Chemical processing vessels that include beams and attachment rails, and methods of using the same

Abstract

Disclosed herein are chemical processing vessels and methods for the use thereof. A chemical processing vessel may include one or more side walls defining a main interior space, an I-beam positioned within the main interior space, and a bubble breaker positioned in a horizontal plane. The I-beam may include a web, a lower flange, and an upper flange. A plurality of attachment rails may extend from the web of the I-beam. At least a portion of the plurality of attachment rails may be in contact with the bubble breaker and may support the bubble breaker. A gap in the horizontal direction may exist between the lower flange of the I-beam and the bubble breaker. The plurality of attachment rails may span the gap between the lower flange of the I-beam and the bubble breaker, which may overlap with the bubble breaker in the horizontal direction.

Description

CHEMICAL PROCESSING VESSELS THAT INCLUDE BEAMS AND ATTACHMENT RAILS, AND METHODS OF USING THE SAMECROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application Serial No. 63 / 665,541 filed June 28, 2024, the contents of which are incorporated in their entirety herein.FIELD

[0002] The embodiments described herein generally relate to chemical processing and, more particularly, to equipment utilized in chemical processing.BACKGROUND

[0003] Reactor vessels may include mechanical components that are housed within the vessels, commonly referred to as “internals” in industry. For example, in fluidized bed reactors, bubble breakers such as gratings may be utilized as internals, which aid in breaking bubbles that form in the solid particulate fluidized bed. Such internals must be adequately mechanically supported within the vessels, which can be challenging due to the fact that internals may be heavy and large, and that internals may significantly thermally expand during exposure to normal chemical processing temperatures.SUMMARY

[0004] Described herein are chemical processing vessels, and methods for their use, that include at least an I-beam, a bubble breaker (such as a grating, chevron, or structured packing), and a plurality of attachment rails. The attachment rails allow for a gap between the I-beam and the bubble breaker, which is believed to reduce coking as compared with conventional embodiments employing bubble breakers.

[0005] According to one or more embodiments of the present disclosure, a chemical processing vessel may comprise one or more side walls defining a main interior space, an I-beam positioned within the main interior space, and a bubble breaker positioned within the main interior space in a horizontal plane. The I-beam may comprise a web, a lower flange, and an upper flange. The I-beam may extend in a substantially horizontal direction. A plurality of attachment rails mayextend from the web of the I-beam in a direction substantially perpendicular to the web. At least a portion of the plurality of attachment rails may be in contact with the bubble breaker and may support the bubble breaker. A gap in the horizontal direction may exist between the lower flange of the I-beam and the bubble breaker. The plurality of attachment rails may span the gap between the lower flange of the I-beam and the bubble breaker, which may overlap with the bubble breaker in the horizontal direction.

[0006] According to one or more additional embodiments of the present disclosure, a method for chemical processing may comprise contacting a reactant with fluidized particles in a chemical processing vessel. The fluidized particles may comprise a fluidized bed flow regime. The fluidized bed flow regime may be chosen from fast fluidized flow, turbulent flow, or bubbling bed fluidization The chemical processing vessel may comprise one or more side walls defining a main interior space, an I-beam positioned within the main interior space, and a bubble breaker positioned within the main interior space in a horizontal plane. The I-beam may comprise a web, a lower flange, and an upper flange. The I-beam may extend in a substantially horizontal direction. A plurality of attachment rails may extend from the web of the I-beam in a direction substantially perpendicular to the web. At least a portion of the plurality of attachment rails may be in contact with the bubble breaker and may support the bubble breaker. A gap in the horizontal direction may exist between the lower flange of the I-beam and the bubble breaker. The plurality of attachment rails may span the gap between the lower flange of the I-beam and the bubble breaker, which may overlap with the bubble breaker in the horizontal direction.

[0007] These and other features, and characteristics of the present technology, as well as the methods of operation and functions of the related elements of structure and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following description and the appended claims with reference to the accompanying drawings, all of which form a part of this specification, wherein like reference numerals designate corresponding parts in the various figures. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the invention. As used in the specification and in the claims, the singular form of 'a', 'an', and 'the' include plural referents unless the context clearly dictates otherwise.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The following detailed description of specific embodiments of the present disclosure can be best understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which:

[0009] FIG. 1A schematically depicts a front view of a chemical processing vessel, according to one or more embodiments illustrated and described herein;

[0010] FIG. IB schematically depicts a perspective view of a layer of the interior of the chemical processing vessel of FIG. 1 A, according to one or more embodiments illustrated and described herein;

[0011] FIG. 2A schematically depicts a top-view of the interior of a chemical processing vessel such as that of FIG. 1A, according to one or more embodiments illustrated and described herein;

[0012] FIG. 2B schematically depicts a perspective view of the interior of the chemical processing vessel depicted in FIG. 2A, according to one or more embodiments illustrated and described herein;

[0013] FIG. 2C schematically depicts another perspective view of the interior of the chemical processing vessel of FIG. 2A, according to one or more embodiments illustrated and described herein;

[0014] FIG. 3A schematically depicts a perspective view of a grating that includes a plurality of rectangular openings, according to one or more embodiments illustrated and described herein;

[0015] FIG. 3B schematically depicts a perspective view of a grating that includes a plurality of parallelogram-shaped openings, according to one or more embodiments illustrated and described herein;

[0016] FIG. 4 schematically depicts a perspective view of a chevron, according to one or more embodiments illustrated and described herein; and

[0017] FIG. 5 schematically depicts a plurality of chevrons supported by a support, according to one or more embodiments illustrated and described herein.

[0018] It should be understood that the drawings are schematic in nature, and do not include some components of a fluid catalytic reactor system commonly employed in the art, such as, without limitation, temperature transmitters, pressure transmitters, flow meters, pumps, valves, and the like. It would be known that these components are within the spirit and scope of the present embodiments disclosed. However, operational components, such as those described in the present disclosure, may be added to the embodiments described in this disclosure.

[0019] Reference will now be made in greater detail to various embodiments, some embodiments of which are illustrated in the accompanying drawings. Whenever possible, the same reference numerals will be used throughout the drawings to refer to the same or similar parts.DETAILED DESCRIPTION

[0020] Embodiments described herein are generally directed to chemical processing vessels and methods for their use. The chemical processing vessels described herein include I-beams, bubble breakers, and a plurality of attachment rails, where the plurality of attachment rails span a gap between an I-beam and the bubble breakers. The present embodiments, as described herein, may reduce coking, especially in conditions where coking is prominent and causes reduced process efficiencies, such as reactions operating at relatively high temperatures in the presence of hydrocarbons.

[0021] Some processing vessels, in which fluidized bed operation may take place, may utilize internal structures (e.g., gratings acting as bubble breakers) that need to be supported by I- beams that may run across the interior region of the processing vessel. According to some conventional embodiments, the bubble breakers may lie directly on the I-beam. While the support of the bubble breakers in this arrangement is suitable, it has been discovered that such conventional embodiments may have a high propensity for coking. Coke build-up is unwanted and may cause process irregularities and eventual need for process shut-down to repair damages and / or clean out the coke, which will generally reduce efficiency for making chemical products.

[0022] To this point, in operating conditions that generate coke in the processing vessel, it has been observed that conventional embodiments may be particularly susceptible to coking at thecontact point of the bubble breakers and the I-beam. Such areas of contact may have high gas stagnation, and it is believed that this gas stagnation promotes coke build-up over time.

[0023] As is described herein, it has been discovered that coke buildup may be reduced by utilizing the embodiments disclosed herein whereby attachment rails are utilized to support the bubble breakers. Such configurations, particularly where a gap is present between the I-beam and the bubble breakers, as described herein, may reduce coke build-up by having relatively large open areas through which gases may pass and not stagnate. Such configurations may, unexpectedly, reduce coke buildup in the processing vessel.

[0024] Now referring to FIG. 1A, one embodiment of a chemical processing vessel 100 is schematically depicted in a front-view. FIG. IB additionally depicts a perspective view of a layer of the embodiment of FIG. 1A. This embodiment is not the only contemplated embodiment, and it should be understood that those skilled in the art may generalized the teachings with respect to FIG. 1A and FIG. IB, and various modifications and variations can be made to the described embodiments of FIG. 1A and FIG. IB.

[0025] The chemical processing vessel 100 of FIG. 1A includes side walls 102, and the side walls 102 define a main interior space 104. An I-beam 106 is placed within the main interior space 104 and the I-beam 106 includes a web 108, a lower flange 110, and an upper flange 112. The I- beam 106 extends in a substantially horizontal direction. A bubble breaker 114 (depicted as a grating in the embodiments of FIGS. 1-3B) is positioned within the main interior space 104 in a horizontal plane (as defined by the x-y axes of FIG. 1A and FIG. IB).

[0026] FIG. IB depicts a simplified perspective view of the approximate location of the bubble breakers 114 as compared to the I-beams 106, but will be described in greater detail with respect to the figures the follow, where a gap is present between the I-beams 106 and the bubble breakers 114. Importantly, FIG. IB does not include the attachment rails 116 that may be present in the embodiments described herein.

[0027] As depicted in FIGS. 2A-2C, a plurality of attachment rails 116 extend from the web 108 of the I-beam 106 in a direction substantially perpendicular to the web 108. Moreover, at least a portion of the plurality of attachment rails 116 are in contact with the bubble breaker 114 to support the bubble breaker 114. A gap 118 exists in the horizontal direction between the lowerflange 110 of the I-beam 106 and the bubble breaker 114. The plurality of attachment rails 116 span the gap 118 between the lower flange 110 of the I-beam 106 and the bubble breaker 114, such that the plurality of attachment rails 116 overlap with the bubble breaker 114 in the horizontal direction, as explained further herein.

[0028] As described herein, it should be understood that “substantially vertical” and “substantially horizontal” are intended to include directions or planes that are not completely vertical or horizontal, such as directions or planes 1 degree, 2 degrees, 3 degrees, 4 degrees, or even 5 degrees off of horizontal or vertical.

[0029] According to one or more embodiments, the chemical processing vessel 100 includes the side walls 102 that define the main interior space 104. The side walls 102 making up the chemical processing vessel 100 may be side walls of a vessel, drum, barrel, vat, or any other container suitable for a given chemical reaction, such that the chemical processing vessel 100 may be any of these geometric configurations. As described in greater detail herein, the chemical processing vessel 100 may operate as a fluidized bed reactor. The side walls 102 may be made up of metal or any other suitable material for withstanding temperatures of up to, from example, 925 °C within the main interior space 104, and optionally may be coated with refractory materials for heat management. Various components may be positioned within the main interior space 104, as is described herein.

[0030] According to one or more embodiments, the I-beam 106 is positioned within the main interior space 104. While FIG. IB depicts six I-beams 106 within the main interior space 104, it should be understood that any number of I-beams 106 may be placed within the main interior space 104, depending on the size and shape of the chemical processing vessel 100. The I- beam 106 may substantially lie in the horizontal plane. The substantially horizontal plane is defined by the x-y axes of FIG. 1. The I-beam 106 may be used to support various structures within the main interior space 104, such as the bubble breaker 114.

[0031] In embodiments, the bubble breaker 114 may also lie substantially in the horizontal plane. The bubble breaker 114 may function to break up a plurality of fluidized gas bubbles flowing in a vertical direction defined by the z-axis by allowing for restricted passage of fluids. The bubble breaker 114 may function to redistribute a flow of the plurality of fluidized gas bubbles to prevent “short-circuiting” of the fluidized bed. The bubble breaker 114 may also reduce back-mixing of a catalyst emulsion phase and gases entrained in the catalyst emulsion phase. The bubble breaker 114 may be made of metal or any other suitable material capable of withstanding reaction temperatures within the main interior space 104 of the chemical processing vessel 100. In some embodiments, a plurality of bubble breakers 114 are positioned along multiple vertical elevations along the z-axis; the plurality of the bubble breakers 114 may be spaced vertically with a distance of 2 feet to 6 feet apart. As such, there may be one, two, three four, or more layers of bubble breakers 114 positioned along multiple vertical elevations along the z-axis.

[0032] Examples of bubble breaker 114 are depicted in FIGS. 3A and 3B, which depict gratings. Specifically, the bubble breaker 114 may include grating 115. The grating 115 may include a plurality of openings 136. The plurality of openings 136 may be through a substantially horizontal surface portion of the grating 115 in the substantially horizontal plane, defined by the x-y axes of FIG. 3 A. The plurality of openings 136 may include from 30% to 95% of the horizontal surface portion of the grating 115. The plurality of openings 136 may make up a square, rectangular, hexagonal, honeycomb, or any other suitable pattern. As an exemplary embodiment, FIG. 3 A depicts a plurality of rectangular openings 136a (sometimes called “subway grating” in industry) and FIG. 3B depicts a plurality of diamond-shaped openings 136b. The plurality of openings 136 may be from 0.5 inches to 10 inches in width or diameter, or from 1 inch to 4 inches in width or diameter, such that the plurality of openings 136 are smaller in width or diameter than the plurality of fluidized gas bubbles; thus, the plurality of openings 136 may break up the plurality of fluidized gas bubbles flowing in the vertical direction defined by the z-axis in FIG. 3A. The grating 115 is in contact with at least a portion of the plurality of attachment rails 116, as discussed further below.

[0033] While the embodiments described herein with respect to FIGS. 1-3B utilize a grating as the bubble breaker 114, other bubble breakers are contemplated as being suitable for use with the presently disclosed embodiments. For example, bubble breakers 114 may comprise chevrons and / or structured packing.

[0034] Referring now to FIG. 4, the chevron 150 is depicted, which may be utilized as a bubble breaker 114. The chevron 150 may include a first end 152 and a second end 154 opposite from the first end 152. The first end 152 and / or the second end 154 of the chevron 150 may be supported by an attachment rail 116, as described herein. The chevrons 150 may break up theplurality of fluidized gas bubbles flowing in the vertical direction defined by the z-axis in FIG. 3A.

[0035] Now referring to additional embodiments, and referring now to FIG. 5, several chevrons 150 may be aligned and connected to one another via a support rod 152, which may be a bar or other like mechanical support means. The support rod 152 may be supported by the attachment rails 116 on the top and bottom of the support rod 152, similar in arrangement to that depicted with respect to embodiments utilizing grating.

[0036] The collection of bubble breakers 114 may span from one side wall 102 to another side wall 102, and may be contoured in shape to the arrangement of the side walls 102. Without use of I-beams 106 and attachment rails 116, the bubble breaker 114 may bend under a weight of the bubble breaker 114 when spanning the side walls 102, or may not be able to be supported at all with perimeter attachments directly to the side walls 102. Thus, to prevent deformation of the bubble breaker 114, the I-beam 106 and attachment rails 116 support the bubble breaker 114. The attachment rails 116 may support the bubble breaker 114 in a variety of manners.

[0037] As depicted in FIG. 2A, according to one or more embodiments, the attachment rails 116 may be connected to the I-beam 106. The attachment rails 116 may be connected to the web 108, the lower flange 110, or the upper flange 112 of the I-beam 106. In embodiments, the attachment rails 116 may be welded to the web of 108 of the I-beam 106, and extend substantially perpendicular of the I-beam 106. Moreover, as depicted in FIG. 2B, the attachment rails 116 may be welded to the lower flange 110 of the I-beam and include a first portion 116a that extends substantially parallel to the web 108 of the I-beam 106 (i.e., in the substantially vertical direction), and a second portion 116b that extends substantially perpendicular to the web 108 of the I-beam 106 (i.e., in the substantially horizontal direction). The attachment rails 116 may extend from one side of the I-beam 106, or from both sides of the I-beam 106 in the substantially horizontal direction. The attachment rails 116 may be coupled to the I-beam 106 through welding, bolting, or any other suitable coupling means. The attachment rails 116 may be 1 inch, 2 inches, 3 inches, 6 inches, 1 foot, 2 feet, 3 feet, or even 6 feet in length in either the substantially vertical direction or the substantially horizontal direction.

[0038] Referring again to FIG. 2A, in one or more embodiments, the attachment rails 116 contact the bubble breaker 114, such that the attachment rails 116 support the bubble breaker 114.In embodiments, at least one of the attachment rails 116 may be welded to both the I-beam 106 and the bubble breaker 114, as depicted on the first side 120 of the bubble breaker 114 of the FIG. 2 A. The second side 122 of the bubble breaker 114 may be slidably coupled to the attachment rails 116; such embodiments allow for thermal expansion of the second side 122 of the bubble breaker 114 toward the I-beam 106 when the main interior space 104 of the chemical processing vessel 100 heats up during chemical reactions. Moreover, the bubble breaker 114 may be slidably coupled to the attachment rails 116 on both the first side 120 and the second side 122 of the bubble breaker 114. In embodiments, the attachment rails 116 may attach to the bubble breaker 114 through welding, bolting, or any other suitable coupling means.

[0039] Referring now to FIG. 2C, the attachment rails 116 may span the gap 118 between the lower flange 110 of the I-beam 106 and the bubble breaker 114 above and below the bubble breaker 114 to secure the bubble breaker 114 in the substantially vertical direction. Specifically, the fluidized gas bubbles traveling in the substantially vertical direction within the main interior space 104 may displace the bubble breaker 114 in the substantially vertical direction. The attachment rails 116 being placed above the bubble breaker 114 may inhibit such displacement.

[0040] According to embodiments, the gap 118 between the lower flange 110 of the I-beam 106 and the bubble breaker 114 may allow for thermal expansion of the bubble breaker 114 toward the I-beam. The gap 118 between the lower flange 110 of the I-beam 106 and the bubble breaker 114 may be less than or equal to 6 inches, less than or equal to 1 foot, less than or equal to 2 feet, less than or equal to 3 feet, less than or equal to 4 feet, less than or equal to 5 feet, or less than or equal to 6 feet. A preferable gap size, 118, is between 1 and 6 inches, or more preferably between 2 and 4 inches.

[0041] Additionally, without being bound by any theory, it is believed that the existence of the gap 118 allow for reduced fluid stagnation, where such stagnation may cause coking at the metal surfaced. The gap may generally allow for fluid flow, reducing propensity for coking even at relatively high temperatures.

[0042] According to one or more embodiments, and referring again to FIG. IB, the I-beam 106 is positioned within the main interior space 104 of the chemical processing vessel 100. The I-beam 106 includes opposing ends 126. The I-beam 106 extends from the side wall 102 and may be coupled to the side wall 102 through welding, bolting, or any other suitable coupling means.In embodiments, the I-beam 106 may be coupled to the side walls 102 through a support assembly 124. The I-beam 106 may rest on the support assemblies 124. The opposing ends 126 of the I- beam 106 may rest on the support assemblies 124 freely or may be welded, bolted, or otherwise coupled to the support assemblies 124. The support assemblies 124 may include slots that the opposing ends 126 may be bolted to; such a connection may allow for the I-beam 106 to thermally expand when heated and the opposing ends 126 may slide within the slots. In some embodiments, the support assemblies 124 may point upward and downward, in a mirror- like fashion. The upward and downward orientation of the support assemblies 124 permits the support assemblies 124 to support the I-beams 106 in varying vertical elevations without the support assemblies 124 interfering with one another.

[0043] Additional embodiments disclosed herein are directed to methods for chemical processing which utilize the chemical processing vessels presently disclosed. The methods may include contacting a reactant with fluidized particles in the chemical processing vessel. As described herein, the fluidized particles may comprise a fluidized bed flow regime.

[0044] In one or more embodiments, based on the shape, size, flows of gases, and other processing conditions (such as temperature and pressure) in chemical processing vessel 100, the chemical processing vessel 100 may operate as a fluidized bed, referred to herein as a fluidized bed flow regime. As is understood by those in the art, fluidized bed flow regime generally occurs when a solid particulate substance is under the right conditions so that it behaves like a fluid. The usual way to achieve a fluidized bed is to pump pressurized fluid into the particles. According to various embodiments, the fluidized bed regime may be classified as a fast fluidized, turbulent, or bubbling bed fluidization. As described herein, a “fast fluidized” reactor may refer to a reactor utilizing a fluidization regime wherein the superficial velocity of the gas phase is greater than the choking velocity and may be semi-dense in operation. As described herein, a “turbulent” reactor may refer to a fluidization regime where the superficial velocity of less than the choking velocity and is more dense than the fast fluidized regime. As described herein, a “bubbling bed” reactor may refer to a fluidization regime wherein well defined bubbles in a highly dense bed are present in two distinct phases. The “choking velocity” refers to the minimum velocity required to maintain solids in the dilute -phase mode in a vertical conveying line.

[0045] It is contemplated herein that the fluidized particulates may be solid catalysts or non- catalytic solids such as, for example, materials capable of carrying oxygen. In non-limiting examples, the chemical processing vessel 100 described herein may be utilized to produce light olefins from hydrocarbon feed streams, such as propylene from propane or ethylene from ethane. Light olefins may be produced from a variety of hydrocarbon feed streams by utilizing different reaction mechanisms. For example, light olefins may be produced by at least dehydrogenation reactions, cracking reactions, dehydration reactions, and methanol-to-olefin reactions. These reaction types may utilize different feed streams and different catalytic particulate solids to produce light olefins.

[0046] According to one or more embodiments, the contacting of the reactant with the fluidized particles may be at relatively high temperatures, which may promote coking. For example, reactor temperatures may be at least 500 °C, at least 550 °C, at least 600 °C, at least 650 °C, at least 700 °C, at least 750 °C, at least 800 °C, at least 850 °C, or even at least 900 °C.

[0047] According to some embodiments, the chemical processing may comprise a dehydrogenation reaction that utilizes circulating a catalyst between the chemical processing vessel 100 and a regeneration unit, where alkanes are converted to alkenes in the chemical processing vessel 100 and where the catalyst is heated by a supplemental fuel in the regeneration unit. Such a process may convert propane to propylene, such as is described in U.S. Pat. No. 10,227,271, the entirety of which is incorporated by reference in this disclosure.

[0048] In additional embodiments, chemical processing may comprise a dehydrogenation reaction that utilizes circulating a solid particulate oxygen carrier material between the chemical processing vessel 100 and a regeneration unit, where alkanes are converted to alkenes in the chemical processing vessel 100 by thermal dehydrogenation, and where the produced hydrogen gas is converted to water by contact with oxygen released from the oxygen carrier material. Such a process may convert ethane to ethylene, such as is described in WO 2024 / 059554 Al, the entirety of which is incorporated by reference in this disclosure.

[0049] In additional embodiments, chemical processing may comprise a dehydrogenation reaction that utilizes circulating both a catalyst and a solid particulate oxygen carrier material between the chemical processing vessel 100 and a regeneration unit, where alkanes are converted to alkenes in the chemical processing vessel 100 by catalytic dehydrogenation, and where theproduced hydrogen gas is converted to water by contact with oxygen released from the oxygen carrier material. Such a process may convert ethane to ethylene, such as is described in U.S. Patent No. 11,724,974, the entirety of which is incorporated by reference in this disclosure.

[0050] In some embodiments, the fluidized particulates may exhibit properties known in the industry as “Geldart A” or “Geldart B” properties. Particles may be classified as “Group A” or “Group B” according to D. Geldart, Gas Fluidization Technology, John Wiley & Sons (New York, 1986), 34-37; and D. Geldart, “Types of Gas Fluidization,” Powder Technol. 7 (1973) 285-292, which are incorporated herein by reference in their entireties.

[0051] According to embodiments described herein, the chemical processing vessels may be reactors or other devices, such as solid particulate combustors or solid particulate regenerators that operate as fluidized beds. In this context, reactors may refer to vessels where the main reaction of a process takes place to make the product, whereas the combustor or regenerator may be a vessel where particulate solids are heated or de-coked by burning of coke or supplemental fuels.

[0052] Group A is understood by those skilled in the art as representing an aeratable powder, having a bubble-free range of fluidization; a high bed expansion; a slow and linear deaeration rate; bubble properties that may include a predominance of splitting / recoalescing bubbles, with a maximum bubble size and large wake; high levels of solids mixing and gas backmixing, assuming equal U-Umf (U is the velocity of the carrier gas, and Umf is the minimum fluidization velocity, typically though not necessarily measured in meters per second, m / s, i.e., there is excess gas velocity); axisymmetric slug properties; and no spouting, except in very shallow beds. The properties listed tend to improve as the mean particle size decreases, assuming equal particle size (cfp); or as the <45 micrometers (pm) proportion is increased; or as pressure, temperature, viscosity, and density of the gas increase. In general, the particles may exhibit a small mean particle size and / or low particle density (<1.4 grams per cubic centimeter, g / cm3), fluidize easily, with smooth fluidization at low gas velocities, and may exhibit controlled bubbling with small bubbles at higher gas velocities.

[0053] Group B is understood by those skilled in the art as representing a “sand-like” powder that starts bubbling at Umf; that exhibits moderate bed expansion; a fast deaeration; no limits on bubble size; moderate levels of solids mixing and gas backmixing, assuming equal U- Umf; both axisymmetric and asymmetric slugs; and spouting in only shallow beds. Theseproperties tend to improve as mean particle size decreases, but particle size distribution and, with some uncertainty, pressure, temperature, viscosity, or density of gas seem to do little to improve them. In general, most of the particles having a particle size (cfp) of 40 pm <cfp <500 pm when the density (pp) is 1.4 <pp <4 g / cm3, and 60 pm <cfp <500 pm when the density (pp) is 4 g / cm3and 250 pm <cfp <100 pm when the density (pp) is 1 g / cm3.

[0054] According to one or more embodiments, all of or a portion of one or more of the I- beam 106, the bubble breaker 114, or the plurality of attachment rails 116 comprise an anti -coking coating. The anti-coking coating refers to any coating that reduces coking of hydrocarbons at elevated temperatures, as compared with exposure of the hydrocarbons to the raw surface of the metal component upon which it is applied. A variety of compositions may be utilized as the anticoking coating, some of which are described hereinbelow.

[0055] According to one or more embodiments, the anti-coking coating may comprise a ceramic material. Such coatings may include, without limitation, metal oxides and / or metal carbides, such as SiC and AI2O3. Contemplated commercially available coating compositions that may be suitable for use as the anti -coking coating include, without limitation, Cerakote V-Series, Cerablak HTP-100, and Emisshield M-l or M-6 sintered coatings. According to some embodiments, the coatings may be applied as ceramic particles suspended in an inorganic binder matrix, which may be painted onto the metal component. In some other embodiments, the coatings may be applied by spray gun application. Curing may be needed to remove solvents and / or chemically change the coating composition following application.

[0056] According to one or more embodiments, the anti-coking coating that is positioned over the metal component may comprise one or more of aluminum, silicon, chromium, or cerium. In some embodiments, the anti-coking coating may include aluminum, silicon, chromium, and cerium. In some embodiments, the anti-coking coating is a ceramic material that comprises aluminum, silicon, chromium, and cerium. The aluminum, silicon, chromium, and / or cerium may be present as oxides, nitrides, alloys of other metals (such as those in the composition of the metal component), or as elemental constituents. For example, the anti-coking coating may include one or more of AIN, Cr3Si, AlNi, AlFe, CeFeSi, and Ce. According to one or more embodiments, the anti-coking coating that includes one or more of aluminum, silicon, chromium, or cerium may be fabricated over the metal component by a variety of techniques. For example, pack cementationcoatings from intermetallic compounds may be applied. Two application methods for this technique include chemical vapor deposition (CVD) and thermal diffusion. Without being bound by any particular theory, it is believed that these methods may ensure the anti-coking coating completely covers the substrate surface and prevents any direct contact between hydrocarbons and the substrate. In utilizing this fabrication technique to apply the anti -coking coating to the metal component, the constituent elements of the anti-coking coating in the solid phase may be reacted in activators such as sodium chloride and ammonium chloride. This reaction may generate gaseous metal halides that are capable of diffusing to the substrate surface, where they undergo disproportionate reaction. As the resulting permeating source material accumulates on the substrate surface, it may further diffuse into the substrate, forming a diffusion coating. The diffusion coating may comprise of aluminum nitrides, chromium silicate, aluminum nickel, silicon dioxide, cerium, cerium iron silicide, and aluminum iron, which may create three regions. The three regions may include an outer layer, an inter-diffusion layer, and a transitional layer. The outer layer may contain relatively large amounts of aluminum and chromium in the form of aluminum nitrides and chromium silicates, as well as relatively small amounts of silicon, cerium, nitrogen, oxygen, iron, and nickel.

[0057] According to one or more embodiments, without being bound by any particular theory, it is believed that, at high temperatures, the aluminum and chromium may oxidize on the substrate surface, which still may offer protection. The inter-diffusion layer may be composed of aluminum, iron, and nickel in the form of aluminum nickel and aluminum iron. Additionally, the transitional layer may be comprised of high amounts of chromium, iron, and nickel.

[0058] To produce one or more of the embodiments described herein, uncoated samples may be encapsulated in a retort with composite powder, which may include aluminum, chromium, silicon, and cerium (IV) oxide. Then an activator, such as ammonium chloride, and an inert filler, such as aluminum oxide, may be added. The retort may be sealed with refractory mud and placed in an oven for about 2 hours. Following this, the retort may be heat treated for eight hours at about 1000 °C in a preheated muffle furnace in the air atmosphere. After being heat treated, the sample may be cooled to room temperature, polished with sandpaper, and ultrasonically cleaned with ethanol for about three minutes.

[0059] According to other embodiments, the anti-coking coating may comprise a metalized surface, whereby a portion of the metal component is metalized. In some embodiments, the metallization is an aluminized surface, such that the anti-coking coating comprises aluminum. In one or more embodiments, morphology of the aluminized surface depends upon the conditions which are used to perform the coating, but may involve the alloying of aluminum with the underlying substrate across a thin band within the coating. Total thickness of this type of coating may be from 50 microns to 150 microns. Aluminization may be performed via pack cementation (PC), though may also be performed via vapor phases aluminizing (VP A), chemical vapor deposition (CVD), or other methods. In PC, the metal substrate will be surrounded by a “pack”, consisting of an inert filler (e.g. AI2O3 powder), the coating material (aluminum metal), and a halide salt “activator” (e.g. ammonium chloride). The substrate and surrounding packing will then be heated (commonly in either an inert or hydrogen atmosphere) to high temperature (e.g. 800- 1100 °C). At this point a gaseous metal halide (e.g. aluminum chloride) will form from the coating material and the activator. The metal halide deposits the aluminum onto the substrate surface forming a layer with thicknesses commonly ranging 50-150 um. The aluminum diffuses into the substrate with prolonged heat treatment. The ultimate morphology and thickness (commonly 50- 150 um) of this layer depends on the conditions and the packing. Upon exposure to atmosphere, and inert aluminum oxide layer is formed.

[0060] In one or more embodiments, and according to the composition of the anti -coking coating, the anti -coking coating may be applied in a variety of thicknesses. For example, in some embodiments, the anti-coking coating may have a thickness of from 25 microns to 500 microns, such as at least 25 microns and less than 400 microns, less than 300 microns, less than 200 microns, less than 100 microns, or less than 50 microns, or such as less than or equal to 500 microns and at least 50 microns, at least 100 microns, at least 200 microns, at least 300 microns, or at least 400 microns.

[0061] Numerous technical aspects are described in the present disclosure, including Aspects 1-15 described below.

[0062] Aspect 1. A chemical processing vessel comprising: one or more side walls defining a main interior space; an I-beam positioned within the main interior space, the I-beam comprising a web, a lower flange, and an upper flange, the I-beam extending in a substantially horizontaldirection; a bubble breaker positioned within the main interior space in a horizontal plane; and a plurality of attachment rails extending from the web of the I-beam in a direction substantially perpendicular to the web, at least a portion of the plurality of attachment rails in contact with the bubble breaker and supporting the bubble breaker, wherein: a gap in the horizontal direction exists between the lower flange of the I-beam and the bubble breaker; and the plurality of attachment rails span the gap between the lower flange of the I-beam and the bubble breaker, overlapping with the bubble breaker in the horizontal direction.

[0063] Aspect 2. The chemical processing vessel of aspect 1, wherein the plurality of attachment rails span the gap between the lower flange of the I-beam and the bubble breaker above and below the bubble breaker to secure the bubble breaker in a vertical direction.

[0064] Aspect 3. The chemical processing vessel of any preceding aspect, wherein at least one of the plurality of attachment rails are welded to the I-beam and the bubble breaker.

[0065] Aspect 4. The chemical processing vessel of any preceding aspect, wherein a first side of the bubble breaker is welded to the plurality of attachment rails and a second side of the bubble breaker is slidably coupled to the plurality of attachment rails.

[0066] Aspect 5. The chemical processing vessel of any preceding aspect, wherein the plurality of attachment rails extend from the lower flange of the I-beam.

[0067] Aspect 6. The chemical processing vessel of any preceding aspect, wherein the plurality of attachment rails extend from the upper flange of the I-beam.

[0068] Aspect 7. The chemical processing vessel of any preceding aspect, wherein the plurality of attachment rails extend from both sides of the I-beam in the horizontal direction.

[0069] Aspect 8. The chemical processing vessel of any preceding aspect, wherein the gap between the lower flange of the I-beam and the bubble breaker allows for thermal expansion of the bubble breaker toward the I-beam.

[0070] Aspect 9. The chemical processing vessel of any preceding aspect, wherein the gap between the lower flange of the I-beam and the bubble breaker is less than or equal to 3 feet.

[0071] Aspect 10. The chemical processing vessel of any preceding aspect, wherein the gap between the lower flange of the I-beam and the bubble breaker is less than or equal to 1 foot.

[0072] Aspect 11. The chemical processing vessel of any preceding aspect, wherein the bubble breaker comprises a grating, a chevron, or structured packing.

[0073] Aspect 12. The chemical processing vessel of any preceding aspect, wherein all of or a portion of one or more of the I-beam, the bubble breaker, or the plurality of attachment rails comprise an anti-coking coating.

[0074] Aspect 13. A method for chemical processing, the method comprising contacting a reactant with fluidized particles in the chemical processing vessel of any of aspects 1-12, wherein the fluidized particles comprise a fluidized bed flow regime, wherein the fluidized bed flow regime is chosen from fast fluidized flow, turbulent flow, or bubbling bed fluidization.

[0075] Aspect 14. The method of aspect 13, wherein the fluidized particles pass through the gap in the horizontal direction between the lower flange of the I-beam and the bubble breaker.

[0076] Aspect 15. The method of any of aspects 13 or 14, wherein the fluidized particles are catalysts.

[0077] The subject matter of the present disclosure has been described in detail and by reference to specific embodiments. It should be understood that any detailed description of a component or feature of an embodiment does not necessarily imply that the component or feature is essential to the particular embodiment or to any other embodiment. Further, it should be apparent to those skilled in the art that various modifications and variations can be made to the described embodiments without departing from the spirit and scope of the claimed subject matter.

[0078] It is noted that one or more of the following claims utilize the term "wherein" as a transitional phrase. For the purposes of defining the present invention, it is noted that this term is introduced in the claims as an open-ended transitional phrase that is used to introduce a recitation of a series of characteristics of the structure and should be interpreted in like manner as the more commonly used open-ended preamble term "comprising."

Claims

CLAIMS1. A chemical processing vessel comprising: one or more side walls defining a main interior space; an I-beam positioned within the main interior space, the I-beam comprising a web, a lower flange, and an upper flange, the I-beam extending in a substantially horizontal direction; a bubble breaker positioned within the main interior space in a horizontal plane; and a plurality of attachment rails extending from the web of the I-beam in a direction substantially perpendicular to the web, at least a portion of the plurality of attachment rails in contact with the bubble breaker and supporting the bubble breaker, wherein: a gap in the horizontal direction exists between the lower flange of the I-beam and the bubble breaker; and the plurality of attachment rails span the gap between the lower flange of the I- beam and the bubble breaker, overlapping with the bubble breaker in the horizontal direction.

2. The chemical processing vessel of claim 1, wherein the plurality of attachment rails span the gap between the lower flange of the I-beam and the bubble breaker above and below the bubble breaker to secure the bubble breaker in a vertical direction.

3. The chemical processing vessel of any preceding claim, wherein at least one of the plurality of attachment rails are welded to the I-beam and the bubble breaker.

4. The chemical processing vessel of any preceding claim, wherein a first side of the bubble breaker is welded to the plurality of attachment rails and a second side of the bubble breaker is slidably coupled to the plurality of attachment rails.

5. The chemical processing vessel of any preceding claim, wherein the plurality of attachment rails extend from the lower flange of the I-beam.

6. The chemical processing vessel of any preceding claim, wherein the plurality of attachment rails extend from the upper flange of the I-beam.

7. The chemical processing vessel of any preceding claim, wherein the plurality of attachment rails extend from both sides of the I-beam in the horizontal direction.

8. The chemical processing vessel of any preceding claim, wherein the gap between the lower flange of the I-beam and the bubble breaker allows for thermal expansion of the bubble breaker toward the I-beam.

9. The chemical processing vessel of any preceding claim, wherein the gap between the lower flange of the I-beam and the bubble breaker is less than or equal to 3 feet.

10. The chemical processing vessel of any preceding claim, wherein the gap between the lower flange of the I-beam and the bubble breaker is less than or equal to 1 foot.

11. The chemical processing vessel of any preceding claim, wherein the bubble breaker comprises a grating, a chevron, or structured packing.

12. The chemical processing vessel of any preceding claim, wherein all of or a portion of one or more of the I-beam, the bubble breaker, or the plurality of attachment rails comprise an anticoking coating.

13. A method for chemical processing, the method comprising contacting a reactant with fluidized particles in the chemical processing vessel of any of claims 1-12, wherein the fluidized particles comprise a fluidized bed flow regime, wherein the fluidized bed flow regime is chosen from fast fluidized flow, turbulent flow, or bubbling bed fluidization.

14. The method of claim 13, wherein the fluidized particles pass through the gap in the horizontal direction between the lower flange of the I-beam and the bubble breaker.

15. The method of any of claims 13 or 14, wherein the fluidized particles are catalysts.

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