Hydroprocessing Reactor Internals With Reduced Interbed Mixing Height
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Solution Overview
Problem
Existing hydroprocessing reactors face challenges with uneven temperature and composition distribution between catalyst beds, leading to hot spots and catalyst deactivation, while requiring significant space for quench fluid injection and mixing systems, which increases reactor size and reduces catalyst loading.
Innovation Solution
A redesigned hydroprocessing reactor internals (HRI) with a collection tray, rough liquid distribution tray, and vapor-liquid distribution tray, incorporating features like vapor chimneys, fluid distribution troughs, and a ring distributor to enhance mixing and distribution of fluids between catalyst beds, minimizing the interbed space and optimizing catalyst loading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If complex mixing and distribution systems are used to improve temperature and composition distribution, then mixing quality is improved, but device complexity and space requirements increase
Solution Approach 1:
The distribution system is segmented into multiple functional trays (rough liquid distribution tray, vapor-liquid distribution tray) with specialized functions. Each tray handles specific aspects of fluid distribution, allowing simplified individual components to achieve complex overall mixing through modular arrangement rather than requiring a single complex system.
Solution Approach 2:
The invention transitions from traditional horizontal mixing approaches to a vertical dimension by using stacked trays arranged in the height direction. Fluids are distributed and mixed across multiple levels (rough liquid distribution tray at upper level, vapor-liquid distribution tray at lower level), utilizing the vertical space to achieve mixing that would require complex horizontal systems in conventional designs.
2Productivity
If interbed space is reduced to increase catalyst loading, then productivity is improved, but mixing and distribution quality deteriorates
Solution Approach 1:
The invention resolves the space conflict by moving the mixing and distribution functions to the vertical dimension. Multiple distribution trays are stacked vertically between catalyst beds, allowing adequate mixing space in the height direction while maintaining compact horizontal footprint. This enables reduced interbed horizontal space for increased catalyst loading while preserving mixing quality through vertical tray arrangement.
Solution Approach 2:
The mixing function is segmented across multiple vertically stacked trays, with each tray providing a discrete mixing zone. The rough liquid distribution tray handles liquid phase mixing while the vapor-liquid distribution tray handles vapor phase mixing. This segmentation allows adequate mixing space to be distributed vertically rather than requiring large horizontal spaces, enabling higher catalyst loading.
3Volume of stationary object
If reactor size is reduced to decrease capital expenditure, then cost is reduced, but mixing and distribution capability is compromised
Solution Approach 1:
The invention optimizes reactor volume utilization by arranging distribution trays in the vertical dimension rather than requiring large horizontal spaces. The rough liquid distribution tray and vapor-liquid distribution tray are stacked vertically, allowing efficient use of the reactor's height dimension. This vertical arrangement achieves adequate mixing and distribution capability within a compact overall reactor volume, reducing capital expenditure while maintaining fluid distribution quality.
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 redesigned HRI system improves temperature and composition distribution, reduces reactor size, increases catalyst loading, and extends operation cycle length, thereby enhancing process efficiency and cost-effectiveness.
Implementation Method 1
a ring distributor with an injector for injecting quench fluid into a space above the collection tray
Implementation Method 2
vapor chimneys for vapor flow
Implementation Method 3
The fluid distribution troughs have holes in a bottom plate for liquid flow to the vapor-liquid distribution tray below
Implementation Method 4
The side walls of the fluid distribution troughs are sloped from the central pan to the end wall to create turbulence
Implementation Method 5
a collection tray with a central opening for downward fluid flow
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The hydroprocessing reactor internals (HRI) have reduced height compared to standard HRI designs. The HRI height reduction is achieved by a more open design of a rough liquid distribution tray so that the required spaces above and below the tray for vapor flow are reduced. The hydroprocessing reactor quench zone internals comprise a collection tray, a rough liquid distribution tray, and a vapor-liquid distribution tray. Fluid mixing occurs above both the collection tray and the rough liquid distribution tray.