portion may have a second allowable stress. The first allowable stress may be 200 psi less than the second allowable stress at 1,400°F. The second allowable stress may be greater than 3,000 psi at 1,400°F.

[0007] According to another embodiment, a plenum for removing fluid from a vessel may comprise a plate and a skirt. The plate may comprise a top surface and a bottom surface opposite the top surface. The skirt may be in direct contact with the top surface of the plate at or near the periphery of the plate. The skirt may extend substantially vertically from the plate towards the top of the vessel. The skirt may comprise a first portion and a second portion. The first portion may be in direct contact with the plate. The material of the first portion may have a first allowable stress. The second portion may be located above the first portion and may be in direct contact with the first portion. The second portion may extend upward towards the top of the vessel. The material of the second portion may have a second allowable stress. The first allowable stress may be 200 psi less than the second allowable stress at 1,400°F. The second allowable stress may be greater than 3,000 psi at 1,400°F.

[0008] According to another embodiment, a method of distributing a fluid in a vessel may include passing a fluid into the vessel at reaction conditions through a gas supply conduit below a plate grid distributor and directing the fluid through the plate grid distributor in the vessel. The plate grid distributor may comprise a plate and a skirt. The plate may comprise a top surface, a bottom surface opposite the top surface, and a plurality of openings extending from the top surface to the bottom surface. The skirt may be in direct contact with the bottom surface of the plate at or near the periphery of the plate. The skirt may extend substantially vertically from the plate to a floor of the vessel. The skirt may comprise a first portion and a second portion. The first portion may be in direct contact with the plate. The material of the first portion may have a first allowable stress. The second portion may be located below the first portion and in direct contact with the first portion. The second portion may extend downwardly toward the floor of the vessel. The material of the second portion may have a second allowable stress. The first allowable stress may be 200 psi less than the second allowable stress at 1,400° F. The second allowable stress may be greater than 3,000 psi at 1,400° F. A temperature differential between the top surface of the plate and the floor of the vessel may be greater than or equal to 500° F.

[0009] Additional features and advantages are set forth in the following Detailed Description of the Invention, 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 the following Detailed Description of the Invention, and the claims.

[0010] 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]

[0011] [Figure 1] 1 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. FIG. [Diagram 2]FIG. 1 is a schematic diagram of a plate grid distributor and skirt in accordance with one or more embodiments of the present disclosure. [Diagram 3] FIG. 2 is a schematic diagram of a cross-sectional view of a vessel and a plenum in accordance with one or more embodiments of the present disclosure.

[0012] 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

[0013] The present disclosure is directed to plate grid distributors, plenums, and methods for using such, according to one or more embodiments described herein. Generally, the plate grid distributors and plenums described herein may comprise a plate and a skirt. The plate grid distributors described herein may be used to distribute fluids into a vessel. The plenums described herein may be used to remove fluids from the vessel. The vessel may comprise a gas supply conduit that may be distributed into the vessel by the plate grid distributor. The vessel may comprise a plenum outlet in the vessel that may remove fluids from the vessel. Generally, the plate distributors and plenums described herein comprise a skirt that may help support the plate. In some embodiments, such a skirt may be required to provide support around the plate. As the chemical process proceeds in the vessel, the plate may thermally expand due to the reaction conditions. The skirt may comprise a first portion and a second portion. As further described herein, the first portion and the second portion may flex as the plate thermally expands to continue to support the plate as the chemical process proceeds in the vessel at high temperatures.

[0014] 1, the plate grid distributor 100 of the present disclosure may be positioned within a vessel 110. The vessel 110 may have a variety of configurations. The vessel 110 may include one or more polyhedrons, spheres, cylinders, cones, irregular shapes, combinations thereof, and / or portions thereof. For example, the vessel 110 may include a straight hollow cylinder having a longitudinal axis. The vessel 110 may include a refractory-lined inner wall 112, an outer wall 114, a bed 116, a top 118, a catalyst supply conduit receiving passage 120, and a gas supply conduit receiving passage 122.

[0015] According to one or more embodiments, a plate grid distributor 100 for distributing a fluid within a 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 plate 102 may include an outer surface 108. The outer surface 108 may have a portion that is perpendicular to the top surface 104 and the bottom surface 106. The outer surface 108 may be welded to the top surface 104 and / or the bottom surface 106. The plate 102 may have an average diameter of 5 feet (1.5 m) or more and 75 feet (22.9 m) or less, such as 10 feet (3.0 meters (m)) or more and 50 feet (15.2 m) or less. The plate 102 may be substantially planar (i.e., the top surface 104 and the bottom surface 106 may be substantially parallel). However, in further embodiments, it is contemplated that the plate 102 may be non-planar.

[0016] The bottom surface 106, the top surface 104, or both of the plate 102 may be lined with refractory. 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 refractory lining, the insulating material, or both may help prevent the bottom surface 106 of the plate 102 from heating up.

[0017] The plate 102 may include a plurality of openings 130. Each of 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. The plurality of openings 130 may be flush with (i.e., do not extend farther than) the top surface 104 and / or the bottom surface 106. Alternatively, the plurality of openings 130 may extend beyond (i.e., downward) the bottom surface 106 and / or beyond (i.e., upward) the top surface 104. The plurality of openings 130 may include a lip that extends beyond the bottom surface 106, the top surface 104, or both. The second opening 134 may have a larger cross-sectional area than the first opening 132.

[0018] The first apertures 132 and the second apertures 134 of the plate 102 may have uniform or varying cross-sectional areas to help provide an even distribution of gas passing through each of the plurality of apertures 130. For example, the first apertures 132 closer to the gas supply conduit 123 may have a larger pressure differential between the bottom surface 106 and the top surface 104 of the plate 102. Thus, the first apertures 132 of the plate 102 closer to the gas supply conduit 123 may have a smaller cross-sectional area than the first apertures 132 further from the gas supply conduit 123 to help balance the pressure differential across the plate 102.

[0019] 1, the plate 102 may include a bottom surface 106 and an outer surface 108. The bottom surface 106 may include a plurality of apertures 130 formed by a first open portion 132 of the plate 102. The plurality of apertures 130 may be arranged around the catalyst supply conduit passage 136 in a geometric pattern. The geometric pattern may vary for various applications. For example, the plurality of apertures 130 may be arranged around the catalyst supply conduit passage 136 in a grid and / or concentric circles. The plate 102 may include 10-50 apertures 130 per square meter, such as 20-35 apertures 130 per square meter. Other numbers of apertures 130 per square meter are contemplated.

[0020] 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 0.63, 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 container 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 container 110 may be 0.008 to 0.163, for example, 0.026 to 0.067.

[0021] 1 and 2, the plate grid distributor 100 may include a skirt 150. The skirt 150 may attach and support the plate 102 to the vessel 110 at or near the floor 116 of the vessel 110. The skirt 150 may extend downwardly at or near the outer periphery of the plate 102. As used in this disclosure, the "outer periphery of the plate 102" may refer to the outermost 25% of the plate 102 (i.e., the portion closest to the refractory-lined inner wall 112), or near that area. The skirt 150 may extend substantially vertically from the plate 102 to the floor 116 of the vessel 110. As used in this disclosure, "substantially vertical" may refer to an angle of 45° or less (when at room temperature).

[0022] The skirt 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 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 surface 156 of the skirt 150. The outer surface 156 may be spaced apart from an inner surface 158 that defines a width of the skirt 150. The outer surface 156 may be spaced apart from the refractory-lined inner wall 112. In an embodiment, the skirt 150 may be sloped (i.e., not vertical).

[0023] The skirt 150 may comprise a first portion 160 and a second portion 162. The first portion 160 may be in direct contact with the plate 102, such as at or near the second end 154 of the skirt 150. The second portion 162 may be located below the first portion 160 and in direct contact with the first portion 160. The second portion 162 may extend downward toward the floor 116 of the vessel 110, such as to the first end 152 of the skirt 150. The first portion 160 and the second portion 162 may be attached to one another. The first portion 160 and the second portion 162 may be welded, brazed, soldered, or attached to one another, or may be attached using any other conventional or yet to be developed means.

[0024] The first and second portions 160, 162 of the skirt 150 may be substantially ring-shaped members. The first and second portions 160, 162 of the skirt 150 may follow the same shape as the refractory-lined inner wall 112, but may be hollow in the center to allow other components of the vessel 110 or plate grid distributor 100 to be positioned below the plates 102 and within the skirt 150.

[0025] The skirt 150 may include a third portion 164 positioned below the second portion 162. The third portion 164 may be in direct contact with or integral to the second portion 162 and the floor 116 of the vessel 110. The third portion 164 may be welded, brazed, soldered, or attached to the second portion 162, or may be attached using any other conventional or hereafter developed means. The third portion 164 may be a substantially ring-shaped member. The third portion 164 of the skirt 150 may follow the same shape as the refractory-lined inner wall 112, but may be hollow in the center to allow other components of the vessel 110 or the plate grid distributor 100 to be positioned below the plate 102 and within the skirt 150.

[0026] Generally, the temperature at or near the plate 102 may be much higher than the temperature at the bed 116, and large temperature differences are observed during operation of the reactor. Such temperature differences may allow the first portion 160 to expand outwardly under high temperatures, while the third portion 164 does not expand as much due to its lower temperature. This may result in bending of the skirt 150. Without being bound by theory, it is believed that the maximum stress on the skirt 150 as the first portion 160 expands is in the central region surrounding the second portion 160. Therefore, it may be desirable to utilize a material with a high allowable stress for the second portion compared to other portions of the skirt 150. However, such material may be very expensive, and therefore the material is utilized only in the second portion 158 where the stress is greatest.

[0027] The material of the first portion 160 may have a first allowable stress and the material of the second portion 162 may have a second allowable stress. As used in this disclosure, "allowable stress" refers to the maximum stress that can be safely applied to a structure or material. As used herein, the allowable stress of a particular material is documented by ASME Section 2 Part D, and the criteria used to determine the allowable stress in ASME Section 2 Part D may be applied to determine the allowable stress of a given material. As one skilled in the art would understand, allowable strength may be used interchangeably with allowable stress. Because the mechanical properties of a structure or material change with changes in temperature, allowable stress is generally measured at a particular temperature. For example, the allowable stress of a material may not be higher at a higher temperature than the allowable stress of the same material at room temperature. As described herein, it is understood that a material that cannot withstand any stress or is unstable at a particular temperature has an allowable stress of zero at that temperature.

[0028] In one or more embodiments, the second allowable stress may be greater than 3,000 psi at 1,400° F., such as greater than 3,050 psi, greater than 3,100 psi, greater than 3,150 psi, greater than 3,200 psi, greater than 3,250 psi, greater than 3,300 psi, greater than 3,350 psi, greater than 3,400 psi, greater than 3,450 psi, or greater than 3,500 psi at 1,400° F. 1,400° F. is selected because it may be close to the temperature of the atmosphere surrounding the plate 102. However, the apparatus described herein may be useful for reactors at different temperatures.

[0029] In one or more embodiments, the first allowable stress may be at least 200 psi less than the second allowable stress at 1,400°F, such as at least 250 psi less, at least 300 psi less, at least 350 psi less, at least 400 psi less, at least 450 psi less, or at least 500 psi less than the second allowable stress at 1,400°F.

[0030] The material of the third portion 164 may have a third allowable stress. The third allowable stress may be less than the first allowable stress. Additionally, the third allowable stress may be less than the second allowable stress. In an embodiment, the third allowable stress may be at least 200 psi less than the first allowable stress at 1,400°F, e.g., at least 250 psi less, at least 300 psi less, at least 350 psi less, at least 400 psi less, at least 450 psi less, or at least 500 psi less than the second allowable stress at 1,400°F. The third allowable stress may be at least 200 psi less than the second allowable stress at 1,400°F, e.g., at least 250 psi less, 300 psi less, 350 psi less, 400 psi less, 450 psi less, or 500 psi less than the second allowable stress at 1,400°F.

[0031] The materials of the portions of the skirt 150 may each have a respective coefficient of thermal expansion. The material of the second portion 162 may have a second coefficient of thermal expansion. The material of the third portion 164 may have a third coefficient of thermal expansion. In one or more embodiments, the coefficients of thermal expansion of the second portion 162 and the third portion 164 are relatively similar, such as within 50%, 40%, 30%, 20%, or even 10% of each other. For example, the coefficient of thermal expansion of the second portion 162 may be about 9.4 in / °F and the coefficient of thermal expansion of the third portion 164 may be about 8.1 in / °F. Similarity of these coefficients of thermal expansion may be desirable because distortion at relatively high temperatures during processing conditions may be reduced at the junction of the second portion 162 and the third portion 164.

[0032] In an embodiment, the material of the first portion 160 may be SAE 304H stainless steel. The material of the second portion 162 may be INCOLOY® 800HT®. INCOLOY® 800HT® is a nickel-iron-chromium alloy having a minimum iron content of 39.5%, a nickel content in the range of 30-35%, a chromium content in the range of 19-23%, an aluminum content in the range of 0.25-0.60%, a titanium content in the range of 0.25-0.60%, an aluminum and titanium content in the range of 0.85-1.20%, and a carbon content in the range of 0.06-0.10%. The material of the third portion 164 may be the same material as the shell (i.e., the outer wall 114) of the vessel 110. In an embodiment, the material of the third portion 164 may be carbon steel. Table I shows some properties of these materials. [Table 1]

[0033] Advantages of utilizing the materials disclosed herein for the second portion 162 include a relatively matched thermal expansion coefficient with the third portion 164, as well as relatively high allowable stresses at high temperatures. However, these materials are utilized only in portions of the system as described herein. Disadvantages of utilizing such materials include very high cost and increased issues in manufacturing and machinability. Additionally, nickel, present in some embodiments, may cause undesirable coking. Furthermore, adding an additional metal weld (compared to a comparative embodiment that does not include the second portion 162) is undesirable as it introduces a relative weakness. However, it has now been discovered in the embodiments described herein that the additional weakness introduced by the additional bimetal weld is overcome by the need for high temperature stability properties of the material of the second portion 162 due to the expansion of the plate under high operating temperatures. This is particularly important when utilizing large plate grids, such as those over 20 feet in diameter.

[0034] 1 , the 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 116 of the vessel 110. The 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 the longitudinal axis of the vessel 110.

[0035] The gas supply conduit 123 may be mounted flush with the refractory-lined inner wall 112 or may extend beyond the refractory-lined inner wall 112. The ratio of the inner diameter of the gas supply conduit 123 to the inner diameter of the vessel 110 may be between 0.06 and 0.77, for example between 0.20 and 0.23.

[0036] 1 , the vessel 110 may include a catalyst supply conduit 121. The catalyst supply conduit 121 may be connected to a catalyst supply conduit receiving passage 120 that extends through the bed 116 of the vessel 110. In an embodiment, the vessel 110 may include multiple catalyst supply conduits 121. The multiple catalyst supply conduits 121 may be connected to multiple catalyst supply conduit receiving passages 120. The multiple catalyst supply conduit receiving passages 120 may circumscribe a longitudinal axis of the vessel 110.

[0037] The catalyst supply conduit 121 may include a first end 121A and a second end 121B. The catalyst supply conduit 121A may extend through the refractory-lined inner wall 112 and the outer wall 114 of the vessel 110. The second end 121B may be positioned above the upper surface 104 of the plate 102. The catalyst supply conduit 121 may extend through the catalyst supply conduit receiving passage 120 and the catalyst supply conduit passage 136 such that the second end 121B extends beyond the upper surface 104 of the plate 102. The catalyst supply conduit cap 125 may be connected to the second end 121B by one or more connectors 127. The one or more connectors 127 may define a gap 129 through which catalyst can flow into the vessel 110. The ratio of the inner diameter of the catalyst supply conduit 121 to the inner diameter of the vessel 110 may be between 0.08 and 0.23, for example between 0.12 and 0.15.

[0038] 1, the plate grid distributor 100 may include a catalyst supply conduit housing 180. The catalyst supply conduit 121 may be slidably received within the catalyst supply conduit housing 180. The catalyst supply conduit 121 may be spaced from an inner surface 182 of the catalyst supply conduit housing 180. The catalyst supply conduit 121 may be slidably received within the catalyst supply conduit housing 180 to allow for expansion of the catalyst supply conduit 121. For example, the catalyst feed passing through the catalyst supply conduit 121 may be heated to cause the catalyst supply conduit 121 to expand in length and diameter. Thus, the catalyst supply conduit 121 may expand as compared to the vessel 110 where the catalyst supply conduit 121 is welded in place, which may cause the weld to crack.

[0039] The catalyst supply conduit housing 180 may have a first end 180A proximate the floor 116 of the vessel 110. The catalyst supply conduit housing 180 may have a second end 180B spaced from the floor 116 of the vessel 110 and proximate the top surface 104 of the plate 102. The catalyst supply conduit housing 180 may have an outer surface 181 spaced from an inner surface 182 of the catalyst supply conduit housing 180. The outer surface 181 of the catalyst supply conduit housing 180 may be connected to the inner periphery of the catalyst supply conduit passage 136 and the catalyst supply conduit receiving passage 120. The inner diameter of the top surface 104 and / or bottom surface 106 may be welded to and / or supported by the catalyst supply conduit housing 180.

[0040] A catalyst feed conduit insulating packing may be disposed between the catalyst feed conduit 121 and the inner surface 182 of the catalyst feed conduit housing 180. The catalyst feed conduit insulating packing may help maintain the temperature of the catalyst feed. For example, the temperature of the gas feed entering through the gas feed conduit 123 may be different than the temperature of the catalyst feed entering through the catalyst feed conduit 121. For example, when a particular reaction is being carried out in the vessel 110, the gas feed may enter through the gas feed conduit 123 at 25 degrees Celsius (°C) to 700°C, and the catalyst may enter the catalyst feed conduit 121 at 600°C to 900°C. As such, when the gas feed contacts the catalyst feed conduit 121, the catalyst feed conduit 121 may heat up to 600°C to 900°C as a result of the catalyst flowing through it, and the gas feed may begin to coke and clog the vessel 110 and / or the plate grid distributor 100.

[0041] In an embodiment, catalyst supply conduit 121 may include a catalyst backflow diverter 184. Catalyst backflow diverter 184 may be connected to catalyst supply conduit 121 proximate second end 121B of catalyst supply conduit 121 above upper surface 104 of plate 102. Catalyst backflow diverter 184 may extend from catalyst supply conduit 121 and extend beyond second end 180B of catalyst supply conduit housing 180. Catalyst backflow diverter 184 may reduce catalyst introduction into the catalyst supply conduit insulation packing.

[0042] 1 , the present disclosure is also directed to a method of distributing a fluid through a plate grid distributor 100 in a vessel 110. The method of distributing a fluid through a plate grid distributor 100 in a vessel 110 may include passing a fluid into the 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 within the vessel 110. The plate grid distributor 100 may include a plate 102 and a skirt 150.

[0043] The plate grid distributor 100, the plates 102, and the skirt 150 can have any of the features previously described in this disclosure with respect to the plate grid distributor 100, the plates 102, and the skirt 150, respectively.

[0044] During operation of the vessel 110, the floor 116 of the vessel 110 may be at a lower temperature than the upper portions of the vessel 110, such as the plates 102 of the plate grid distributor 100. In an embodiment, the floor 116 of the vessel 110 may be at a temperature in the range of 350° F. or more and 600° F. or less during operation. The plates 102 of the plate grid distributor 100 may be at a temperature in the range of 1,400° F. or more and 1,700° F. or less during operation. The temperature difference between the floor 116 of the vessel 110 and the plates 102 of the plate grid distributor 100 may be at least 100° F. during operation, such as at least 200° F., at least 300° F., or at least 400° F.

[0045] The plates 102 of the plate grid distributor 100 may have a greater coefficient of thermal expansion than the floor 116 of the vessel 110. Thus, due to the greater coefficient of thermal expansion and higher temperatures during operation, the amount of expansion in the plates 102 may be greater than the amount of expansion in the floor 116. The skirt 150 may flex to continue to support the plate grid distributor 100 as the plates 102 expand outward during operation.

[0046] 3, a plenum 300 for removing fluid from the vessel 110 may comprise a plate 302 and a skirt 350. The plate 302 may comprise a top surface 304 and a bottom surface 306 opposite the top surface 304. The skirt 350 may be in direct contact with the top surface 304 of the plate 302 at or near the periphery of the plate 302. The skirt 350 may extend substantially vertically from the plate 302 towards the top 118 of the vessel 110. The skirt 350 may comprise a first portion 360 and a second portion 362. The first portion 360 may be in direct contact with the plate 302. The material of the first portion 360 may have a first allowable stress. The second portion 362 may be located above the first portion 360 and may be in direct contact with the first portion 360. The second portion 362 may extend upwardly towards the top 118 of the vessel 110. The material of the second portion 362 may have a second allowable stress.

[0047] The plenum 300 of the present disclosure may be positioned within the vessel 110. The vessel 110 may have any of the features previously described for the vessel 110 in this disclosure.

[0048] According to one or more embodiments, a plenum 300 for removing fluid from a vessel 110 may include a plate 302. The plate 302 may include a top surface 304 and a bottom surface 306. The bottom surface 306 may be opposite the top surface 304 and may be spaced apart from the top surface 304. The plate 302 may include an outer surface 308. The outer surface 308 may have a portion that is perpendicular to the top surface 304 and the bottom surface 306. The outer surface 308 may be welded to the top surface 304 and / or the bottom surface 106. The plate 302 may have an average diameter of 5 feet (1.5 m) or more and 75 feet (22.9 m) or less, such as 10 feet (3.0 meters (m)) or more and 50 feet (15.2 m) or less. The plate 302 may be substantially planar (i.e., the top surface 304 and the bottom surface 306 may be substantially parallel). However, in further embodiments, it is contemplated that the plate 302 may be non-planar.

[0049] The plenum 300 may include a skirt 350. The skirt 350 may attach and support the plenum 300 to the vessel 110 at or near the top 118 of the vessel 110. The skirt 350 may extend upwardly at or near the outer periphery of the plenum 300. As used in this disclosure, the "outer periphery of the plenum 302" may refer to the outermost 25% of the plenum 300 (i.e., the portion closest to the refractory-lined interior wall 112), or near that area. The skirt 350 may extend substantially vertically from the plenum 300 toward the top 118 of the vessel 110. As used in this disclosure, "substantially vertical" may refer to an angle of 45 degrees or less.

[0050] The skirt 350 may include a first end 352 and a second end 354. The first end 352 may be connected to the top 118 of the vessel 110. The second end 354 may be connected to the plenum 300. The first end 352 and the second end 354 may be spaced apart from one another. A space between the first end 352 and the second end 354 may define an outer plane 356. The outer plane 356 may be spaced apart from an inner plane 358. The outer plane 356 may be spaced apart from the refractory-lined interior wall 112. The outer plane 356 may be connected to a portion of the inner plane 358 adjacent the second end 354 and spaced apart from the first end 352. In an embodiment, the skirt 350 may be sloped.

[0051] The skirt 350 may include a first portion 360 and a second portion 362. The first portion 360 may be in direct contact with the plenum 300, such as at the second end 354 of the skirt 350. The second portion 362 may be positioned above the first portion 360 and may be in direct contact with the first portion 360. The second portion 362 may extend upward toward the top 118 of the vessel 110, such as to the first end 352 of the skirt 350. The first portion 360 and the second portion 362 may be attached to one another. The first portion 360 and the second portion 362 may be welded, brazed, soldered, or attached to one another, or may be attached using any other conventional or yet to be developed means.

[0052] The first and second portions 360, 362 of the skirt 350 may be substantially ring-shaped members. The first and second portions 360, 362 of the skirt 350 may follow the same shape as the refractory-lined inner wall 112, but may be hollow in the center to allow other components of the vessel 110 or plenum 300 to be positioned above the plate 302 and within the skirt 350.

[0053] The skirt 350 may include a third portion 364 positioned above the second portion 362. The third portion 364 may be in direct contact with the second portion 362 and the top 118 of the vessel 110. The third portion 364 may be welded, brazed, soldered, or attached to the second portion 362, or may be attached using any other conventional or hereafter developed means. The third portion 364 may be a substantially ring-shaped member. The third portion 364 of the skirt 350 may follow the same shape as the refractory-lined inner wall 112, but may be hollow in the center to allow other components of the vessel 110 or plenum 300 to be positioned above the plate 302 and within the skirt 350.

[0054] The materials and operation of the plenum of Figure 3 may be similar to the plate distributor of Figure 1. For example, the temperature difference between the first end 352 and the second end 354 of Figure 3 may be similar to the temperature difference between the first end 152 and the second end 154 of Figure 1. Similarly, the materials of construction, allowable stresses, and other properties of the first portion 360, the second portion 362, and the third portion 364 of the embodiment of Figure 3 may be similar to the first portion 160, the second portion 162, and the third portion 164 of the embodiment of Figure 1. Thus, all features disclosed with respect to the first portion 160, the second portion 162, and the third portion 164 should be understood to be disclosed with respect to the first portion 360, the second portion 362, and the third portion 364.

[0055] The plenum 300 may be attached to a cyclonic separating apparatus 320. The cyclonic separating apparatus 320 may include at least one primary cyclone 321. The primary cyclone 321 may be housed within the vessel 110. The primary cyclone 321 may include a body 322, an inlet 323, an outlet 324, and a solids discharge dipleg 325. During operation, a flowing solids stream may enter the primary cyclone 321 through the inlet 323. In the primary cyclone 321, a majority of the entrained solids (e.g., catalyst particles) may be separated from the flowing solids stream. The separated solids may exit the primary cyclone 321 through the discharge dipleg 325. The primary cyclone effluent, including solids and fluids (e.g., gaseous products) not removed by the primary cyclone 321, may continue vertically upward through the primary cyclone 321. The primary cyclone effluent may pass vertically upward and exit the primary cyclone 321 through outlet 324 and flow through secondary cyclone inlet(s) 331 into one or more secondary cyclones 330. The one or more secondary cyclones may comprise a body 332, an outlet 333, and a solids discharge dipleg 334. The secondary cyclone 330 may further separate solids from the primary cyclone effluent. Solids separated in the secondary cyclone 330 may exit downwardly through the dipleg 334. The secondary cyclone outlet 333 is fluidly connected to the plenum 300.

[0056] The vessel 110 may also contain a riser 370. In operation, an unseparated flow of fluidized solid particles may enter the vessel 110 through the riser 370. The riser 370 may terminate at a plate 372. The riser 370 may be in fluid communication with (i.e., allow the passage of) an inlet of the primary cyclone 321 such that the unseparated flow of fluidized solid particles may pass from the riser 370 into the primary cyclone 321. If more than two cyclone stages are used, it is the effluent from the final cyclone stage that enters the second plenum. Although FIG. 3 shows only one primary cyclone 321 and one secondary cyclone 330, it will be understood that additional primary and secondary cyclones may be disposed around the riser. For example, the discharge tube 360 ​​may be connected to another secondary cyclone (not shown) that is in turn fed by either the primary cyclone 321 or another primary cyclone (not shown). For a further discussion of cyclone separating devices, see U.S. Patent No. 10,016,736 (B2) (Attorney Docket No. 75034-US-PCT / DOW 75034 PA).

[0057] During operation of the vessel 110, the top 118 of the vessel 110 may be at a lower temperature than lower portions of the vessel 110, such as the plates 302 of the plenum 300. In an embodiment, the top 118 of the vessel 110 may be at a temperature in the range of 350° F. to 600° F. during operation. The plates 302 of the plenum 300 may be at a temperature in the range of 1,400° F. or greater, such as 1,400° F. to 1,700° F. during operation. The temperature difference between the top of the vessel 110 and the plates 102 of the plenum 300 may be at least 100° F. during operation, such as at least 200° F., at least 300° F., or at least 400° F.

[0058] The plates 302 of the plenum 300 may have a greater coefficient of thermal expansion than the top 118 of the vessel 110. Thus, due to the greater coefficient of thermal expansion and higher temperatures during operation, the amount of expansion at the plates 302 may be greater than the amount of expansion at the top 118 of the vessel 110. As previously described in this disclosure, the skirt 350 may flex to continue to support the plenum 300 as the plates 302 expand outward during operation.

[0059] One or more aspects of the present disclosure are described herein. A first aspect may include a plate grid distributor for distributing a fluid in a vessel, the plate grid distributor comprising: a plate having a top surface, a bottom surface opposite the top surface, and a plurality of openings extending from the top surface to the bottom surface; a skirt in direct contact with the bottom surface of the plate at or near the periphery of the plate and extending substantially vertically from the plate to a floor of the vessel, the skirt having a first portion in direct contact with the plate, the first portion having a material with a first allowable stress; and a second portion located below the first portion, in direct contact with the first portion, and extending downwardly to the floor of the vessel, the second portion having a material with a second allowable stress, the second allowable stress being greater than 3000 psi at 1,400°F, and the second allowable stress being at least 200 psi greater than the first allowable stress at 1,400°F.

[0060] A second aspect may include a plenum for removing fluid from a vessel comprising: a plate having a top surface and a bottom surface opposite the top surface; and a skirt in direct contact with the top surface of the plate at or near the periphery of the plate and extending substantially vertically from the plate toward a top of the vessel, the skirt having a first portion in direct contact with the plate, the first portion having a first allowable stress; and a second portion located above the first portion, in direct contact with the first portion and extending upward toward the top of the vessel, the second portion having a second allowable stress, the second allowable stress being greater than 3000 psi at 1,400° F., the second allowable stress being at least 200 psi greater than the first allowable stress at 1,400° F.

[0061] Another embodiment includes any of the above embodiments, wherein the second allowable stress is greater than 3,200 psi at 1,400°F.

[0062] Another embodiment includes any of the above embodiments, wherein the second allowable stress is between 3350 psi and 3450 psi at 1,400°F.

[0063] Another embodiment includes any of the above embodiments, wherein the material of the first portion is SAE 304H stainless steel.

[0064] Another embodiment includes any of the above embodiments, wherein the material of the second portion is INCOLOY® 800HT®.

[0065] Another embodiment includes any of the above embodiments, wherein the skirt further comprises a third portion positioned below the second portion and in direct contact with the second portion and the floor of the vessel, wherein a material of the third portion has a third allowable stress, the third allowable stress being less than the first allowable stress at 1,400° F.

[0066] Another embodiment includes any of the above embodiments, wherein the third portion comprises a material that is the same material as the shell of the container.

[0067] Another embodiment includes any of the above embodiments, wherein the material of the third portion is carbon steel.

[0068] A third aspect is a method of distributing a fluid in a vessel comprising: passing a fluid at reaction conditions into the vessel through a gas supply conduit below a plate grid distributor; and directing the fluid through a plate grid distributor in the vessel, the plate grid distributor comprising a plate having a top surface, a bottom surface opposite the top surface, and a plurality of openings extending therethrough from the top surface to the bottom surface; and a skirt in direct contact with the bottom surface of the plate at or near a periphery of the plate and extending substantially perpendicularly from the plate to a floor of the vessel, the skirt being in direct contact with the plate. and a second portion located below and in direct contact with the first portion and extending downward toward a floor of the vessel, the second portion having a material having a second allowable stress, the first allowable stress being 200 psi less than the second allowable stress at 1,400°F and the second allowable stress being greater than 3000 psi at 1,400°F, and a temperature differential between the top surface of the plate and the floor of the vessel being 500°F or greater.

[0069] Another embodiment includes any of the above embodiments, wherein the temperature of the upper surface of the plate is 1,400° F. or greater.

[0070] Another embodiment includes any of the above embodiments, wherein the temperature at the bed of the vessel is greater than or equal to 350°F and less than or equal to 600°F.

[0071] Another embodiment includes any of the above embodiments, wherein the skirt further comprises a third portion in direct contact with the second portion and the floor of the vessel, wherein a material of the third portion has a third allowable stress, the third allowable stress being less than the first allowable stress at 1,400° F.

[0072] Another embodiment includes any of the above embodiments, wherein the first portion material is SAE 304 stainless steel and the second portion material is INCOLOY® 800HT®.

[0073] Another embodiment includes any of the above embodiments, wherein the material of the third portion is carbon steel.

[0074] 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 plate grid dispenser for distributing fluid within a container, a plate comprising a top surface, a bottom surface opposite the top surface, and a plurality of openings extending through from the top surface to the bottom surface; a skirt in direct contact with the bottom surface of the plate at or near the outer periphery of the plate and extending substantially perpendicular from the plate towards the floor of the container, the skirt having a first portion in direct contact with the plate, the material of the first portion having a first allowable stress; a second portion positioned below the first portion and in direct contact with the first portion, the second portion extending downwardly towards the floor of the container, the material of the second portion having a second allowable stress; wherein the second allowable stress is greater than 3000 psi at 1,400°F, and the second allowable stress is at least 200 psi greater than the first allowable stress at 1,400°F. Plate grid dispenser.

2. The plate grid dispenser according to claim 1, wherein the second allowable stress is greater than 3,200 psi at 1,400°F.

3. The plate grid dispenser according to claim 1, wherein the second allowable stress is 3350 psi to 3450 psi at 1,400°F.

4. The plate grid dispenser according to any one of claims 1 to 3, wherein the material of the first portion is SAE 304H stainless steel.

5. The plate grid dispenser according to any one of claims 1 to 3, wherein the material of the second portion is INCOLOY® 800HT®.

6. The skirt is positioned below the second portion and further includes a third portion that is in direct contact with the second portion and the floor of the container, the material of the third portion having a third allowable stress, the third allowable stress being less than the first allowable stress at 1,400°F, the plate grid distributor according to any one of claims 1 to 3.

7. The third portion includes a material that is the same as the material of the shell of the container, or the material of the third portion is carbon steel, or both, the plate grid distributor according to claim 6.

8. A plenum for removing fluid from a container, comprising a plate having a top surface and a bottom surface opposite the top surface, and a skirt in direct contact with the top surface of the plate at or near the outer periphery of the plate and extending substantially vertically upward from the plate toward the upper portion of the container, the skirt comprising a first portion in direct contact with the plate, the material of the first portion having a first allowable stress, and a second portion positioned above the first portion and in direct contact with the first portion and extending upwardly toward the upper portion of the container, the material of the second portion having a second allowable stress, the second allowable stress being greater than 3000 psi at 1,400°F, and the second allowable stress being at least 200 psi greater than the first allowable stress at 1,400°F, the plenum.

9. The second allowable stress is greater than 3,200 psi at 1,400°F, the plenum according to claim 8.

10. A method of distributing fluid within a container, comprising passing fluid through the gas supply conduit below the plate grid distributor to the container under reaction conditions, directing the fluid through a plate grid dispenser within the container, the plate grid dispenser comprising: a plate having a top surface, a bottom surface opposite the top surface, and a plurality of openings extending therethrough from the top surface to the bottom surface; a skirt in direct contact with the bottom surface of the plate at or near the outer periphery of the plate and extending substantially perpendicular from the plate toward the floor of the container, the skirt comprising: a first portion in direct contact with the plate, the material of the first portion having a first allowable stress; a second portion positioned below the first portion and in direct contact with the first portion, the second portion extending downwardly toward the floor of the container, the material of the second portion having a second allowable stress; wherein the first allowable stress is 200 psi less than the second allowable stress at 1,400°F; wherein the second allowable stress is greater than 3000 psi at 1,400°F; wherein the temperature difference between the top surface of the plate and the floor of the container is 500°F or greater. **Claim 11** The method of claim 10, wherein the temperature of the top surface of the plate is 1,400°F or greater. **Claim 12** The method of claim 10 or 11, wherein the temperature at the floor of the container is 350°F or greater and 600°F or less. **Claim 13** The method of claim 10 or 11, wherein the skirt further comprises a third portion in direct contact with the second portion and the floor of the container, the material of the third portion having a third allowable stress, and the third allowable stress is less than the first allowable stress at 1,400°F. **Claim 14** The method of claim 10 or 11, wherein the material of the first portion is SAE 304 stainless steel and the material of the second portion is INCOLOY® 800HT®. Claim 15 The method according to claim 13, wherein the material of the third portion is carbon steel.

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