MULTI-STAGE CONTACT PROCESS AND APPARATUS

Abstract

A method may include: introducing a fluid comprising a first immiscible phase and a second immiscible phase into a contact vessel comprising multiple contact stages; flowing the fluid through a first fiber bundle disposed in the contact vessel; separating at least a portion of the first immiscible phase from the second immiscible phase; and flowing the separated portion of the first immiscible phase through a second fiber bundle disposed in the contact vessel.

Description

MULTI-STAGE CONTACT PROCESS AND APPARATUS BACKGROUND OF THE INVENTION Chemical processes often require multiple unit operations to produce a particular product stream. A particular unit operation might be a fluid-fluid contact operation, in which two fluids are brought into intimate contact to promote mass transfer between the fluids, a reaction between components within the fluids, or both. An example of fluid-fluid contact is liquid-liquid contact. Liquid-liquid contact can be beneficial in some types of chemical reactions where a reactant is miscible in a first liquid but immiscible in a second liquid. An example of such a reaction might be where a first reactant is present in a polar solvent such as water and a second reactant is present in a nonpolar solvent such as a hydrocarbon, and water and the hydrocarbon are immiscible.Liquid-liquid contact can have several applications such as liquid-liquid extraction, whereby a species present in a first liquid is extracted into a second liquid by mass transfer through the liquid-liquid interface. A particular challenge of fluid-fluid contact can be ensuring an adequate contact area between the two fluids so that mass transfer or reactions can occur to a significant degree and in an economically viable manner. In general, fluid-fluid contact operations can be performed with immiscible fluids, such as, for example, an aqueous liquid and a hydrocarbon liquid. Using two immiscible fluids can allow the fluids to separate easily after fluid-fluid contact is complete. However, when a fluid-fluid contact operation is performed with immiscible fluids, phase separation can occur before adequate contact between the fluids is achieved. Several fluid-fluid contact vessels and techniques have been developed to increase the contact area between fluids in a fluid-fluid contact process, including, but not limited to, fiber bundle contactors. A fiber bundle contactor typically comprises one or more fiber bundles suspended within a housing and one or more inlets where fluids can be introduced into the housing. The fiber bundle promotes contact between the fluids by allowing a first fluid to flow along the individual fibers of the bundles and a second fluid to flow between the individual fibers, thereby increasing the effective contact area between the fluids. The two fluids can flow from an inlet section of the housing to an outlet section of the housing while maintaining intimate contact, so that reaction, mass transfer, or both can be sustained between the two fluids.There can be challenges in designing and operating fiber bundle contactors. Some fluid-fluid contactors may require large physical footprints to achieve adequate mass transfer between the fluid phases. Mass transfer between phases can be a function of surface area, and therefore increasing the surface area by making the fiber bundles larger or longer can also increase mass transfer between the fluids. Producing a physically larger fiber bundle not only increases the cost, but there may also be secondary considerations when the fiber bundle is larger. One consideration may be the pressure drop across the fluid-fluid contactor, which can increase with larger vessels and longer fiber bundles.Another consideration for larger fiber bundles is phase separation, whereby the relatively heavier, or denser, fluids may migrate toward the center of the bundle, while the relatively lighter, or less dense, fluid may migrate toward the outside. Similarly, in reaction applications, some reactions may require long residence times within a reactor to achieve adequate conversion, which may in turn necessitate larger fiber bundles. SUMMARY In one embodiment, the apparatus may comprise: a body; a first partition in the body defining a first flow path between the body and the first partition; a first fiber bundle arranged within the first flow path; a second partition in the body defining a second flow path between the first partition and the second partition; a third partition in the body defining a third flow path between the second partition and the third partition; and a second fiber bundle arranged within the third flow path.In another embodiment, a method may comprise: introducing a fluid comprising a first immiscible phase and a second immiscible phase into a contact vessel comprising multiple contact stages; flowing the fluid through a first fiber bundle disposed in the contact vessel; separating at least a portion of the first immiscible phase from the second immiscible phase; and flowing the separated portion of the first immiscible phase through a second fiber bundle disposed in the contact vessel.In another embodiment, a method may comprise: introducing a fluid comprising a hydrocarbon fluid and an aqueous fluid into a contact vessel; flowing the fluid through a first fiber bundle arranged in the contact vessel; separating a portion of the hydrocarbon from the fluid; combining the separated portion of the hydrocarbon with an additional amount of the aqueous solution to form a second fluid; and flowing the second fluid through a second fiber bundle arranged in the contact vessel. BRIEF DESCRIPTION OF THE DRAWINGS These drawings illustrate certain aspects of some of the modalities in this description, and should not be used to limit or define the description. Figure 1 is a schematic diagram illustrating one modality of a fluid-fluid mass transfer device. Figure 2 is a schematic diagram illustrating one modality of a contact vessel. Figure 3A is a schematic diagram illustrating a side profile view of one modality of a contact vessel. Figure 3B is a schematic diagram illustrating a cross-sectional view of one modality of a contact vessel. Figure 4A is a schematic diagram illustrating a side profile view of one modality of a contact vessel. Figure 4B is a schematic diagram illustrating a cross-sectional view of one modality of a contact vessel. Figure 4C is a schematic diagram illustrating a side profile view of one modality of a contact vessel. Figure 4D is a schematic diagram illustrating a side profile view of one modality of a contact vessel. Figure 5A is a schematic diagram illustrating a side profile view of one modality of a contact vessel. Figure 5B is a schematic diagram illustrating a top view of a perforated plate assembly. Figure 5C is a schematic diagram illustrating a side profile view of a perforated plate assembly. DETAILED DESCRIPTION The present description may relate to fluid-fluid mass transfer devices, and in some embodiments, to a multi-stage liquid-liquid mass transfer device or a multi-stage gas-liquid mass transfer device comprising multiple contact zones within a vessel. A fiber bundle may be arranged in each contact zone, providing non-dispersive phase contact between the fluids in the contact zone, which may offer certain advantages over dispersive mixing mass transfer devices. A multi-stage fluid-fluid mass transfer device may have a smaller physical footprint than a single-stage fluid-fluid mass transfer device that achieves the same mass transfer. Figure 1 schematically illustrates one embodiment of a fiber bundle mass transfer device 100. The fiber bundle mass transfer device 100 may comprise the vessel 106, which may contain and / or otherwise support the equipment and features necessary for fluid-fluid contact. As illustrated, the vessel 106 may comprise two sections 107a, 107b joined by a flange 114, which may provide a mounting point for securing the two sections 107a, 107b of the vessel 106 together. Alternatively, the vessel 106 may comprise a single continuous vessel (not shown) without a flange 114, or it may comprise a plurality of parts (not shown) joined by flanges or secured together in any other way. As illustrated, the fiber bundle mass transfer device 100 is oriented in a vertical direction.A person skilled in the art will appreciate that the fiber bundle mass transfer device 100 can be oriented in any direction, such as horizontally, vertically, or at any angle between them. The vessel 106 may comprise several inlets configured to allow fluids to enter the vessel 106. The vessel 106 may comprise a first inlet 110 and a second inlet 112, for example, which can allow fluids such as gases, liquids, and vapors to enter the vessel 106. Although only two inlets are illustrated, a person skilled in the art will understand that any number of inlets can be used for a particular application. The fiber bundle mass transfer device 100 may further include features that promote mixing and contact between the fluids introduced into the vessel 106.For example, the fiber bundle-type mass transfer device 100 may include a mixing zone 102 and a contact vessel 104. The mixing zone 102 may comprise various features such as fluid inlets and mechanical features that can promote fluid mixing and distribution before the fluids enter the contact vessel 104. The contact vessel 104 may comprise various features that can promote fluid-fluid contact to effect mass transfer, chemical reactions, or both between the fluids. ινΐΛ / a / zuzz / uuo ι oi In some embodiments, the contact vessel 104 may comprise one or more fiber bundles 108. Although only one fiber bundle 108 is illustrated, a person skilled in the art will appreciate that any number of fiber bundles may be present. Additionally, without limitation, the fiber bundles may be arranged in series, parallel, series and parallel, or any other configuration. The fiber bundle 108 may comprise elongated fibers extending from or below the mixing zone 102 through the contact vessel 104. The fiber bundle 108 may promote contact between the fluids introduced into the vessel 106 by allowing a first fluid to flow along the individual fibers of the fiber bundle 108 and a second fluid to flow between the individual fibers. In some embodiments, the fibers of the fiber bundle 108 may be metallic or non-metallic.Any suitable fibers may be used for fiber bundle 108, including, but not limited to, glass, fiberglass, rayon, nylon, polyesters, polyolefins, polytetrafluoroethylene, steel, aluminum, tungsten, nickel, and combinations thereof. In some embodiments, the fiber bundle may comprise metallic fibers. Each of the embodiments described herein can generally operate by the same physical phenomena. Two immiscible fluids can be individually introduced into the vessel 106 through the first inlet 110 and the second inlet 112 and flow through the mixing zone 102 into the contact vessel 104. In some embodiments, a first fluid introduced through the first inlet 110 may be relatively lighter, or less dense, than a second fluid introduced through the second inlet 112. Alternatively, a first fluid introduced through the first inlet 110 may be relatively heavier, or denser, than a second fluid introduced through the second inlet 112.As a person skilled in the art will appreciate, mixing the two fluids can increase the effective surface area of ​​the extraction zone 104, which in turn can reduce the required length of the extraction zone 104, decrease the pressure drop across the fiber bundle type mass transfer device 100, reduce material costs, reduce operating costs, and other benefits readily apparent to those skilled in the art. The fiber bundle mass transfer device 100 can be used to promote mass transfer in unit operations. In some embodiments, the fiber bundle mass transfer device 100 can be used in caustic treatment, amine treatment, or acid treatment processes, for example. Some other applications of the fiber bundle mass transfer device 100 may include liquid-liquid extraction, gas-liquid extraction, liquid-liquid reactions, and gas-liquid reactions, for example. Although only a few selected processes and fluids will be described herein, it will be readily apparent to those skilled in the art that there may be other potential applications for the fiber bundle mass transfer device 100 that are not described.A person skilled in the art, with the benefit of this description, should be able to adapt the fiber bundle type mass transfer device 100 to any number of applications not explicitly listed in the present description. In one embodiment, the Fiber Bundle Type 100 mass transfer device can be used in a caustic treatment application by introducing a hydrocarbon fluid and a caustic fluid into the device. The hydrocarbon fluid and the caustic fluid are then in contact, allowing impurities in the hydrocarbon fluid to react with the caustic fluid and reduce the amount of impurities in the hydrocarbon fluid. Some common impurities that can be removed include carbon dioxide, organic acids such as carboxylic acids, mercaptans (also known as thiols), as well as hydrogen sulfide, carbonyl sulfide, and other common sulfur impurities found in hydrocarbon fluids.The caustic fluid may comprise water and a caustic agent such as sodium hydroxide, potassium hydroxide, or other compounds that release a hydroxide ion when added to water. The caustic treatment process may be appropriate for treating any hydrocarbon fluid, including, but not limited to, hydrocarbons such as alkanes, alkenes, alkynes, and aromatics. The hydrocarbons may comprise hydrocarbons of any chain length, for example, from approximately C3 to approximately C30, or longer, and may comprise any amount of branching.Some illustrative hydrocarbon fluids may include, but are not limited to, crude oil, propane, LPG, butane, light naphtha, isomerate, heavy naphtha, reformate, jet fuel, kerosene, diesel oil, hydrotreated distillate, heavy vacuum gas oil, light vacuum gas oil, gas oil, coke gas oil, alkylates, gasolines, light cycle oils and combinations thereof. Another application of the fiber bundle mass transfer device 100 is in an amine treatment application. A hydrocarbon fluid and an amine fluid are introduced into the fiber bundle mass transfer device 100. The hydrocarbon fluid and the amine fluid are in contact so that impurities in the hydrocarbon feed react with the amine feed, reducing the amount of impurities in the hydrocarbon feed. The amine treatment can be used to remove contaminants that react with an amine, such as hydrogen sulfide and carbon dioxide. The hydrocarbon fluid can be any hydrocarbon feed as described previously.In an amine application, the amine fluid may comprise water, for example, and an amine such as diethanolamine, monoethanolamine, methyldiethanolamine, diisopropanolamine, aminoethoxyethanol, diglycolamine, and combinations thereof. As mentioned earlier, challenges can arise when designing and operating fiber-bundle contactors, such as the fiber-bundle mass transfer device 100 illustrated in Figure 1. As will be explained in detail below, one method to overcome some of these challenges with fiber-bundle contactors is to incorporate multiple fluid-fluid contact stages. Multiple fluid-fluid contact stages can increase the surface area of ​​contact between the fluids and thus enhance mass transfer between the fluid phases. Figures 2–5 illustrate contact vessel configurations with multiple fluid contact stages that can improve mass transfer in fiber-bundle contactors.Any of the contact vessels described in Figures 2-5 can be used as a standalone unit or incorporated into larger units, such as the fiber bundle-type mass transfer device 100. For example, any of the contact vessel modality described in Figures 2-5 can be used in conjunction with or instead of the contact vessel 104 in Figure 1. Figure 2 is a cross-sectional view of the contact vessel 200, which may include multiple fluid contact stages. In some examples, the contact vessel 200 may comprise a body 202, which may include partitions 204, 206, and 208 that can segregate various sections of the body 202. As illustrated, a first flow path 210 can be defined between the body 202 and partition 204, a second flow path 212 can be defined between partition 204 and partition 206, a third flow path 214 can be defined between partition 206 and partition 208, and a fourth flow path 234 can be defined between the body 202 and partition 208. A first fiber bundle 216 can be arranged within the first flow path 210, and a second fiber bundle 218 can be arranged within the third flow path 214.The fiber bundles may include any construction material, including, but not limited to, the materials described earlier in this description. The contact vessel 200 may further include the first inlet 220, the second inlet 222, the first outlet 224, and the second outlet 226, which may provide for mass flow into and out of the body 202. ινΐΛ / a / zuzz / uuo ι oi The Contact Vessel 200 can be used for various unit operations, including liquid-liquid extraction, gas-liquid extraction, liquid-liquid reactions, and gas-liquid reactions. Specific liquid-liquid extractions may include caustic treatment and amine treatment. Furthermore, the geometry of the Contact Vessel 200, including the positioning and number of partitions and fiber bundles, can be modified to adapt it to various requirements. Some more advanced geometries will be discussed in detail below. A fluid comprising two immiscible phases (the fluid) can be introduced into the vessel 202 through the first inlet 220. The two immiscible phases can include any of the fluids described above. For example, the immiscible phases can include a hydrocarbon fluid and an aqueous fluid that do not readily mix to form a homogeneous mixture. In some embodiments, the two immiscible phases can include a caustic fluid and a hydrocarbon fluid. The caustic fluid can comprise an aqueous caustic solution as described above. In some embodiments, the fluid comprising two immiscible fluids can comprise an amine fluid and a hydrocarbon fluid. The amine fluid can comprise an aqueous amine solution as described above.Although the fluids are described as immiscible, some mass transfer between them may occur, such that a portion of the first phase's mass disperses within the second phase's bulk. The two immiscible phases may have disparate densities, with the first phase considered the relatively less dense, or lighter, phase and the second phase considered the relatively denser, or heavier, phase. These disparate densities may cause the two immiscible fluids to spontaneously stratify into distinct phases upon settling. In some embodiments, the two immiscible phases may have similar densities, resulting in no clear boundary between them. However, such fluids can still be used in the embodiments described here, as additional forces may be present to drive phase separation.For example, disparate types of intermolecular forces and polarity can drive spontaneous phase separation. While the methods described herein can be applied to a fluid consisting of two immiscible phases, in some methods the fluid may contain more than two immiscible phases, such as three, four, or more. The fluid introduced into the contact vessel 200 through the first inlet 220 can be from any source, including from a mixing zone, such as mixing zone 102, as shown in Figure 1. Alternatively, the contact vessel 200 can be a self-contained unit, so that the fluid comprising the two immiscible fluids can be introduced directly into the contact vessel 200 without prior mixing. Furthermore, individual fluid phases can be introduced individually into the contact vessel 200 through one or more inlets to the contact vessel 200. After introducing the fluid into the contact vessel 200, the fluid can come into contact with the first fiber bundle 216 and begin to flow along the length of the fiber bundle 216. One phase of the fluid may be differentially attracted to the fibers of the first fiber bundle 216, which may cause the attracted fluid to flow at least partially along the individual fibers of the first fiber bundle 216. The fluid phase that is not differentially attracted may flow at least partially between the individual fibers of the first fiber bundle 216. Depending on the chemical identity of the components contained within the fluid phases, mass transfer or chemical reactions take place as the fluid moves through the first fiber bundle 216.In some examples, such as caustic treatment, hydroxide ions present in an aqueous phase can react with thiol-containing compounds in a hydrocarbon phase. A thiol-hydroxide reaction product may be more soluble in the aqueous phase than in the hydrocarbon phase, which can drive the reaction product to dissolve in the aqueous phase. Similarly, mass transfer between phases can occur in liquid-liquid extraction, gas-liquid extraction, liquid-liquid reactions, and gas-liquid reactions, for example. The fluid phases can traverse the length of the first fiber bundle 216 and separate into stratified layers at the interface 236. At the interface 236, the two immiscible phases can separate into two distinct phases such that the relatively less dense, or lighter, phase can form a fluid layer above the relatively denser, or heavier, phase. Density differences between the fluid phases can be the primary driving force for phase separation at the interface 236. Once the relatively lighter phase has separated from the relatively denser phase, the lighter phase can flow through the second flow path 212 as indicated by arrow 228. Typically, when the fluid introduced into the contact vessel 200 is a hydrocarbon / aqueous mixture, such as in caustic treatment, the less dense phase is the hydrocarbon portion of the mixture, and the denser phase is the aqueous portion.In these examples, the hydrocarbon phase can be separated at interface 236 and flow through the second flow path 212. ιнΐЛ / a / zuzz / uuo io / After flowing through the second flow path 212, the less dense phase can flow into the third flow path 214. Since the denser phase has separated at the interface 236, additional composition of the denser phase may be required to continue the unit operation. An additional denser compensating phase can be introduced through the second inlet 222 so that the additional denser composition phase and the lighter phase from the second flow path 212 can come into contact. The additional denser composition phase may have the same chemical identity as the denser phase introduced at the first inlet 220 or it may have a different chemical identity. The lighter phase from the second flow path 212 and the additional denser composition phase from the second inlet 222 can then flow into the third flow path 214 and come into contact with the second fiber bundle 218.Again, one of the phases can be differentially attracted to the fibers of the second fiber bundle 218, which can cause the attracted fluid to flow at least partially along the individual fibers of the second fiber bundle 218. The fluid phase that is not differentially attracted can flow at least partially between the individual fibers of the second fiber bundle 218. The contact between the phases in the first fiber bundle 216 can be considered a first contact stage. The contact between the phases in the second fiber bundle 218 can be considered a second contact stage. Although only two contact stages are illustrated in Figure 2, the number of contact stages can be extended to three, four, or even more stages. After the denser phase of additional composition and the lighter phase of the second flow path 212 have traversed a length of the second fiber bundle 218, the phases can separate again at the interface 230. Again, density differences, intermolecular forces, and polarity can drive spontaneous phase separation. A coalescer 232 can be arranged within the body 202 to promote the separation of the lighter and denser phases. The coalescer 232 can be any device that promotes the coalescence of dispersed droplets. Some non-limiting examples of suitable coalescers may include, but are not limited to, mechanical coalescers, coalescing pads, electrostatic coalescers, and combinations thereof.Once the phases are separated at interface 230, the relatively lighter phase can be extracted from the contact vessel 200 through the first outlet 224 and the relatively denser phase can be extracted from the contact vessel 200 through the second outlet 226. Figure 3A is a side profile view of another embodiment of a 300 contact vessel, and Figure 3B is a cross-sectional view of the 300 contact vessel. The 10 contact vessel 300 may include a plurality of nested conduits that can be placed within the contact vessel 300 so as to form flow channels between the plurality of nested conduits. The conduits may function as partitions to define flow channels as described above. The flow channels may define a plurality of contact stages through which fluids introduced into the contact vessel 300 may flow. As shown in Figures 3A and 3B, the contact vessel 300 may comprise body 302, first conduit 304, second conduit 306, and third conduit 308. Although only three conduits are shown in Figures 3A and 3B, any number of nested conduits may be used to achieve any arbitrary number of flow paths and contact stages.Body 302, first duct 304, second duct 306, and third duct 308 are illustrated in Figures 3A and 3B as circular ducts; however, body 302 and ducts 304, 306, and 308 can comprise any geometry. The first fiber bundle 310 can be arranged within the first conduit 304. The first fiber bundle 310 can be constructed of any suitable material, including those described earlier in this description. A fluid comprising two immiscible phases, such as the fluids described above, can be introduced into the contact vessel 300 through the first inlet 312. The fluid can enter the first flow path 322 and flow through the first conduit 304 along the first fiber bundle 310 until the fluid reaches the interface 314. As described above, the fluid phases can have different affinities for the fibers of the fiber bundle 310, which can cause one phase to flow at least partially along the individual fibers and the second phase to flow at least partially between the individual fibers. The interface 314 can comprise stratified layers of the two fluid phases.As discussed previously, the two immiscible fluid phases can spontaneously separate into two distinct phases after passing through a fiber bundle due to differences in density, polarity, intermolecular forces, or any combination thereof. The relatively lighter fluid phase can flow into the second flow path 316 defined between duct 304 and duct 306, as indicated by arrow 328. After flowing through the second flow path 316, the less dense phase can flow into the third flow path 318, defined between conduit 306 and conduit 308. Since the denser phase has separated at the interface 314, additional denser phase composition may be required to continue the unit operation. A denser phase of additional composition can be introduced through the second inlet 330, and this additional denser phase and the lighter phase in the second flow path 316 can come into contact. The additional denser phase composition may have the same chemical identity as the denser phase introduced at the first inlet 312 or it may have a different chemical identity.The lighter phase of the second flow path 316 and the denser phase of additional composition from the second inlet 330 can flow into the third flow path 318 and come into contact with the second fiber bundle 332. Again, one of the phases can be differentially attracted to the fibers of the second fiber bundle 332, which can cause the attracted fluid to flow at least partially along the individual fibers of the second fiber bundle 332. The fluid phase that is not differentially attracted can flow at least partially between the individual fibers of the second fiber bundle 332. The contact between the phases in the first fiber bundle 310 can be considered a first contact stage. The contact between the phases in the second fiber bundle 332 can be considered a second contact stage.Although only two contact stages are illustrated in Figures 3A and 3B, the number of contact stages can be extended to three, four, or even more stages by incorporating additional ducts and fiber bundles. After the denser phase of additional composition and the lighter phase of the second flow path 316 have traversed a length of the second fiber bundle 332, the phases can be separated again at the interface 334. A coalescer 340 can be arranged within the body 302 to promote the separation of the lighter and denser phases. The coalescer 340 can include any of the coalescers discussed previously. Again, density differences, intermolecular forces, and polarity can drive the spontaneous separation of the phases. Once the phases are separated at the interface 334, the relatively lighter phase can be extracted from the contact vessel 300 through the first outlet 336, and the relatively denser phase can be extracted from the contact vessel 300 through the second outlet 338. Figure 4A is a side profile view of another embodiment of a contact vessel 400, and Figure 4B is a cross-sectional view of the contact vessel 400. The contact vessel 400 may include the body 402 and a series of partitions that define interconnected flow paths. With reference to Figure 4B, the body 402 includes a first partition 404 and a second partition 406 disposed within the body 402 and arranged such that the first flow path 408, the second flow path 410, the third flow path 412, and the fourth flow path 414 are defined within the body 402. Although only two partitions defining four independent flow paths are illustrated in Figure 4B, any number of partitions and corresponding flow paths may be defined within the body. 402. For example, body 402 may comprise a single partition and two flow paths. Alternatively, body 402 may comprise three, four, five, six, or more partitions and the corresponding number of flow paths for each number of partitions. The first partition 404 and the second partition 406 may be arranged so that the flow paths defined between them are seamlessly connected. With reference to Figure 4A, a side profile view of the contact vessel is illustrated, showing the partition 406 arranged within the body 402, which defines the flow path 408 and the flow path 410. As in the previous embodiments described herein, a first fiber bundle 416 can be arranged within the first flow path 408. The first fiber bundle 416 can be constructed of any suitable material, including those described earlier herein. A fluid comprising two immiscible phases, such as the fluids described above, can be introduced into the contact vessel 400 through the first inlet 418. The fluid can be made contact with the first fiber bundle 416 and flow through the first flow path 408 until the fluid reaches the interface 428.As described above, the fluid phases may have different affinities for the fibers of the fiber bundle 416, which can cause one phase to flow at least partially along the individual fibers and the second phase to flow at least partially between the individual fibers. The interface 428 may comprise stratified layers of the two fluid phases. As discussed above, the two immiscible fluid phases may spontaneously separate into two distinct phases after passing through a fiber bundle due to differences in density, polarity, intermolecular forces, or any combination thereof. The relatively lighter fluid phase may flow into the second flow path 410, as indicated by arrow 420. Figure 4C is a second side profile view of the contact vessel 400 showing the second flow path 410 and the third flow path 412. The relatively lighter phase of the fluid separated at the interface 428 can flow through the second flow channel 410, as indicated by arrow 420, and into the third flow path 412, as indicated by arrow 422. Since the denser phase has been separated at the interface 428, additional denser phase composition may be required to continue the unit operation. A denser phase of additional composition can be introduced through the second inlet 424, and the denser phase of additional composition and the lighter phase in the second flow path 410 can come into contact. The denser phase of additional composition may have the same chemical identity as the denser phase introduced at the first inlet 418 or it may have a different chemical identity.The lighter phase from the second flow path 410 and the denser phase of additional composition from the second inlet 424 can flow into the third flow path 412 and come into contact with the second fiber bundle 426. Again, one of the phases can be differentially attracted to the fibers of the second fiber bundle 426, which can cause the attracted fluid to flow at least partially along the individual fibers of the second fiber bundle 426. The fluid phase that is not differentially attracted can flow at least partially between the individual fibers of the second fiber bundle 426. The contact between the phases in the first fiber bundle 416 can be considered a first contact stage. The contact between the phases in the second fiber bundle 426 can be considered a second contact stage.After flowing through the third flow path 412, the fluid can leave the second fiber bundle 426 and separate as described above at interface 438. Figure 4D is a third side profile view of the contact vessel 400 showing the third flow path 412 and the fourth flow path 414. After the fluid has flowed through the third flow path and separated at the interface 438 as described with reference to Figure 4C, the relatively lighter phase can flow through the fourth flow path 414 as indicated by arrow 430. In some embodiments, the fourth flow path 414 and the first flow path 408 can be fluidically connected so that the relatively lighter phase separated at the interface 438 can be “recycled” by a pump back to the first flow path 408 for further contact to further advance mass transfer and / or reactions between the fluid phases.Alternatively, the relatively lighter phase separated at interface 438 can be extracted from contact vessel 400 via outlet 432 and the relatively heavier phase can be extracted via outlet 440. Figure 5A is a side profile view of another embodiment of a contact vessel 500. The contact vessel 500 may comprise the body 502 and a series of conduits that can define interconnected flow paths within the body 502. The conduits can function as partitions to define flow paths as described above. A first flow path 526 can be defined between the first conduit 504 and the body 502. A second flow path 528 can be defined between the first conduit 504 and the second conduit 506. A third flow path 530 can be defined as the interior of the conduit 506. A first fiber bundle 508a can be arranged within the first flow path 526, a second fiber bundle 508b can be arranged within the second flow path 528, and a third fiber bundle 530 can be arranged within the second flow path 528. 508c can be arranged within the third flow path 530. Although represented as individual fiber bundles, in some embodiments, fiber bundles 508a, 508b, and 508c may comprise a fiber bundle spanning the first flow path 526, the second flow path 528, and the third flow path 530. While only two ducts are represented in Figure 5A, in the embodiments, there may be any arbitrary number of ducts and corresponding flow paths, as well as any number of fiber bundles arranged therein. Figure 5A further illustrates a mixing zone 540 such that a fluid comprising two immiscible phases, such as the fluids described above, can be introduced, such as through inlets into the mixing zone 540, and brought into contact. As depicted in Figure 5A, the fluid can be stratified into distinct layers or phases as represented by the interface 512. At the interface 512, the relatively less dense phase can float on top of the relatively denser phase. The contact vessel 500 can further comprise a perforated plate assembly 524, which can include a plate 534 comprising perforations 525. The relatively denser fluid phase can flow into the second flow path 528 and the third flow path 530 through the perforations 525.The downpipe 532 can be arranged in the perforated plate assembly 524, which can provide fluid communication between the mixing zone 540 and the first flow path 526. A cap 514 can be attached to the downpipe 532, which can direct the fluid to an interior of the downpipe 532. We will now refer to Figure 5B and Figure 5C. Figure 5B illustrates a top view of the perforated plate assembly 524. The perforated plate assembly 524 may comprise a plate 534 and a plurality of perforations 525 arranged in the plate 534 to provide fluid communication through the plate 534. Additionally, Figure 5B illustrates a plurality of caps 514. As mentioned above, the cap 514 may direct flow to the downpipe 532. Figure 5C is a side profile view of the perforated plate assembly 524. As illustrated, the plate 534 may comprise the perforation 525 and the downpipe 532 arranged in the plate 534. The downpipe 532 may be arranged in the perforation 525 to allow fluid communication through the downpipe 532 and the perforation 525. The cap 514 may be arranged in the downpipe 532.Cap 514 may comprise perforations 533 so that fluids may flow into an interior of downpipe 532 through the perforations 533. With further reference to Figure 5A, fluids introduced into the mixing zone 540 can flow into the first flow path 526 by passing through the perforation 525 (illustrated in 15 MA / a / ZUZZ / UUO l O l Figure 5C) or through the downpipe 532. The fluid flowing into flow path 526 may include the relatively less dense phase, the relatively denser phase, or a combination of both. The fluid may come into contact with the first fiber bundle 508a and flow through the first flow path 526 until the fluid reaches the interface 510. As described above, the fluid phases may have different affinities for the fibers of the fiber bundle 508a, which may cause one phase to flow at least partially along the individual fibers and the second phase to flow at least partially between the individual fibers. The interface 510 may comprise stratified layers of the two fluid phases.As discussed previously, the two immiscible fluid phases can spontaneously separate into two distinct phases after passing through a fiber bundle due to differences in density, polarity, intermolecular forces, or any combination thereof. The relatively lighter fluid phase can flow into the second flow path 528, as indicated by arrow 536, and the relatively denser phase separated at the interface 510 can flow into the third flow path 530, as indicated by arrow 538. The relatively lighter phase separated at the interface 510 can flow through the second fiber bundle 508b within the second flow channel 528 into the perforated plate assembly 524. After the relatively less dense phase has flowed through the second flow path 526, it can mix with fluid from the additional, relatively denser phase flowing into the second flow path 528 and the third flow path 530 through the perforations 525. The relatively less dense phase can then mix with the fresh, relatively denser phase provided by the perforations 525 and flow into the third flow path 530, as indicated by arrow 550. The fluid comprising the relatively less dense phase from the interface 510 and the additional, relatively denser phase can contact the third fiber bundle 508c and flow through the third flow path 530 until it reaches the interface 518. At the interface 518, the phases can again stratify into distinct layers.A coalescer 516 can promote the coalescence of entrained droplets to form stratified phase layers. The relatively lighter phase can be drawn off through the first outlet 520, and the relatively denser phase can be drawn off through the second outlet 522. While some of the embodiments described herein have been discussed in view of liquid-liquid applications, any of the above embodiments, including those described in Figures 1, 2, 3A, 3B, 4A, 4B, 4C, 4D, 5A, 5B, or 5C, may be used in gas-liquid applications where the relatively less dense phase is a gas or vapor and the relatively denser phase is a liquid. Furthermore, any of the above embodiments may be used in reaction applications such that a chemical reaction occurs between the liquids in liquid-liquid applications or between the gas and the liquid in gas-liquid applications. In catalyst applications, the fiber bundles may include a catalyst impregnated or otherwise bonded to the fibers of the fiber bundles. Examples of catalysts may include, but are not limited to, those containing nickel, cobalt, iron, and other transition metals.Some reactions can be carried out at temperatures ranging from approximately 0-1204 °C (0-2200 °F) and 0-2000 psig. Some specific reactions and applications may include bioreactors, steam methane reforming, hydrocarbon upgrading reactions, alkylation, hydrotreating, and homogeneous catalysis reactions, for example. Accordingly, this description may provide methods, systems, and apparatus that may relate to fluid-fluid contact. The methods, systems, and apparatus may include any of the various features described herein, including one or more of the following statements. Declaration 1. An apparatus comprising: a body; a first partition in the body defining a first flow path between the body and the first partition; a first fiber bundle arranged within the first flow path; a second partition in the body defining a second flow path between the first partition and the second partition; a third partition in the body defining a third flow path between the second partition and the third partition; and a second fiber bundle arranged within the third flow path. Declaration 2. The fiber bundle contactor of declaration 1 wherein the vessel further comprises a first fluid communication inlet with the first flow path. Declaration 3. The fiber bundle contactor of any of declarations 1-2 wherein the vessel further comprises a second fluid inlet in communication with the second flow path. Statement 4. The fiber bundle contactor of any of statements 1-3 wherein the first flow path and the second flow path are in fluid communication, and wherein the second flow path and the third flow path are in fluid communication. Statement 5. The fiber bundle contactor of any of statements 1-4, wherein a fourth flow path is defined between the body and the third partition, and wherein a coalescer is disposed within the fourth flow path. Declaration 6. The fiber bundle contactor of any of Declarations 1-5 further comprising a perforated plate assembly comprising a plate, a plurality of openings in the plate, and a plurality of downpipes extending from the plate and arranged to permit fluid flow through additional openings in the plate. Statement 7. The fiber bundle contactor of any of statements 1-6 wherein the fiber bundles comprise a catalyst. Declaration 8. A method comprising: introducing a fluid comprising a first immiscible phase and a second immiscible phase into a contact vessel comprising multiple contact stages; flowing the fluid through a first fiber bundle disposed in the contact vessel; separating at least a portion of the first immiscible phase from the second immiscible phase; and flowing the separated portion of the first immiscible phase through a second fiber bundle disposed in the contact vessel. Statement 9. The method of statement 8 wherein the contact vessel comprises a series of nested conduits and a plurality of flow paths between the series of nested conduits. Statement 10. The method of any of statements 8-9 wherein the first immiscible phase comprises a hydrocarbon fluid and wherein the second immiscible phase comprises an aqueous fluid. Statement 11. The method of any of statements 8-10 wherein the aqueous fluid comprises at least one element selected from the group consisting of an amine, a hydroxide, a homogeneous catalyst, a bacterium, an enzyme, and combinations thereof. Statement 12. The method of any of statements 8-11 wherein the separation step comprises settling the fluid and forming stratified layers of the first immiscible phase and the second immiscible phase. Statement 13. The method of any of statements 8-12 further comprising mixing the separated portion of the first immiscible phase with an additional second immiscible phase prior to the step of flowing the separated portion of the first immiscible phase through a second fiber bundle. Statement 14. The method of any of statements 8-13 further comprising contacting the separated portion of the first immiscible phase with a coalescer after the step of flowing the separated portion of the first immiscible phase through the second fiber bundle. Statement 15. The method of any of statements 8-14 wherein at least one of the first fiber bundle, the second fiber bundle, or both comprise a catalyst, and wherein the method further comprises contacting at least one of the first immiscible phase, the second immiscible phase, or both with the catalyst, thereby catalyzing a reaction between at least one chemical species present in at least one of the first immiscible phase, the second immiscible phase, or both. Declaration 16. A method comprising: introducing a fluid comprising a hydrocarbon fluid and an aqueous fluid into a contact vessel; flowing the fluid through a first fiber bundle disposed in the contact vessel; separating a portion of the hydrocarbon from the fluid; combining the separated portion of the hydrocarbon with an additional amount of the aqueous solution to form a second fluid; and flowing the second fluid through a second fiber bundle disposed in the contact vessel. Statement 17. The method of statement 16 wherein the aqueous fluid comprises a hydroxide. Statement 18. The method of any of statements 16-17 wherein the aqueous fluid comprises at least one element selected from the group consisting of an amine, a homogeneous catalyst, a bacterium, an enzyme, and combinations thereof. Statement 19. The method of any of statements 16-18 further comprising separating a second portion of the hydrocarbon fluid from the second fluid, combining the second portion of the hydrocarbon fluid with an additional amount of the aqueous fluid to form a third fluid, and flowing the third fluid through a third fiber bundle disposed in the contact vessel. Statement 20. The method of any of statements 16-19 wherein at least one of the first fiber bundle, the second fiber bundle, or both comprise a catalyst. Therefore, the present description is well suited to achieve the aforementioned purposes and advantages, as well as those inherent therein. The particular embodiments described above are merely illustrative, as the present description may be modified and implemented in different but equivalent ways that are obvious to those skilled in the art who benefit from the teachings of the present description. Although individual embodiments are discussed, the description covers all combinations thereof. Furthermore, it is not intended to limit the details of construction or design shown in the present description, other than as described in the claims below. Moreover, the terms in the claims have their plain, ordinary meaning unless explicitly defined otherwise by the patent holder.Therefore, it is evident that the specific illustrative methods described above may be altered or modified, and all such variations are considered within the scope and spirit of this description. If there is any conflict in the uses of a word or term in this description and one or more patents or other documents that may be incorporated herein by reference, the definitions consistent with this description shall be adopted.

Claims

1. An apparatus comprising: a body; a first partition in the body defining a first flow path between the body and the first partition; a first fiber bundle arranged within the first flow path; a second partition in the body defining a second flow path between the first partition and the second partition; a third partition in the body defining a third flow path between the second partition and the third partition; and a second fiber bundle arranged within the third flow path.

2. The fiber bundle contactor of claim 1, wherein the container further comprises a first fluid inlet in communication with the first flow path.

3. The fiber bundle contactor of claim 1, wherein the container further comprises a second fluid inlet in communication with the second flow path.

4. The fiber bundle contactor of claim 1, wherein the first flow path and the second flow path are in fluid communication, and wherein the second flow path and the third flow path are in fluid communication.

5. The fiber bundle contactor of claim 1, wherein a fourth flow path is defined between the body and the third partition, and wherein a coalescer is disposed within the fourth flow path.

6. The fiber bundle contactor of claim 1, further comprising a perforated plate assembly comprising a plate, a plurality of openings in the plate, and a plurality of downpipes extending from the plate and arranged to allow fluid flow through additional openings in the plate.

7. The fiber bundle contactor of claim 1, wherein the fiber bundles comprise a catalyst.

8. A method comprising: introducing a fluid comprising a first immiscible phase and a second immiscible phase into a contact vessel comprising multiple contact stages; flowing the fluid through a first fiber bundle arranged in the contact vessel; separating at least a portion of the first immiscible phase from the second immiscible phase; and flowing the separated portion of the first immiscible phase through a second fiber bundle arranged in the contact vessel.

9. The method of claim 8, wherein the contact vessel comprises a series of nested conduits and a plurality of flow paths between the series of nested conduits.

10. The method of claim 8, wherein the first immiscible phase comprises a hydrocarbon fluid, and wherein the second immiscible phase comprises an aqueous fluid.

11. The method of claim 10, wherein the aqueous fluid comprises at least one element selected from the group consisting of an amine, a hydroxide, a homogeneous catalyst, a bacterium, an enzyme, and combinations thereof.

12. The method of claim 8, wherein the separation step comprises settling the fluid and forming stratified layers of the first immiscible phase and the second immiscible phase.

13. The method of claim 8, further comprising mixing the separated portion of the first immiscible phase with an additional second immiscible phase prior to the step of flowing the separated portion of the first immiscible phase through a second fiber bundle.

14. The method of claim 8, further comprising contacting the separated portion of the first immiscible phase with a coalescer after the step of flowing the separated portion of the first immiscible phase through the second fiber bundle.

15. The method of claim 8, wherein at least one of the first fiber bundle, the second fiber bundle, or both comprise a catalyst, and wherein the method further comprises contacting at least one of the first immiscible phase, the second immiscible phase, or both with the catalyst, thereby catalyzing a reaction between at least one chemical species present in at least one of the first immiscible phase, the second immiscible phase, or both.

16. A method comprising: introducing a fluid comprising a hydrocarbon fluid and an aqueous fluid into a contact vessel; flowing the fluid through a first fiber bundle disposed in the contact vessel; separating a portion of the hydrocarbon from the fluid; combining the separated portion of the hydrocarbon with an additional amount of the aqueous solution to form a second fluid; and flowing the second fluid through a second fiber bundle disposed in the contact vessel.

17. The method of claim 16, wherein the aqueous fluid comprises a hydroxide.

18. The method of claim 16, wherein the aqueous fluid comprises at least one element selected from the group consisting of an amine, a homogeneous catalyst, a bacterium, an enzyme, and combinations thereof.

19. The method of claim 16, further comprising separating a second portion of the hydrocarbon fluid from the second fluid, combining the second portion of the hydrocarbon fluid with an additional amount of the aqueous fluid to form a third fluid, and flowing the third fluid through a third fiber bundle arranged in the contact vessel.

20. The method of claim 16, wherein at least one of the first fiber bundle, the second fiber bundle, or both comprise a catalyst.

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