Reforming Reactor Centerpipe Geometry Without Shell Expansion
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Solution Overview
Problem
Existing reforming processes face challenges in achieving improved aromatic yield, hydrogen yield, and unit throughput without increasing the size of the reforming reactor, while dealing with issues of catalyst pinning, vapor mal-distribution, and higher reactor pressure drop.
Innovation Solution
Optimizing the centerpipe geometry in reforming reactors by reducing the diameter of the intermediate section of the centerpipe, maintaining the top and bottom diameters, and implementing a non-uniform opening pattern to enhance catalyst volume and improve gas flow distribution, thereby increasing aromatic yield and hydrogen yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the reactor size is increased to improve aromatic yield and hydrogen yield, then the production capacity increases, but the capital cost and reactor footprint increase
Solution Approach 1:
The patent applies local quality by creating a non-uniform centerpipe structure where the intermediate section has a reduced diameter compared to the top and bottom sections. This localized geometric modification optimizes the catalyst bed volume distribution in specific regions, allowing increased aromatic yield without proportionally increasing the overall reactor volume. The non-uniform opening pattern in the intermediate section further refines the local flow characteristics to enhance reaction efficiency.
Solution Approach 2:
The patent utilizes dimensional optimization by modifying the centerpipe geometry in the radial dimension (reducing intermediate section diameter) to increase the annular catalyst bed volume. This dimensional change allows more catalyst to be packed into the existing reactor volume, effectively increasing aromatic yield without expanding the reactor's external dimensions.
2Productivity
If the catalyst volume is increased to improve aromatic yield, then the production capacity increases, but the reactor pressure drop increases
Solution Approach 1:
The non-uniform opening pattern in the centerpipe intermediate section creates localized flow optimization. By strategically positioning and sizing openings in different regions, the patent enhances gas distribution uniformity across the catalyst bed, reducing channeling and dead zones. This local flow optimization allows increased catalyst volume while minimizing excessive pressure drop through improved flow path efficiency.
3Productivity
If the centerpipe diameter is reduced to increase catalyst volume, then the aromatic yield improves, but the gas flow distribution may be affected
Solution Approach 1:
The patent applies local quality through the non-uniform opening pattern in the centerpipe intermediate section. Different regions of the centerpipe have differently sized and positioned openings tailored to local flow requirements. This localized optimization ensures uniform gas distribution across the catalyst bed despite the reduced overall centerpipe diameter, maintaining ease of operation while increasing aromatic yield.
Solution Approach 2:
The patent utilizes parameter changes by modifying the geometric parameters of the centerpipe (diameter, opening size, opening position, opening pattern) to optimize gas flow distribution. These parameter adjustments compensate for the reduced centerpipe diameter, ensuring that gas flows uniformly through the increased catalyst volume without creating flow maldistribution or operational difficulties.
4Productivity
If a non-uniform opening pattern is implemented to improve gas flow distribution, then the aromatic yield increases, but the manufacturing complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the centerpipe intermediate section into multiple zones with different opening patterns. This segmentation allows the complex non-uniform pattern to be broken down into manageable sections that can be manufactured using standard fabrication techniques. Each segment can be independently fabricated and then assembled, reducing overall manufacturing complexity while achieving the desired gas flow distribution for high aromatic yield.
Data Source
AI summary
A method of increasing aromatic yield, or hydrogen yield, or reformate octane, or combinations thereof for a selected set of operating conditions in a reforming process is described. The process uses a centerpipe having a top connection section, a bottom connection section, and an intermediate connection section in which the diameter of the intermediate section is less than a diameter of the top connection section, or the bottom connection section, or both. This arrangement can be present in one or more of the reforming reactors in the reforming reaction zone. A method of optimizing the diameter of the intermediate section is also described.