Bubble Column Reactor Counter-Current Flow Hydrocracking
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Solution Overview
Problem
Hydrocracking processes in petroleum refineries face challenges such as low hydrogen purity at the reactor outlet and solids accumulation in co-current upflow designs, which require additional resources and vigilance for removal.
Innovation Solution
Implementing a counter-current flow system in bubble column reactors, where a petroleum fraction with a high boiling point is reacted with a hydrogen-rich gas, preventing solids accumulation and maintaining high hydrogen purity throughout the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a co-current upflow bubble column reactor is used, then the reactor can process heavy crude oil residual fraction, but the hydrogen purity at the outlet is low
Solution Approach 1:
The patent inverts the conventional co-current flow arrangement by implementing a counter-current flow system where the liquid petroleum fraction flows downward while the hydrogen-rich gas flows upward. This inversion allows the hydrogen-poor liquid outlet to be positioned at the bottom and the hydrogen-rich gas outlet at the top, thereby achieving high hydrogen purity at the gas outlet while maintaining effective mass transfer and conversion efficiency throughout the reactor.
2Productivity
If a co-current upflow design is used, then the reactor can process the feed, but solids accumulate at the bottom requiring additional removal resources
Solution Approach 1:
The counter-current flow arrangement inverts the conventional co-current design, causing the liquid stream to flow downward while the gas stream flows upward. This inversion creates a continuous outlet at the bottom for the liquid product, preventing solids accumulation through continuous removal rather than requiring intermittent cleaning operations and additional solid removal equipment.
Solution Approach 2:
The counter-current flow system establishes continuous outlet streams for both liquid and gas products, eliminating the need for intermittent solid removal operations. The continuous flow prevents solids from accumulating at the bottom, maintaining steady-state operation and reducing the need for additional solid removal resources and vigilance.
3Quantity of substance
If additional equipment like hot separators is added, then hydrogen purity can be improved, but device complexity and resource requirements increase
Solution Approach 1:
The counter-current flow bubble column reactor achieves high hydrogen purity through its inherent flow arrangement and mass transfer characteristics, eliminating the need for external hot separator equipment. The reactor itself performs the separation function by positioning the hydrogen-poor liquid outlet at the bottom and the hydrogen-rich gas outlet at the top, thereby achieving self-service hydrogen purification without additional equipment.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The counter-current flow design enhances hydrogen purity, prevents solids accumulation, and eliminates the need for additional equipment like hot separators, improving operational efficiency and reducing resource requirements.
Implementation Method 1
the petroleum fraction can be in counter-current flow with respect to the gas rich in hydrogen inside the bubble column reactor
Implementation Method 2
a hydrocracking process can split feed molecules into smaller molecules having a higher average volatility and a greater economic value. At the same time, a hydrocracking process can improve material quality by increasing the hydrogen to carbon ratio of the stream and by removing sulfur and nitrogen
Implementation Method 3
the reactor can provide a gas-suspension separation at the top of the reactor
Data Source
AI summary
In one exemplary embodiment, a system for reacting a first feed can include a petroleum fraction having at least about 90%, by volume, with a boiling point of at least about 300° C. The system can include a bubble column reactor. The bubble column reactor, in turn, can include a first inlet for the first feed and a second inlet for a second feed including a gas rich in hydrogen. In addition, the petroleum fraction may be in counter-current flow with respect to the gas rich in hydrogen inside the bubble column reactor.