Integrated Hydroprocessing Vessel with Counter-Flow Mass Transfer
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Solution Overview
Problem
Current hydro-processing technologies face challenges in effectively integrating heat and mass transfer across multiple stages for low boiling hydrocarbon feeds, particularly in removing sulfur compounds and olefins, with existing systems often requiring external heat sources and experiencing issues with flooding and catalyst bed loading.
Innovation Solution
An integrated hydro-processing reaction vessel with a stabilizer, reactor, and separator section, utilizing a demister, liquid and vapor phase distributors, and a self-regulating liquid seal mechanism, where low boiling hydrocarbon streams with sulfur compounds and heavy boiling olefinic streams undergo counter-flow hydro-processing, generating in-situ heat and optimizing mass transfer stages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple stages of hydro-processing are integrated in a single vessel, then mass transfer efficiency and sulfur removal are improved, but device complexity increases
Solution Approach 1:
The reaction vessel is divided into multiple functional zones: a first reaction zone for initial hydro-processing, a second reaction zone for subsequent treatment, a stripping zone for removing light components, and a separation zone for product separation. This segmentation allows multiple mass transfer stages to occur in sequence within a single vessel, improving overall productivity while maintaining manageable complexity through zoned functionality.
Solution Approach 2:
The patent introduces vertical stacking of reaction zones and stripping sections, transitioning from conventional horizontal multi-vessel arrangements to a vertical integrated configuration. This dimensional change enables multiple process stages to occupy the same horizontal footprint while utilizing vertical space, thereby improving mass transfer efficiency without proportionally increasing device complexity.
2Use of energy by moving object
If counter-current flow configuration is used, then heat integration and energy efficiency are improved, but flooding risks increase
Solution Approach 1:
A stripping section with stripping plates is introduced as an intermediary zone between the reaction zones and the separation zone. This stripping section acts as a buffer that manages liquid-gas flow dynamics, preventing direct flooding between counter-current reacting streams while still enabling effective heat integration. The stripping plates provide controlled mass transfer surfaces that regulate flow distribution.
Solution Approach 2:
The patent replaces traditional mechanical flood control mechanisms (such as extensive downcomer systems) with a vapor-phase stripping section that uses phase change and vapor-liquid equilibrium to manage flow. This substitution reduces mechanical complexity and flooding risks while maintaining heat integration benefits of counter-current flow.
3Temperature
If external heat sources are used for hydro-processing, then reaction temperature control is improved, but energy consumption increases
Solution Approach 1:
The patent merges heating and cooling functions within the integrated vessel by allowing exothermic reactions in lower zones to pre-heat incoming feeds and by using steam injection in the stripping zone to provide controlled heating. This internal heat integration reduces or eliminates the need for external heat sources, thereby reducing energy consumption while maintaining effective temperature control across different reaction zones.
Solution Approach 2:
The patent converts the heat that would normally be considered waste heat from exothermic hydro-processing reactions into a useful resource for pre-heating incoming feeds and for providing steam in the stripping zone. This transformation of harmful excess heat into beneficial thermal energy reduces external energy requirements while maintaining reaction temperature control.
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 configuration enhances heat integration, minimizes external heat energy requirements, and effectively removes sulfur compounds and olefins, achieving efficient hydro-processing with reduced flooding risks and optimized catalyst bed utilization.
Implementation Method 1
the reaction between sulphur compounds of the primary stream and the olefins of the secondary stream results in formation of heavy boiling sulphur compounds in liquid state and heteroatom lean low boiling stream
Implementation Method 2
The demister is made of a mesh type coalescer arrangement which is adapted to restrict the entrainment of liquid
Implementation Method 3
The bottom portion acting as a separator section consisting of a liquid seal mechanism containing an inverted outer pipe
Implementation Method 4
the reactor section comprises of two distributors; a liquid phase distributor located at a top part of the reactor section, and a vapour phase distributor located at a bottom part of the reactor section
Data Source
AI summary
The present invention relates to an integrated hydro-processing reaction vessel which comprises of all the reactor, separator and stabilization sections integrated in a single vessel or system for hydro-processing of low boiling vapour phase hydrocarbon feed; as primary stream undergoing multitude of mass transfer stages with the heavy boiling liquid phase hydrocarbon feed; as secondary stream.