Hydroprocessing Quench Zone Internals for Uniform Interbed Distribution
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing hydroprocessing reactors face challenges in minimizing the space between catalyst beds for effective quench fluid injection, mixing, and distribution, leading to uneven reactions and catalyst deactivation due to poor temperature and composition distribution.
Innovation Solution
The introduction of a hydroprocessing reactor internals system comprising a collection tray, mixing chamber, ring quench distributor, rough liquid distribution tray, and vapor-liquid distribution tray, with longitudinal and cross baffles to enhance fluid distribution and minimize turbulence, ensuring uniform fluid distribution to lower catalyst beds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the space between catalyst beds is reduced to increase catalyst loading, then productivity is improved, but the ability to achieve proper fluid mixing and distribution deteriorates
Solution Approach 1:
The quench zone is divided into multiple functional segments: a rough liquid distribution tray with radial troughs for initial distribution, a vapor-liquid distribution tray with distributors for final distribution, and a mixing chamber. This segmentation allows each component to perform a specific function, achieving proper mixing and distribution in a compact space.
Solution Approach 2:
The invention uses radial troughs extending from the center to the periphery, utilizing radial flow patterns to enhance mixing. The longitudinal baffles in the troughs create three-dimensional flow patterns that improve mixing efficiency without increasing vertical space requirements.
2Temperature
If complex mixing and distribution systems are used to control temperature and composition distribution, then temperature distribution is improved, but the space occupied in the reactor increases
Solution Approach 1:
The invention combines multiple functions into integrated components. The rough liquid distribution tray and vapor-liquid distribution tray work together as a unified system, with the mixing chamber serving both as a mixing zone and a distribution chamber. This merging reduces the overall volume required compared to separate systems for each function.
Solution Approach 2:
The invention uses fluid dynamics principles where vapor and liquid flows interact naturally in the mixing chamber. The radial troughs and distributors utilize pressure gradients and flow patterns to achieve mixing and distribution without requiring additional mechanical mixing devices, saving space.
3Volume of stationary object
If insufficient space is provided for quench fluid injection and mixing, then reactor size is reduced, but fluid distribution uniformity deteriorates
Solution Approach 1:
The invention provides enhanced mixing and distribution capabilities at critical locations. The rough liquid distribution tray with radial troughs ensures uniform initial distribution across the reactor cross-section, while the vapor-liquid distribution tray with distributors maintains uniformity at the point of catalyst contact. This localized quality enhancement achieves precision without increasing overall reactor volume.
4Productivity
If the interbed space is minimized for increasing catalyst loading, then productivity is improved, but the ability to prevent hot spots and catalyst deactivation deteriorates
Solution Approach 1:
The rough liquid distribution tray performs preliminary distribution of quench fluid before the vapor-liquid distribution tray. This preliminary action ensures that cooling and mixing begin early in the quench zone, preventing hot spot formation even in the reduced space available, thereby protecting catalyst integrity and extending operation cycle length.
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 improves fluid distribution uniformity, reduces reactor size, increases catalyst loading, and extends operation cycle length, enhancing reactor efficiency and cost-effectiveness.
Implementation Method 1
Fluid mixing occurs mainly in the mixing chamber
Implementation Method 2
A ring quench distributor is located above the fluid collection tray between the mixing chamber and the reactor shell to eliminate the vertical space occupied by the distributor. The injectors attached to the ring quench distributor manifold are positioned above the top plate of the mixing chamber
Implementation Method 3
a rough liquid distribution tray, and a vapor-liquid distribution tray. Fluid mixing occurs mainly in the mixing chamber
Data Source
Figure 1
Figure 2
AI summary
The hydroprocessing reactor quench zone internals comprise a collection tray, a mixing chamber, a ring quench distributer, a rough liquid distribution tray, and a vapor-liquid distribution tray. The rough liquid distribution tray has a central pan for receiving vapor and liquid out of the mixing chamber and multiple fluid distribution troughs attached to the central pan that extended radially outwards with the outer end close to the reactor shell. The fluid distribution troughs can include at least one longitudinal baffle, or at least one cross baffle, or both, and optionally an end baffle. The baffles improve the liquid and/or vapor flow in the rough liquid distribution tray.