阅读说明：本技术 用于下流式反应器的污垢收集装置 (Dirt collecting device for downflow reactor ) 是由 徐占平 陈鹏飞 于 2018-12-20 设计创作，主要内容包括：本发明涉及一种污垢收集装置,该污垢收集装置位于下流式反应器头部内,用于从进料流中去除固体以增加反应器操作循环时间,而不影响用于催化剂装填的有效反应器空间和反应器压降。更具体地,污垢收集装置在粗液体分配托盘和蒸气-液体分配托盘上方的反应器容器的上部部分中。(The present invention relates to a fouling collection device located within a downflow reactor head for removing solids from a feedstream to increase reactor operating cycle time without affecting the effective reactor space and reactor pressure drop for catalyst loading. More specifically, the foulant collection device is in an upper portion of the reactor vessel above the raw liquid distribution tray and the vapor-liquid distribution tray.)

1. A reactor comprising an upper portion and a lower portion, wherein the upper portion contains a fouling collection device above a raw liquid distribution tray, wherein a vapor-liquid distribution tray is located below the raw liquid distribution tray, and wherein the fouling collection device comprises a cylindrical wall attached to a floor of the raw liquid distribution tray and a layer of spacer material seated on the raw liquid distribution tray floor having a plurality of perforations, and a series of riser with caps attached to the raw liquid distribution tray.

2. The reactor of claim 1, wherein the dirt collection device has a filter region spaced a short distance above the floor of the raw liquid distribution tray, and the filter region comprises a single layer of filter material having the same physical and chemical properties.

3. The reactor of claim 1 wherein the diameter of the cylindrical wall is less than the diameter of the raw liquid distribution tray.

4. The reactor of claim 1, wherein the fouling collection device has a filtration zone with two or more layers of filtration material having different physical or chemical properties.

5. The reactor of claim 1, wherein the filtration region comprises porous ceramic particles.

6. The reactor of claim 1, wherein the filter region comprises a filter material containing an active material for promoting certain chemical reactions.

7. The reactor of claim 1, wherein the foulant collection device is spaced above the raw liquid distribution tray by a plurality of partitions or grids.

8. The reactor of claim 1, wherein the fouling collection device comprises a profiled wire.

9. The reactor of claim 1, wherein the fouling collection device comprises a grid.

10. The reactor of claim 1 wherein the fouling collection means comprises a wire mesh.

11. The reactor of claim 1, wherein the fouling collection device comprises a riser covered by a cap.

12. The reactor of claim 11, wherein the riser and cap are in the shape of an elongated rectangle positioned across the raw liquid distribution tray.

13. The reactor of claim 11, wherein the riser and cap are in the shape of a circle or square distributed across the raw liquid distribution tray.

14. The reactor of claim 11, wherein the chimney is sized such that liquid overflowing through the chimney does not fall onto the top of the distributor on a vapor-liquid distribution tray.

15. The reactor of claim 1, wherein a sidewall of the foulant collection device includes a notch.

16. The reactor of claim 11, wherein the cap comprises an upper portion that extends downward below the filter bed.

17. The reactor of claim 1, wherein the raw liquid distribution tray comprises holes, the number and size of the holes being set to produce a desired liquid level within the foulant collection device.

18. The reactor of claim 1, wherein the raw liquid distribution tray is larger than the foulant collection device such that overflow liquid from the sidewall can be captured by the raw liquid distribution tray for redistribution.

19. An apparatus comprising an upper portion and a lower portion, wherein the upper portion contains a fouling collection device located above a raw liquid distribution tray, wherein a vapor-liquid distribution tray is located below the raw liquid distribution tray, and wherein the raw liquid distribution tray 22 comprises a plurality of riser cartridges and caps.

20. The apparatus of claim 19, wherein the dirt collection means comprises a filtration region, wherein the filtration region comprises one or more layers of filtration material having the same or different physical or chemical properties.

21. The apparatus of claim 20, wherein the filter region comprises porous ceramic particles.

22. The apparatus of claim 19, wherein the coarse liquid distribution tray comprises apertures sized and numbered to produce a desired liquid level within the filtration zone.

Technical Field

The present invention relates to an apparatus for improving the operation of a downflow reactor. More particularly, the present invention relates to a fouling collection device located within the downflow reactor head for removing solids from the feedstream to increase reactor operating cycle time without affecting the effective reactor space and reactor pressure drop for catalyst loading.

Background

In downflow reactors, such as downflow reactors, a layer of filter material is typically placed on top of the first catalyst bed to capture particulates such as fines and fouling. Typically, the layer may be 6 to 36 inches thick and reduces the available space occupied by the catalyst. In addition, when solids accumulate within the filter material layer or between the filter material and the catalyst bed, causing high pressure drops, the filter material must be removed and replaced during the operating cycle. In commercial operations, the feed rate may vary widely (e.g., 60% to 110% of design). The challenge is to design a fouling collection device that can effectively remove solids from the reactor feed stream without reducing catalyst loading and that can be easily cleaned and maintained during service.

Disclosure of Invention

The present invention relates to a reactor comprising an upper section and a lower section, wherein the upper section comprises a fouling collection device. The fouling collection device consists of a filtration zone located above a raw liquid distribution tray, and wherein the vapor-liquid distribution tray is located below the raw liquid distribution tray, and wherein the lower section contains a catalyst bed. The filter region may comprise a single or multiple layers of filter material having the same or different physical and chemical properties. The filter region contains porous ceramic particles or other material that performs a similar function. The filter material is closed by a cylindrical side wall attached to the floor of the coarse liquid distribution tray. The cylindrical wall has a diameter less than the diameter of the coarse liquid distribution tray. The filtration zone is spaced above the bottom perforated plate of the raw liquid distribution tray by a plurality of spacers or grid material so that the holes in the bottom plate of the raw liquid distribution tray are not blocked by the filtration material. The spacer or grid rests directly on the perforated plate of the raw liquid distribution tray within the cylindrical side wall. A layer of wire mesh may be placed over the spacers or grids and at the bottom of the filter bed so that the filter material does not fall onto the perforated plate of the coarse liquid distribution tray. A plurality of riser cartridges with caps are attached to the bottom of the perforated plate of the coarse liquid distribution tray for liquid overflow so that the tray can operate over a wide range of liquid flow rates while remaining liquid full in the filtration zone during operation in order to maximize solids removal efficiency. The addition of a cap to the chimney is to ensure that overflow liquid must enter the chimney from a gap at the bottom of the cap near the bottom of the tray so that the overflow liquid does not bypass the filter material for the solids removal material.

Drawings

Figure 1 shows the upper part of the reactor showing the dirt collection means above the distribution tray.

Detailed Description

It has now been found that different arrangements are preferred to filter particulates from the feed stream in the downflow reactor. More specifically, the foulant collection device is located in the upper portion or reactor head of the downflow reactor for removing solids from the feedstream and increasing the reactor operating cycle time without any effect on the amount of effective reactor space for catalyst loading. It has also been found that by maintaining a certain level of liquid within the device to increase the uniformity of the liquid flow distribution and reduce the liquid flow rate through the filtration zone, the solids removal efficiency can be greatly increased and the effective use of the filter material for solids removal can be greatly improved. This is achieved by a specially designed dirt collection means located within the reactor head. As shown in fig. 1, the dirt collection means is comprised of the cylindrical sidewall 28 and one or more layers of filter material 44 positioned above the raw liquid distribution tray 22. A layer of grid and wire mesh 16 may be placed between the perforated plate 14 of the RLDT and the filter bed so that the filter material does not fall onto the perforated plate causing the holes to become blocked. A plurality of risers with caps 30 are attached to perforated plate 14 within cylindrical wall 28 for liquid overflow at high feed rates. The filter bed 32 comprises one or more layers of filter material having the same or different physical and chemical properties. A hold-down mesh may be present on top of the filter material to prevent the filter material from moving around. The top of the cylindrical side wall is notched to control liquid overflow around the top of the wall when the filter bed is plugged. A riser with a cap extends above the top of the filter bed and overflow liquid needs to pass through the filter bed before entering the riser. The height of the rising drums is designed to maintain a certain level of liquid in the dirt collection device before the liquid overflows through the rising drums. Liquid from the perforated floor and overflow liquid from the chimney fall onto the underlying vapor-liquid distribution tray for redistribution. The chimney is sized and positioned so that if the distributor is without a cap above the top of the vapor entry opening, the overflow liquid does not fall onto the top of the plurality of distributors on the vapor-liquid distribution tray.

Gas and liquid enter the reactor through inlet distributor 34. The inlet flow stream may be straightened vertically downward by an orifice plate at the top of the distributor. The liquid is distributed over the top of the dirt collection means. The gas is separated from the liquid in the space between the inlet distributor 34 and the top of the dirt collection device 20. The liquid flows downwardly through the fouling collection device and the gas passes through the open annular region between the cylindrical sidewall 28 and the reactor head 12. In the case where gas bypasses the filter material, the pressure drop does not increase even if the filter material is filled with solid.

By this design, reactor cycle time can be increased by additional filter beds in the top reactor head 12, or catalyst loading can be increased by reducing filter material on top of the catalyst bed.

The liquid leaving the filtration zone is redistributed by the coarse liquid distribution tray 22 below. The gas and liquid are then distributed to the catalyst bed through a vapor-liquid distribution tray 24 in fluid communication with the coarse liquid distribution tray. The coarse distribution tray 22 includes an upper liquid retention baffle 36.

As shown in fig. 1, an outer reactor shell having a rounded upper portion 12 is shown for removing foulants and fines from a liquid stream within a reactor 10, according to one or more embodiments of the present invention. The lower portion of reactor 10 contains a catalyst bed 26. The fouling collection device 20 is located above a coarse liquid distribution tray 22 and a vapor-liquid distribution tray 24. In the dirt collection device 20, the filter area 32 is located a short distance above the floor 14 having the series of openings 18. Portions of the grid are placed within the cylindrical sidewall 28 on the bottom perforated plate 14 for supporting the filter material in the filter region 32. The grid is mostly open (more than 50%) so as not to restrict the flow of liquid through the dirt collection device to the raw liquid distribution tray 22. The total open area of the perforations 18 in the bottom plate 14 is designed such that a certain level of liquid is maintained in the dirt collection device at a minimum operating liquid load. The top of the cylindrical sidewall 28 of the dirt collection device 20 has a recess or opening, such as a triangular or rectangular opening, for liquid overflow in the event that the filtration zone becomes clogged with solids. To prevent overflow liquid from bypassing the filtration zone without filtration, one or more lift cartridges with caps 30 are attached to the coarse liquid distribution tray 22. The riser extends upwardly above a coarse liquid distribution tray 22 for maintaining a level of liquid on the tray before the liquid overflows through the riser. The cap on the top of the rising cartridge is spaced a short distance above the perforated plate of the raw liquid distribution tray for liquid to enter so that overflow liquid does not bypass the filter material. The riser cartridge and cap can be designed in a variety of shapes and sizes, and preferably the overflow liquid does not fall onto the top of the dispenser 40. In the example shown in fig. 1, there are 8 rectangular riser cartridges and caps 30 in total. Round or square shaped lift cylinders and caps may also be used. The liquid from the foulant collection device then flows down to the raw liquid distribution tray 22 for redistribution to the vapor-liquid distribution tray 24. The gas and liquid from the vapor-liquid distribution tray 24 then pass through the underlying catalyst bed 26. The vapor-liquid distribution tray 24 has a plurality of distributors 40 for uniformly distributing the gas and liquid over the top of the catalyst bed 26.

The fouling collection device 20, coarse liquid distribution tray 22 and vapor-liquid distribution tray 24 may be supported by a set of double truss beams on one support ring attached to the reactor shell 42.

The filter material 44 used in the filter region 32 may include particles, sheets, or other configurations of porous materials known in the art. Preferred materials for the filter region are ceramic particles having a high internal porosity, such as those available from crystallography technologies, Inc, located in Houston, Texas USA. One or more layers of filter material 44 having the same or different physical and chemical properties may be used in the filter region 32. Other filter materials may be used. The grid or the grid with the wire mesh sheet 16 on which the filter material 44 is supported has openings that are smaller than the size of the filter material 44.

This configuration also reduces the tendency of the coarse liquid distribution tray 22 and vapor-liquid distribution tray 24 to become clogged with solids with respect to the collection of solid material from the liquid. The quality of the liquid distribution through the raw liquid distribution tray 22 and the vapor-liquid distribution tray 24 has also been found to improve because the dirt collection device 20 above reduces liquid disturbance on the raw liquid distribution tray 22.

The filter material can be loaded into the dirt collection device using various methods, such as a socket or bucket, and removed by vacuum. The device is easy to clean and maintain after the filter material is removed during service.

The entire dirt collection device is filled with filter material 44 and the total porosity of the filter material can be as high as 93%, so the device has a high solids removal capacity. The solids removal efficiency is also high due to the special design of the dirt collection apparatus in which the filter material is largely submerged in the liquid pool and no liquid bypasses the apparatus without filtering before the apparatus reaches full capacity for solids removal.

Detailed description of the preferred embodiments

While the following is described in conjunction with specific embodiments, it is to be understood that this description is intended to illustrate and not limit the scope of the foregoing description and the appended claims.

While the following is described in conjunction with specific embodiments, it is to be understood that this description is intended to illustrate and not limit the scope of the foregoing description and the appended claims.

A first embodiment of the present invention is an apparatus comprising an upper portion and a lower portion, wherein the upper portion contains a fouling collection device above a raw liquid distribution tray, wherein a vapor-liquid distribution tray is located below the raw liquid distribution tray, and wherein the fouling collection device comprises a cylindrical wall attached to a floor of the raw liquid distribution tray and a layer of spacer material seated on the floor of the raw liquid distribution tray having a plurality of perforations, and a series of chimney barrels with caps attached to the raw liquid distribution tray. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the dirt collection means has a filtration region spaced a short distance above the floor and the filtration region comprises a single layer of filtration material having the same physical and chemical properties. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the diameter of the cylindrical wall is less than the diameter of the raw liquid distribution tray; an embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the dirt collection means has a filtration zone having two or more layers of filtration material having different physical or chemical properties. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the filtration region comprises porous ceramic particles. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the filtration region comprises a filtration material comprising an active material for promoting certain chemical reactions. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the dirt collection means is spaced above the raw liquid distribution tray by a plurality of partitions or grids. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the dirt collection means comprises a profiled wire. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the dirt collection means comprises a grate. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the dirt collection means comprises a wire mesh. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the dirt collection means comprises a chimney covered by a cap. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the riser and the cap are in the shape of an elongated rectangle positioned across the raw liquid dispensing tray. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the riser and the cap are in a circular or square shape distributed across the raw liquid distribution tray. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the chimney is sized such that liquid overflowing the chimney does not fall onto the top of the distributor on the vapor-liquid distribution tray. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the sidewall of the dirt collection means comprises a recess. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the cap comprises an upper portion extending downward below the filter bed. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the raw liquid distribution tray comprises holes in a number and size to produce a desired liquid level within the dirt collection device. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the raw liquid distribution tray is larger than the foulant collection device such that overflow liquid from the sidewall can be captured by the raw liquid distribution tray for redistribution.

A second embodiment of the invention is an apparatus comprising an upper section and a lower section, wherein the upper section contains a fouling collection device located above a raw liquid distribution tray, wherein the vapor-liquid distribution tray is located below the raw liquid distribution tray, and wherein the raw liquid distribution tray comprises a plurality of chimney cans and a cap. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein the dirt collection means comprises a filtration region, wherein the filtration region comprises one or more layers of filtration material having the same or different physical or chemical properties. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein the filtration region comprises porous ceramic particles. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein the coarse liquid distribution tray comprises apertures sized and numbered to produce a desired liquid level within the filtration zone.

Without further elaboration, it is believed that one skilled in the art can, using the preceding description, utilize the present invention to its fullest extent and can readily ascertain the essential characteristics of the present invention without departing from the spirit and scope thereof, to make various changes and modifications of the invention and to adapt it to various usages and conditions. Accordingly, the foregoing preferred specific embodiments are to be construed as merely illustrative, and not limitative of the remainder of the disclosure in any way whatsoever, and is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims. In the foregoing, all temperatures are shown in degrees celsius and all parts and percentages are by weight unless otherwise indicated.