Hydroprocessing Reactor Shutdown via Water Flooding and Nitrogen Purging
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Solution Overview
Problem
Current hydroprocessing reactor shutdown procedures are inefficient, pose safety risks to personnel, and can cause equipment damage due to the need for inert gas environments, which restrict access and lead to prolonged shutdowns and increased costs.
Innovation Solution
A method involving shutting off hydrocarbon feed, stripping hydrocarbons, cooling the reactor, purging with N2 gas, and introducing water to facilitate catalyst removal, with controlled temperature thresholds and quench gas distribution systems to ensure safe and rapid shutdowns, minimizing equipment damage and personnel risk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional shutdown procedures using inert gas environments are used, then personnel safety is improved, but shutdown duration increases and equipment access is restricted
Solution Approach 1:
The patent applies inert atmosphere by maintaining nitrogen gas purging throughout the shutdown process, creating an oxygen-free environment that prevents catalyst oxidation and ensures personnel safety while enabling faster catalyst removal compared to conventional methods
Solution Approach 2:
The patent maintains continuous nitrogen purging and inert atmosphere throughout the entire shutdown sequence, from initial cooling through catalyst removal, eliminating interruptions and extending protective coverage beyond conventional shutdown procedures
2Productivity
If rapid cooling is applied to reduce shutdown time, then productivity is improved, but equipment damage may occur
Solution Approach 1:
The patent applies preliminary action by first purging the reactor with nitrogen gas to establish an inert atmosphere before initiating rapid cooling, preventing catalyst oxidation and equipment damage that would occur with direct rapid cooling in conventional procedures
Solution Approach 2:
The patent provides beforehand cushioning by maintaining continuous nitrogen purging during the rapid cooling phase, creating a protective inert environment that cushions against potential oxidation reactions and equipment damage while enabling faster cooling rates
3Ease of operation
If water flooding is used to facilitate catalyst removal, then ease of operation is improved, but temperature control requirements increase
Solution Approach 1:
The patent uses water as an intermediary medium to facilitate catalyst removal by flooding the reactor with water that suspends catalyst particles for easy discharge, while nitrogen gas acts as a secondary intermediary maintaining the inert atmosphere during water introduction and catalyst removal
Solution Approach 2:
The patent applies parameter changes by introducing water at controlled temperatures and rates, changing the physical state and flow parameters of the reactor contents to enable catalyst suspension and removal while maintaining temperature control within safe limits
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 process enables faster, safer, and more efficient reactor shutdowns, reducing downtime and costs while ensuring personnel safety by allowing manual entry and minimizing equipment damage through controlled cooling and water flooding.
Implementation Method 1
introducing water into the reactor; and dumping a catalyst slurry from the reactor, the catalyst slurry comprising the catalyst and the water
Implementation Method 2
cooling the reactor to a first threshold reactor temperature
Implementation Method 3
stripping hydrocarbons from the catalyst
Data Source
AI summary
Processes for shutting down a hydroprocessing reactor and for removing catalyst from the reactor may comprise shutting off hydrocarbon feed to the reactor, stripping hydrocarbons from the catalyst, cooling the reactor to a first threshold reactor temperature, purging the reactor with N2 gas, introducing water into the reactor, and dumping the catalyst from the reactor, wherein the first threshold reactor temperature may be substantially greater than 200° F. In an embodiment, the water may be introduced into the reactor via a quench gas distribution system when the reactor is at a second threshold reactor temperature not greater than 200° F. to cool the reactor to a third threshold reactor temperature not greater than 120° F.