Hri, Inc.

Hydrocarbon Research, Inc.

Richard M Eccles

Allen S Li

Michael C Chervenak

Govanon Nongbri

Shyy-Jong D Lin

Virginia A Malik

Lloyd M Ruef

An improved flow distribution system for a catalytic reactor plenum chamber for a gas-liquid-solids ebullated bed reactor incudes a baffled nozzle device containing at least two baffle plates usually oriented substantially normal to the nozzle inlet flow direction for providing good mixing and uniform flow distribution of gas-liquid materials in the lower portion of the plenum, used in combination with distribution grid to effect a substantially uniform flow distribution of the gas/liquid mixture upwardly into the ebullated catalyst bed. A sparger can be provided in the plenum above the baffled flow distributor device for feeding additional gas-liquid mixture into the reactor. The flow distribution system provides a substantially uniform flow distribution of the gas-liquid mixture into the ebullated bed and thereby provides fouling-free operation of the reactor.

Fluid flow distribution system for fluidized bed reactor

An improved flow distribution system for a catalytic reactor plenum chamber for a gas-liquid-solids ebullated bed reactor including a downwardly directed conduit and a flow distributor device such as a baffled nozzle attached to the inner end of the conduit, said nozzle containing at least two substantially parallel baffle plates usually oriented substantially normal to the nozzle inlet flow direction for providing initially downward flow and good mixing and radial flow disperson of gas-liquid materials in the lower portion of the plenum. The initially downward flow is then deflected generally upwardly by the curved lower head of the reactor plenum chamber and passes uniformly upwardly through a flow distribution grid into the ebullated catalyst bed. A sparger can be provided in the plenum above the flow distributor device for feeding additional gas-liquid mixture into the reactor. Alternatively, the flow distribution system can include a conical-shaped flow deflector device having its base rigidly attached to the plenum lower wall and having its apex oriented toward and substantially aligned with the centerline of the inner end of the conduit. The flow distribution system provides substantially uniform flow dispersion of the gas-liquid mixture into the ebullated bed, and minimizes stagnant zones in the plenum and thereby provides fouling-free operation of the reactor.

Downwardly directed fluid flow distribution system for ebullated bed

A process for high hydroconversion of petroleum residua containing at least about 25 V % material boiling above 975.degree. F. to produce lower boiling hydrocarbon liquid products and avoid undesirable precipitation of asphaltene compounds. In the process, the feedstock is at least about 80 percent catalytically hydroconverted to material boiling below 975.degree. F. and containing a mixture of gas and liquid fractions, after which the gas fraction is removed while maintaining the resulting liquid fractions temperature above about 730.degree. F. to avoid precipitation of asphaltene compounds which causes operations difficulties in the downstream equipment. Alternatively, the pressure-reduced liquid fraction can be stripped of material boiling below about 650.degree. F. before cooling the liquid to a temperature below about 730.degree. F. to prevent such precipitation of asphaltene compounds in the downstream equipment. The resulting liquid fraction is distilled to produce hydrocarbon liquid products, and a vacuum bottoms fraction is recycled to the catalytic reaction step to obtain increased percent conversion to lower boiling liquid products.

Sustained high hydroconversion of petroleum residua feedstocks

Activated bauxite particulate material having usual nominal particle size range of 20-50 mesh (U.S. Sieve Series) is treated by fluidization in an upflowing gas so as to attrite the particles and stabilize the particle shape and size, thereby making the catalyst more uniform in shape and resistent to attrition in subsequent ebullated bed reactor operations. The treated activated bauxite catalyst material is then rescreened to provide a narrower differential size range having a particle equivalent diameter ratio range for large to small particles of about 1.4-2.0, and a preferred 20-30 mesh (U.S. Sieve Series) particle size range. The selected pretreated catalyst is then introduced into the ebullated bed reactor of a hydrodemetallization process for hydrocarbon feedstocks containing high metals concentration. Use of such pretreated bauxite catalyst particles results in improved reactor fluidization operations and less catalyst loss by attrition and carryover of fines from the reactor, and achieves improved results of 60-70 W % demetallization and 50-55 V % hydroconversion of the 975.degree. F..sup.30 fraction to lower boiling hydrocarbon products in a single stage operation.

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Princeton, NJ, United States of America

Richard M Eccles