Slurry Reactor Internal Cyclone Separator Integration
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Solution Overview
Problem
Conventional slurry-phase reactor systems for hydrocarbon processing are costly due to the high temperature and pressure requirements of the hot separators and cyclones, necessitating a reduction in capital costs.
Innovation Solution
A system comprising serially aligned reactors with a final stage reactor that integrates a separator section and a cyclone separator to produce distinct gas and non-gas streams, eliminating the need for a separate hot separator, and utilizing a nozzle and deflector to enhance vapor-liquid separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate hot separator and cyclone are used for phase separation, then sufficient phase separation is achieved, but capital cost increases due to high temperature and pressure requirements
Solution Approach 1:
The patent combines the hot separator and cyclone functions into a single integrated reactor-vessel system. The reactor vessel serves dual purposes: as the reaction chamber and as the phase separation unit. This eliminates the need for separate hot separator and cyclone vessels, reducing capital costs while maintaining separation functionality through internal geometry design and operational parameters
Solution Approach 2:
The reactor vessel is designed to perform multiple functions simultaneously: hydrocarbon feed conversion through hydrocracking, vapor-liquid separation, and solid catalyst removal. By making the reactor vessel multi-functional, the system eliminates dedicated separation vessels, thereby reducing the number of high-pressure/high-temperature components that require expensive manufacturing
2Ease of manufacture
If the number of separate vessels is reduced, then capital cost decreases, but device complexity increases due to integration requirements
Solution Approach 1:
The patent merges multiple vessel functions into a single reactor vessel, reducing the total number of vessels from three (reactor, hot separator, cyclone) to one. This consolidation simplifies the overall system architecture and reduces interconnections, thereby lowering complexity despite the multi-functional requirements
3Ease of manufacture
If a single reactor vessel performs multiple functions, then capital cost is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The reactor vessel incorporates localized geometric features and internal structures optimized for specific functions: the upper portion is designed with geometry promoting vapor-liquid separation, while the lower portion facilitates solid catalyst removal. This localized optimization allows each region of the vessel to perform its specific function effectively without requiring the entire vessel to be manufactured to uniformly high precision tolerances
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 reduces capital costs by integrating separation functions within the reactor vessel, ensuring sufficient phase separation for further hydroprocessing while maintaining efficient product conversion and minimizing coking reactions.
Implementation Method 1
The cyclone 20 is a separator that uses inertia and a spiral vortex to remove small droplets of liquid and solid particles
Implementation Method 2
The cyclone 20 is a separator that uses inertia and a spiral vortex to remove small droplets of liquid and solid particles
Data Source
AI summary
A system for processing a hydrocarbon feed has a final stage reactor and internal separator with cyclone that forms a substantially gas stream and a substantially non-gas stream. The substantially gas stream is sent directly from the final stage reactor and separator to further downstream processing.