Horizontal Hydroprocessing Reactor with Integrated Gas Separation
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Solution Overview
Problem
Conventional hydroprocessing reactors face limitations such as mass transfer issues, large reactor sizes, exotherm management challenges, secondary cracking of products, and inhibitory effects of reaction products like H2S and NH3, which require additional separation and reaction vessels.
Innovation Solution
A horizontally oriented reactor system with a fixed bed catalyst and a longitudinal sparger for continuous hydrogen replenishment, combined with vertically oriented gas separation and withdrawal means, allows for continuous removal of gaseous products while maintaining a single phase liquid hydrocarbon feed saturated with hydrogen, thereby overcoming mass transfer limitations and enabling efficient multistage hydroprocessing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fixed bed reactor is used for hydroprocessing, then catalyst bed can be maintained, but mass transfer limitations and large reactor size are incurred
Solution Approach 1:
The catalyst bed is segmented into multiple stages with inter-stage separation zones. This segmentation allows for improved mass transfer by creating distinct reaction zones while maintaining catalyst stability, resolving the contradiction between catalyst bed reliability and mass transfer efficiency
Solution Approach 2:
The reactor transitions from a conventional vertical configuration to a horizontal orientation with three-phase flow. This dimensional change enables better mass transfer characteristics and reduced reactor size while maintaining catalyst bed functionality through the segmented design
2Device complexity
If conventional hydroprocessing is carried out in adiabatic mode, then process is simpler, but temperature control and exotherm management become difficult
Solution Approach 1:
The adiabatic reactor is divided into multiple isothermal stages separated by quench zones. Each stage maintains near-isothermal conditions through localized heat management, enabling temperature control without significantly increasing overall process complexity
Solution Approach 2:
The reactor employs periodic quenching between stages to remove heat generated in each reaction zone. This periodic heat removal maintains temperature control while preserving the simplicity of the continuous flow process
3Productivity
If multiple stage configurations are used to overcome mass transfer limitations, then mass transfer efficiency improves, but additional separation vessels and reactor complexity increase
Solution Approach 1:
Multiple reaction stages and separation functions are merged into a single horizontal reactor vessel. The segmented catalyst beds with integrated separation zones eliminate the need for external separation vessels, improving mass transfer efficiency while maintaining device simplicity
Solution Approach 2:
The horizontal reactor design performs multiple functions (reaction, separation, heat management) within a single vessel configuration. This multi-functionality achieves improved mass transfer without increasing overall reactor complexity
4Device complexity
If reaction products like H2S and NH3 are not removed continuously, then reactor operation is simpler, but inhibitory effects and secondary cracking increase
Solution Approach 1:
The reactor is segmented into multiple stages with inter-stage separation zones that continuously remove reaction products. This segmentation enables product removal without significantly complicating the overall operation, reducing inhibitory effects while maintaining process simplicity
Solution Approach 2:
The multi-stage configuration enables continuous removal of inhibitory products throughout the reaction process. This continuous action prevents product accumulation and secondary cracking while maintaining relatively simple operation through the integrated design
5Ease of manufacture
If conventional vertical reactor orientation is used, then catalyst loading is easier, but gaseous product removal and heat management are less efficient
Solution Approach 1:
The reactor orientation is inverted from the conventional vertical configuration to a horizontal orientation. This inversion improves gaseous product removal efficiency through better phase separation while catalyst loading procedures are adapted to the new orientation, maintaining ease of manufacture
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
This design achieves efficient hydroprocessing with lower process temperatures, reduced secondary cracking, higher liquid yields, smaller reactor size, longer catalyst life, and elimination of reactor quench fluid and recycle gas compressor, leading to lower operating costs and higher revenue generation.
Implementation Method 1
a longitudinal sparger running along bottom portion of the reactor with a multitude of nozzles provided at top periphery of the sparger to distribute gaseous hydrogen
Implementation Method 2
a multitude of vertically oriented gas separation and withdrawal means provided at top of the reactor acting as micro separation vessels for removal of product gases
Implementation Method 3
a fixed bed catalyst loaded inside the reactor throughout length of the reactor
Implementation Method 4
Hydroprocessing is a highly exothermic process involving treatment of hydrocarbon feedstock with hydrogen in the presence of a suitable catalyst
Data Source
Figure 1
AI summary
The present invention provides a multistage single reactor system for hydroprocessing and a process of carrying out multistage hydroprocessing in the said reactor assembly consisting of, a fixed bed solid catalyst system, a feed injection system enabling axial flow of hydrogen saturated hydrocarbon feed, a hydrogen dispensing system inside the reactor enabling minimum required hydrogen flow in cross-flow pattern, also using multitudes of integrated separation and withdrawal limbs for continuous staging. The innovative reactor disclosed in the present invention enables continuous separation and withdrawal of gaseous products along the reactor length by means of combined horizontal reactor orientation and vertical separation limbs provided at the top of the horizontally oriented reactor. The advantage of the reactor assembly includes effective heat sink of exothermic reactions and lower severity of operation due to removal of inhibitory gaseous products.