Hydroprocessing Reactor Internals Height Reduction
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Solution Overview
Problem
In hydroprocessing reactors, existing designs face challenges with temperature and composition distribution between catalyst beds, leading to uneven reactions and rapid catalyst deactivation, while also occupying valuable space, which limits catalyst loading and reactor efficiency.
Innovation Solution
The design minimizes the height of hydroprocessing reactor internals by placing a mixing chamber above the collection tray and using a ring quench distributor to eliminate vertical space, with directional baffles and vapor-liquid segregation to enhance fluid mixing and distribution, reducing the space between catalyst beds and improving catalyst loading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional interbed spaces are used to provide intermediate treatment of process fluid, then temperature and composition distribution is improved, but reactor space utilization deteriorates
Solution Approach 1:
The patent combines the quench gas injection function and the fluid mixing function into a single integrated interbed space design. The quench gas is injected directly into the interbed space where it automatically mixes with the process fluid through the upward flow pattern, eliminating the need for separate injection systems and mixing devices while achieving both cooling and distribution objectives.
Solution Approach 2:
The patent utilizes the vertical dimension of the interbed space by creating an upward flow pattern that moves from the collection tray toward the reactor shell. This vertical movement enhances mixing efficiency and temperature distribution without requiring additional horizontal space, effectively using the third dimension to improve fluid dynamics within the constrained interbed volume.
2Stability of the object's composition
If complex mixing and distribution systems are used to control temperature and composition, then fluid distribution is improved, but device complexity increases
Solution Approach 1:
The interbed space design allows the quench gas to self-mix with the process fluid through the natural upward flow pattern created by the collection tray geometry. The system uses the fluid dynamics itself to achieve mixing and distribution without requiring external mixing devices, mechanical agitators, or complex distribution networks, thereby simplifying the overall system while maintaining effective fluid distribution.
3Ease of operation
If larger interbed spaces are provided for quench fluid injection and mixing, then mixing efficiency is improved, but catalyst loading capacity deteriorates
Solution Approach 1:
The patent changes the flow direction parameter from conventional downward flow to upward flow within the interbed space. This parameter change creates a more effective mixing pattern that achieves better temperature and composition distribution in a smaller volume, thereby improving mixing efficiency without sacrificing catalyst loading capacity. The upward flow pattern enhances contact between quench gas and process fluid, achieving thorough mixing in a compact space.
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 reduces the space between catalyst beds by 30.5 to 91.4 cm, enhancing catalyst loading, increasing production rate and operation cycle length, and providing cost savings by optimizing reactor space usage.
Implementation Method 1
The space between catalyst beds is for the injection of a quench gas or liquid and for fluid mixing and distribution
Implementation Method 2
the fluid is usually directed to flow downward through the reactor
Implementation Method 3
In hydrocarbon processing, the quench gas is often a cool hydrogen/hydrocarbon stream
Data Source
Figure 1
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AI summary
The hydroprocessing reactor internals (HRI) have reduced height compared to standard HRI designs. In this design, HRI height reduction is achieved by placing a mixing chamber above the collection tray. A ring quench distributor is located around the fluid collection tray between the mixing chamber and reactor shell to eliminate the vertical space occupied by the distributor. The hydroprocessing reactor quench zone internals comprise a collection tray, a mixing chamber, a ring distributer, a rough liquid distribution tray, and a vapor-liquid distribution tray. Fluid mixing occurs in the mixing chamber and above the rough liquid distribution tray.