Particulate Trap for Vapor Feed Contaminant Removal

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Solution Overview

Problem

Contaminants such as non-distillable components, particulate matter, and metals in hydrocarbon-containing vapor streams can foul heat exchange surfaces and deactivate catalysts in catalytic hydrogenation zones, reducing processing efficiency and catalyst lifespan.

Innovation Solution

A process involving a pressurized vapor liquid separator producing a vapor stream that is passed through a particulate trap with multiple treatment zones, including gross solids, fine solids, and reactive zones, to remove contaminants before the stream enters a catalytic hydrogenation zone, maintaining consistent pressures across the system.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the vapor stream is passed directly to a catalytic hydrogenation zone, then processing efficiency is maintained, but contaminants cause catalyst deactivation and fouling

Engineering Contradiction:

Improveprocessing efficiencyVSAvoidcatalyst lifespan

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent applies preliminary action by installing a particulate trap upstream of the catalytic hydrogenation zone to remove contaminants from the vapor stream before it contacts the catalyst. This preventive measure eliminates particulate matter, metals, and non-distillable components ahead of time, preventing catalyst fouling and deactivation while maintaining continuous operation and processing efficiency

Inventive Principle:

Principle #10Preliminary action

2Object-affected harmful factors

If a particulate trap with multiple treatment zones is added, then contaminant removal is improved, but device complexity increases

Engineering Contradiction:

Improvecontaminant removalVSAvoidsystem structure

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent applies segmentation by dividing the particulate trap into multiple treatment zones with different functions: a gross solids removal zone, a fine solids removal zone, and a reactive zone. Each zone targets specific contaminant types and sizes, enabling comprehensive contaminant removal through progressive treatment stages while organizing complexity into manageable functional segments

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies local quality by providing different treatment capabilities in different zones of the particulate trap. The gross solids zone handles large particles, the fine solids zone handles smaller particles, and the reactive zone handles chemical contaminants. Each zone is optimized for its specific function, creating locally tailored solutions for different contaminant types within the overall system

Inventive Principle:

Principle #3Local 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

Effectively removes contaminants, preventing catalyst deactivation and fouling, thereby extending catalyst life and maintaining processing capacity by ensuring cleaner feedstocks for the catalytic hydrogenation zone.

Implementation Method 1

providing a feed stream to a first pressurized vapor liquid separator that produces a liquid stream and a vapor stream containing hydrocarbon and hydrogen

Methodology Applied

Scientific EffectVapor liquid separation: Phase Change

Implementation Method 2

passing the vapor stream to an inlet of a particulate trap containing a plurality of treatment zones that remove contaminants from the vapor stream

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Implementation Method 3

particulate trap containing a plurality of treatment zones that remove contaminants

Methodology Applied

Scientific EffectAdsorption: Adsorption

Implementation Method 4

passing the particulate trap effluent directly to a catalytic hydrogenation zone

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 5

catalytic hydrogenation zone that produces a hydrotreated product

Methodology Applied

Scientific EffectHydrogenation: Hydrogenation

Data Source

PatentUS8038869B2Integrated process for upgrading a vapor feed

Publication Date: 2011.10.18 UOP LLC

AI summary

Processes and systems are provided for removing contaminants from a vapor stream containing hydrocarbon and hydrogen, and can include: providing a feed stream to a first pressurized vapor liquid separator that produces a liquid stream and a vapor stream containing hydrocarbon and hydrogen, passing the vapor stream to an inlet of a particulate trap containing a plurality of treatment zones that remove contaminants from the vapor stream to produce a particulate trap effluent, and passing the particulate trap effluent directly to a catalytic hydrogenation zone. The processes and systems can also include: passing the liquid stream from the first pressurized vapor liquid separator to a second vapor liquid separator that produces an overhead vapor stream and a liquid bottoms stream, condensing the overhead vapor stream from the second vapor liquid separator to form a liquid overhead stream, routing the liquid overhead stream to the inlet of the particulate trap.