Chemical processing vessels having bubble breakers with refractory coating, and methods of using the same

Abstract

A chemical processing vessel suitable for fluidized bed operation may include one or more side walls defining a main interior space, and a bubble breaker extending across substantially an entirety of a substantially horizontal plane in the main interior space. The bubble breaker may include a plurality of beams positioned within the main interior space, and a plurality of bars extending from the body of one or more of the plurality of beams. The plurality of bars may each be arranged on the substantially horizontal plane. At least 50% of the surface area of the plurality of beams and the plurality of bars may be coated with a refractory material coating having a thickness of at least 0.25 inches. Any point on the substantially horizontal plane may be less than or equal to 3 feet from a beam or a bar.

Description

CHEMICAL PROCESSING VESSELS HAVING BUBBLE BREAKERS WITH REFRACTORY COATING, AND METHODS OF USING THE SAMECROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to U.S. Provisional Application Serial No. 63 / 665,537 filed June 28, 2024, the entire disclosure of which is hereby incorporated by reference.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 often degrade or become coated in coke, resulting in decrease efficiency and effectiveness of such reactor vessels.SUMMARY

[0004] Described herein are chemical processing vessels, and methods for their use. According to embodiments, such chemical processing vessels may include bubble breakers, which can aid in mitigating bubble formation in a fluidized bed. The bubble breakers described herein include a plurality of beams and a plurality of bars that extend from the beams, as are described in detail herein. Such bubble breakers may be able to accommodate refractory material coatings, whereas many conventional bubble breakers may not be able to do so.

[0005] According to one or more embodiments of the present disclosure, a chemical processing vessel suitable for fluidized bed operation may comprise one or more side walls defining a main interior space, and a bubble breaker extending across substantially an entirety ofa substantially horizontal plane in the main interior space. The bubble breaker may comprise a plurality of beams positioned within the main interior space, and a plurality of bars extending from the body of one or more of the plurality of beams. The plurality of beams may each comprise a body extending in a substantially horizontal dimension. And the plurality of beams may be arranged on the substantially horizontal plane. The plurality of bars may each be arranged on the substantially horizontal plane. At least 50% of the surface area of the plurality of beams and the plurality of bars may be coated with a refractory material coating having a thickness of at least 0.25 inches. Any point on the substantially horizontal plane may be less than or equal to 3 feet from a beam or a bar.

[0006] According to one or more additional embodiments of the present disclosure, chemical processing may be performed by a method that may comprise contacting a reactant with fluidized particles in a chemical processing vessel, wherein the fluidized particles may comprise a fluidized bed flow regime. The chemical processing vessel may comprise one or more side walls defining a main interior space, and a bubble breaker extending across substantially an entirety of a substantially horizontal plane in the main interior space. The bubble breaker may comprise a plurality of beams positioned within the main interior space, and a plurality of bars extending from the body of one or more of the plurality of beams. The plurality of beams may each comprise a body extending in a substantially horizontal dimension. And the plurality of beams may be arranged on the substantially horizontal plane. The plurality of bars may each be arranged on the substantially horizontal plane. At least 50% of the surface area of the plurality of beams and the plurality of bars may be coated with a refractory material coating having a thickness of at least 0.25 inches. Any point on the substantially horizontal plane may be less than or equal to 3 feet from a beam or a bar.

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

[0010] FIG. IB schematically depicts a top view of the interior of the chemical processing vessel of FIG. 1A taken along line 1B-1B of FIG. 1A, according to one or more embodiments illustrated and described herein;

[0011] FIG. 2A schematically depicts a side view of another chemical processing vessel, according to one or more embodiments illustrated and described herein;

[0012] FIG. 2B schematically depicts a top view of the interior of the chemical processing vessel of FIG. 2A taken long line 2B-2B of FIG. 2A, according to one or more embodiments illustrated and described herein;

[0013] FIG. 3 schematically depicts a side-view of a beam within a chemical processing vessel, according to one or more embodiments illustrated and described herein; and

[0014] FIG. 4 schematically depicts a cross-sectional view of a beam and a bar, according to one or more embodiments illustrated and described herein.

[0015] 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.

[0016] 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

[0017] Embodiments described herein are generally directed to chemical processing vessels and methods for their use. The chemical processing vessels described herein include a bubble breaker that can accommodate a refractory material coating. The bubble breaker generally may include a plurality of beams and a plurality of bars. The present embodiments, by utilizing refractory coatings 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.

[0018] To this point, conventional fluidized bed vessels may utilize gratings as bubble breakers. Refractory may be needed in reactor units that operate at high temperature conditions to prevent coking. However, grating cannot be utilized with refractory coatings with thicknesses normally associated with refractory coating, which generally have a thickness of a half inch or greater. Described herein are new embodiments of bubble breakers that can accommodate a refractory material coating. Such bubble breakers may include a collection of beams that span across the interior of the vessel, and further include bars that are attached to the beams, embodiments of which are disclosed in detail herein.

[0019] Without being bound by theory, it is believed that the ability to apply refractory coatings over metal surfaces of bubble breakers enables mitigation of coking, which may have a propensity to form when hydrocarbons contact metal surfaces at relatively high temperatures. In particular, metal surfaces such as metal alloys such as stainless steel may have a propensity for coking. The ability to coat such surfaces, such as bubble breakers, diminishes coking as compared with conventional bubble breakers that employ gratings that are unable to be coated with refractory due to clogging of the grating passages with refractory.

[0020] Now referring to FIG. 1A, one embodiment of a chemical processing vessel 100 is schematically depicted in a side view. FIG. IB additionally depicts a cross-sectional view of the embodiment of FIG. 1 A but from a top view compared to that of FIG. 1 A taken along line 1B-1B.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. 1 A and FIG. IB, as well as the embodiments of the other figures, and various modifications and variations can be made to the described embodiments of FIG. 1A and FIG. IB.

[0021] The chemical processing vessel 100 of FIG. 1A includes side walls 102, and the side walls 102 define a main interior space 104. Within the interior space 104 are positioned bubble breakers 106, wherein in the embodiment of FIG. 1A, three rows of bubble breakers 106 are depicted, but any number of rows of bubble breakers 106 may be utilized depending upon the height on the processing vessel 100. The bubble breaker 106 extends across substantially an entirety of a substantially horizontal plane (i.e., in the X-Y plane of FIG. 1A and FIG. IB). The bubble breaker 106 includes a plurality of beams 108 positioned within the main interior space 104. The plurality of beams 108 each include a body 110 extending in a substantially horizontal dimension, such that the plurality of beams 108 are arranged on the substantially horizontal plane. The bubble breaker 106 also includes a plurality of bars 112 extending from the body 110 of one or more of the plurality of beams 108, such that the plurality of bars 112 are also arranged on the substantially horizontal plane. At least 50% (or much more) of the surface area of the plurality of beams 108 and the plurality of bars 112 may be coated with a refractory material coating 114 (as depicted in FIG. 4) having a thickness of at least 0.25 inches. Any point on the substantially horizontal plane may be less than or equal to 3 feet from a beam 108 of the plurality of beams 108 or a bar 112 of the plurality of bars 112.

[0022] 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 at about 1 degree, about 2 degrees, about 3 degrees, about 4 degrees, or even about 5 degrees off of horizontal or vertical.

[0023] 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 forwithstanding temperatures of up to, from example, 925 °C within the main interior space 104, and may be coated with refractory materials for heat management. Various components may be positioned within the main interior space 104, as is described herein.

[0024] As described herein, according to one or more embodiments, the bubble breaker 106 is positioned within the main interior space 104. In embodiments, the bubble breaker 106 may include the plurality of beams 108 and the plurality of bars 112. While FIG. IB depicts six beams 108 within the main interior space 104, it should be understood that any number of beams 108 may be placed within the main interior space 104, depending on the size and shape of the chemical processing vessel 100. The beams 108 may substantially lie in the horizontal plane. The substantially horizontal plane is defined by the X-Y plane of FIG. 1. The beams 108 may be used to support various structures within the main interior space 104, such as the plurality of bars 112.

[0025] According to one or more embodiments, the plurality of bars 112 may also lie in the substantially horizontal plane. The plurality of bars 112 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 plurality of bars 112 may function to redistribute a flow of the plurality of fluidized gas bubbles to prevent “short-circuiting” of the fluidized bed. The plurality of bars 112 may also reduce back-mixing of a catalyst emulsion phase and gases entrained in the catalyst emulsion phase. The plurality of bars 112 may be made of metal (such as steel) 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, the plurality of bars 112 are positioned along multiple vertical elevations along the z-axis (as depicted in FIG. 1A) such that multiple bubble breakers 106 are present; the plurality of bars 112 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 the plurality of bars 112 positioned along multiple vertical elevations along the z-axis.

[0026] The plurality of bars 112 may be arranged in a variety of manners. In one or more embodiments, the plurality of bars 112 may be arranged in a staggered pattern 115, as depicted in FIG. IB. Although the plurality of bars 112 are depicted as alternating in FIG. IB, it is contemplated that the plurality of bars 112 may be parallel to one another, such that the plurality of bars 112 do not alternate. As depicted in FIG. IB, the plurality of bars 112 may overlap one another with respect to the horizontal direction. As such, each of the plurality of beams 108 mayinclude bars 112 on either side of the plurality of beams 108. Moreover, as depicted in FIGS. 2A and 2B, the plurality of bars 112 may not overlap one another with respect to the horizontal direction. The plurality of bars 112 may be 1 foot, 2 feet, 3 feet, 4 feet, 5 feet, or even 6 feet in length.

[0027] The plurality of bars 112 may be coupled to the body of the plurality of beams 108 in a variety of manners. In embodiments, the plurality of bars 112 may be welded or fastened to the plurality of beams 108, such that the plurality of bars 112 include a first end 116 coupled to the body 110 of the beams 108. In such embodiments, the plurality of bars 112 may include cantilevered bars 113. An entirety of each bar 112 may be on a single side of the beam 108. In other embodiments, the plurality of bars 112 may also extend through a hole (not depicted) of the plurality of beams 108, such that a portion of the bar 112 is on one side of the beam 108 and another portion of the bar 112 is on another side of the beam 108.

[0028] As noted hereinabove, the plurality of beams 108 and the plurality of bars 112 may be spaced such that any point in the horizontal plane is less than or equal to 3 feet from one of the plurality of beams 108 or one of the plurality of bars 112. As such, either of the beams 108 or the bars 112 may function break up the plurality of fluidized gas bubbles flowing in the vertical direction defined by the z-axis in FIGS. 1A and 2A. The plurality of beams 108 and the plurality of bars 112 may be spaced such that any point in the horizontal plane is less than or equal to 0.5 feet, less than or equal to 1 foot, less than or equal to 1.5 feet, less than or equal to 2 feet, less than or equal to 2.5 feet, less than or equal to 3.5 feet, or less than or equal to 5 feet from one of the plurality of beams 108 or one of the plurality of bars 112.

[0029] According to embodiments, the plurality of beams 108 and the plurality of bars 112 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. The plurality of bars 112 may extend only from the plurality of beams 108, as depicted in FIG. IB. In embodiments, at least one of the plurality of bars 112 may extend from the one or more side walls 102 on the substantially horizontal plane, as depicted in FIG. 2B. The plurality of bars 112 may be coupled to the side walls 102 through welding or any other suitable fastener. The plurality of bars 112 may also be coupled to the side walls 102 through the use of a support assembly 118 (as described further below).

[0030] Referring now to FIG. 4, according to some embodiments, the beams 108 may be an I-beam 128. The I-beam 128 includes a top flange 127, a bottom flange 129, and a web 131, such that the top flange 127 and the bottom flange 129 provide resistance against bending or buckling. The I-beam 128 may be made of structural steel, aluminum, stainless steel (304H, 321H, 347H), alloy 800 (H or HT), or any other suitable material. In embodiments, the plurality of bars 112 may extend from the web 131 of the beams 108 or rest on the bottom flange 129 or the top flange 127 of the beams 108.

[0031] Referring now to FIG. 3, opposing ends 117 of the plurality of beams 108 in the substantially horizontal dimension may be positioned at or near the side walls 102. The plurality of beams 108 may be supported by a support assembly 118, which may be coupled to one or more of the side walls 102. As described herein, “coupling” of beams 108 to the side walls 102 need not include direct contact between the beams 108 and the side walls 102. For example, as shown in FIG. 3, support assemblies 118, which may secure and / or support the beams 108, may be directly coupled to the side walls 102 through welding, bolting, or any other suitable coupling means. The opposing ends 117 of the beams 108 may be coupled to the side walls 102 through the support assembly 118. The opposing ends 117 of the beams 108 may rest on the support assemblies 118. The opposing ends 117 may rest on the support assembly 118 freely or may be welded, bolted, or otherwise coupled to the support assemblies 118. The support assemblies 118 may include slots that the opposing ends 117 may rest on; such a connection may allow for the support beam 108 to thermally expand when heated and the opposing ends 117 may slide within the slots. In some embodiments, the support assemblies 118 may point upward and downward, in a mirror-like fashion. The upward and downward orientation of the support assemblies 118 permits the support assemblies 118 to support the beams 108 in varying vertical elevations without the support assemblies 118 interfering with one another.

[0032] Referring again to FIG. 4, the surface area of the plurality of beams 108 and the plurality of bars 112 may be coated with the refractory material coating 114. The refractory material coating 114 may be coated onto only the plurality of beams 108, only the plurality of bars 112, or both of the plurality of beams 108 and the plurality of bars 112. The refractory material coating 114 may be coated onto the beams 108 and the bars 112 in a variety of configurations. For example, the refractory material coating 114 may be coated on at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or at least95% of the surface area of the plurality of beams 108 and the plurality of bars 112. In embodiments, the support assemblies 118 may also be coated with the refractory material coating 114 such that 50% of the surface area of the support assemblies 118 is coated with the refractory material coating 114 having a thickness of at least 0.25 inches. In embodiments, the refractory material coating 114 on the support assemblies is of a similar percentage of surface area and of a similar thickness when compared to the refractory material coating 114 on the plurality of beams 108 and the plurality of bars 112 described herein.

[0033] The refractory material coating 114 may also vary in thicknesses. The refractory material coating 114 may have a uniform thickness or a non-uniform thickness along the plurality of beams 108 and the plurality of bars 112. In embodiments, the refractory material may have a thickness of at least 0.25 inches, at least 0.5 inches, at least 0.75 inches, at least 1 inch, at least 1.5 inches, at least 2 inches, or at least 3 inches.

[0034] According to one or more embodiments, the refractory material coating may comprises, without limitation, one or more of alumina, silica, lime, iron oxide (any oxidation state), titania, phosphorus pentoxide, silicon carbide, zirconia, chromium oxide, magnesium oxide, calcium oxide, graphite, yttria-stabilized zirconia, MgAbC (spinnel), calcium aluminate, hafnium carbide, or compounds having refractory metals such as tungsten and / or molybdenum. Such refractory materials may be coated by spraying, dipping, paint application, etc., and is not necessarily limited for the embodiments herein. According to one or more embodiments, the refractory material may have a fired density of from 80 lb / ft3to 250 lb / ft3, such as from 130 lb / ft3to 210 lb / ft3. Some suitable refractory materials that are commercially available include, without limitation Actchem 85, Rescobond AA-22S, R-Max MP, and Thermbond 7018.

[0035] In one or more embodiments, the refractory material coating may be supported by an anchor system commonly used in industry, such as, without limitation, commercially available Hexmetal, Speedhex™, corner tabs, monster tabs, and other general refractory anchor systems used in industry. Such refractory anchors are not depicted in the figures, but may be attached to the beams 108 and bars 112 in areas that include the refractory material covering.

[0036] According to one or more embodiments, the beams 108 and / or the bars 112 may comprise an anti-coking coating. Such an anti-coking coating may rest below the refractorymaterial, where applied over the beams 108 and / or the bars 112. 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 anti-coking coating, some of which are described hereinbelow.

[0037] 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.

[0038] 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.

[0039] 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 cementation coatings 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 theanti-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 interdiffusion 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.

[0040] 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.

[0041] 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 fdler, 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.

[0042] 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 fdler (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.

[0043] 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.

[0044] 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.

[0045] 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 reactorutilizing 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.

[0046] 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.

[0047] 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.

[0048] 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.

[0049] 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 thechemical 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.

[0050] 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 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 U.S. Patent No. 11,724,974, the entirety of which is incorporated by reference in this disclosure.

[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] 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.

[0053] 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.

[0054] 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. These properties 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 / cm3 and 250 pm <cfp <100 pm when the density (pp) is 1 g / cm3.

[0055] Numerous technical aspects are presently disclosed, including aspects 1-15 provided below.

[0056] Aspect 1. A chemical processing vessel suitable for fluidized bed operation, the chemical processing vessel comprising: one or more side walls defining a main interior space; a bubble breaker extending across substantially an entirety of a substantially horizontal plane in the main interior space, the bubble breaker comprising: a plurality of beams positioned within the main interior space, the plurality of beams each comprising a body extending in a substantially horizontal dimension, wherein the plurality of beams are arranged on the substantially horizontal plane; and a plurality of bars extending from the body of one or more of the plurality of beams, the plurality of bars each arranged on the substantially horizontal plane; wherein at least 50% of the surface area of the plurality of beams and the plurality of bars are coated with a refractory material coating having a thickness of at least 0.25 inches; and wherein any point on the substantially horizontal plane is less than or equal to 3 feet from a beam or a bar.

[0057] Aspect 2. The chemical processing vessel of aspect 1, wherein at least 99% of the surface area of the plurality of beams and plurality of bars are coated with a refractory material coating.

[0058] Aspect 3. The chemical processing vessel of aspect 1 or aspect 2, wherein the refractory material coating comprises a thickness of at least 0.5 inches.

[0059] Aspect 4. The chemical processing vessel of any preceding aspect, wherein the plurality of bars comprise a first end coupled to the body of the plurality of beams.

[0060] Aspect 5. The chemical processing vessel of aspect 4, wherein the plurality of bars comprise a plurality of cantilevered bars.

[0061] Aspect 6. The chemical processing vessel of any preceding aspect, wherein the plurality of beams are supported by a support assembly, wherein the support assembly is coupled to one or more of the one or more side walls.

[0062] Aspect 7. The chemical processing vessel of aspect 6, wherein at least 50% of the surface area of the support assembly is coated with the refractory material coating having a thickness of at least 0.5 inches.

[0063] Aspect 8. The chemical processing vessel of any preceding aspect, wherein the plurality of bars are arranged in a staggered pattern.

[0064] Aspect 9. The chemical processing vessel of any preceding aspect, wherein the refractory material coating comprises aluminum oxide, silicon dioxide, chromium oxide, cerium oxide, or combinations thereof.

[0065] Aspect 10. The chemical processing vessel of any preceding aspect, wherein at least one of the plurality of bars extends from the one or more side walls on the substantially horizontal plane.

[0066] Aspect 11. The chemical processing vessel of any preceding aspect, wherein the bubble breaker does not comprise grating

[0067] Aspect 12. The chemical processing vessel of any preceding aspect, wherein one or more of the bars or beams comprise refractory anchors.

[0068] Aspect 13. The chemical processing vessel of any preceding aspect, wherein a portion or all of one or more of the bars or beams comprises an anti-coking coating.

[0069] Aspect 14. A method for chemical processing, the method comprising contacting a reactant with fluidized particles in the chemical processing vessel of any of aspects 1-13, wherein the fluidized particles comprise a fluidized bed flow regime chosen from fast fluidized flow, turbulent flow, or bubbling bed fluidization.

[0070] Aspect 15. The method of aspect 14, wherein the fluidized particles pass through a gap between the plurality of bars.

[0071] 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.

[0072] 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 suitable for fluidized bed operation, the chemical processing vessel comprising: one or more side walls defining a main interior space; a bubble breaker extending across substantially an entirety of a substantially horizontal plane in the main interior space, the bubble breaker comprising: a plurality of beams positioned within the main interior space, the plurality of beams each comprising a body extending in a substantially horizontal dimension, wherein the plurality of beams are arranged on the substantially horizontal plane; and a plurality of bars extending from the body of one or more of the plurality of beams, the plurality of bars each arranged on the substantially horizontal plane; wherein at least 50% of the surface area of the plurality of beams and the plurality of bars are coated with a refractory material coating having a thickness of at least 0.25 inches; and wherein any point on the substantially horizontal plane is less than or equal to 3 feet from a beam or a bar.

2. The chemical processing vessel of claim 1, wherein at least 99% of the surface area of the plurality of beams and plurality of bars are coated with a refractory material coating.

3. The chemical processing vessel of claim 1 or claim 2, wherein the refractory material coating comprises a thickness of at least 0.5 inches.

4. The chemical processing vessel of any preceding claim, wherein the plurality of bars comprise a first end coupled to the body of the plurality of beams.

5. The chemical processing vessel of claim 4, wherein the plurality of bars comprise a plurality of cantilevered bars.

6. The chemical processing vessel of any preceding claim, wherein the plurality of beams are supported by a support assembly, wherein the support assembly is coupled to one or more of the one or more side walls.

7. The chemical processing vessel of claim 6, wherein at least 50% of the surface area of the support assembly is coated with the refractory material coating having a thickness of at least 0.5 inches.

8. The chemical processing vessel of any preceding claim, wherein the plurality of bars are arranged in a staggered pattern.

9. The chemical processing vessel of any preceding claim, wherein the refractory material coating comprises aluminum oxide, silicon dioxide, chromium oxide, cerium oxide, or combinations thereof.

10. The chemical processing vessel of any preceding claim, wherein at least one of the plurality of bars extends from the one or more side walls on the substantially horizontal plane.

11. The chemical processing vessel of any preceding claim, wherein the bubble breaker does not comprise grating12. The chemical processing vessel of any preceding claim, wherein one or more of the bars or beams comprise refractory anchors.

13. The chemical processing vessel of any preceding claim, wherein a portion or all of one or more of the bars or beams comprises an anti-coking coating.

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

15. The method of claim 14, wherein the fluidized particles pass through a gap between the plurality of bars.

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