Reactor system and process for upgrading heavy hydrocarbonaceous material

Patent metadata

Field	Value
Publication number	US-10647930-B2
Application number	US-201816118332-A
Country	US
Kind code	B2
Filing date	Aug 30, 2018
Priority date	Sep 29, 2017
Publication date	May 12, 2020
Grant date	May 12, 2020

Abstract

The present invention relates to a hydrocracking reactor system and a process utilizing the same for upgrading heavy hydrocarbonaceous material to value-added products. Accordingly, an aspect of the present invention includes dispersing a liquid feedstock pre-mixed with a catalyst from top of a reactor vessel to obtain dispersed droplets having a predetermined droplet size less than 500 μm, introducing a gaseous feed comprising primarily of hydrogen from bottom of the reactor vessel to form a continuous gaseous phase throughout a cross-section of the reactor vessel, and allowing the dispersed droplets to contact the continuous gaseous phase throughout the cross-section of the reactor vessel to form reaction effluent comprising one or more lighter product hydrocarbons. The method may further include removing at least a top portion and at least a bottom portion of the reaction effluent from the reactor vessel.

First claim

We claim:

1. A hydrocracking reactor system for upgrading hydrocarbonaceous material into hydrocarbons, the hydrocracking reactor system comprising:
a reactor vessel;
a first inlet for receiving a liquid feedstock pre-mixed with a catalyst, the first inlet in communication with top of the reactor vessel;
a second inlet for receiving a gaseous feed primarily comprising hydrogen, the second inlet in communication with bottom of the reactor vessel;
a spray arrangement including:
a plurality of nozzles configured to disperse the liquid feedstock pre-mixed with the catalyst from the top of the reactor vessel to obtain dispersed droplets having a predetermined droplet size less than 500 μm, and
a plurality of concentric pipes for receiving the liquid feedstock pre-mixed with the catalyst from the first inlet, wherein the plurality of concentric pipes are arranged across a top cross-section of the reactor vessel, and wherein each of the plurality of concentric pipes has same center;

a sparger arrangement including a plurality of sparger holes to introduce the gaseous feed comprising hydrogen from the bottom of the reactor vessel to form a continuous gaseous phase throughout a cross-section of the reactor vessel;
a top exit in communication with the top of the reactor vessel for removing at least a top portion of reaction effluent from the reactor vessel, wherein the reaction effluent comprising one or more hydrocarbons formed during contact of the dispersed droplets with the continuous gaseous phase throughout the cross-section of the reactor vessel; and
a bottom exit in communication with the bottom of the reactor vessel for removing at least a bottom portion of the reaction effluent from the reactor vessel.

2. The hydrocracking reactor system as claimed in claim 1 , wherein the plurality of nozzles is arranged symmetrically within the spray arrangement across the cross-section of the reactor vessel, and is configured to disperse the droplets having the pre-determined droplet size in a range of 50 μm to 500 μm.

3. The hydrocracking reactor system as claimed in claim 1 , wherein the spray arrangement is positioned at a first position level (L 1 ) defined in the reactor vessel in a range of 1500 mm to 3000 mm below the top exit, the sparger arrangement is positioned at a second position level (L 3 ) defined in the reactor vessel in a range of 2000 mm to 4000 mm above a level of the bottom portion of the reaction effluent, and a distance (L 2 ) between the spray arrangement and the sparger arrangement within the reactor vessel is in a range of 10 meters to 80 meters.

4. The hydrocracking reactor system as claimed in claim 1 , wherein the reactor vessel has a diameter in a range of 0.5 m to 8 m.

5. The hydrocracking reactor system as claimed in claim 1 , wherein the reactor vessel comprising one or more intermediate collection and redistribution arrangements at one or more collection and redistribution points in the reactor vessel to collect the dispersed droplets and further redistribute the collected dispersed droplets during downward flow of the dispersed droplets.

6. The hydrocracking reactor system as claimed in claim 1 comprising an asphaltene stabilizer injection arrangement to introduce an asphaltene stabilizer into the reactor vessel.

7. A hydrocracking process of upgrading hydrocarbonaceous material into hydrocarbons, the process comprising:
heating a reactor vessel at a temperature ranging between 400° C. to 700° C.,
dispersing a liquid feedstock pre-mixed with a catalyst from top of the reactor vessel to obtain dispersed droplets having a predetermined droplet size less than 500 μm, wherein the liquid feedstock comprises the hydrocarbonaceous material,
introducing a gaseous feed primarily comprising hydrogen from bottom of the reactor vessel to form a continuous gaseous phase throughout a cross-section of the reactor vessel,
wherein at least one reaction is occurred within the droplets to form one or more hydrocarbons, wherein the at least one reaction is occurred while the droplets are falling from a spray nozzle to the bottom of the reactor vessel, and the dispersed droplets contact the continuous gaseous phase throughout the cross-section of the reactor vessel, and
wherein the at least one reaction comprising:
a thermal cracking reaction due to the temperature within the reactor vessel; and
a hydrogenation reaction due to presence of hydrogen and the catalyst within each droplet;

removing at least a top portion and at least a bottom portion of the reaction effluent from the reactor vessel.

8. The hydrocracking process as claimed in claim 7 wherein the dispersed droplets are obtained by dispersing the liquid feedstock pre-mixed with the catalyst uniformly from the top of the reactor vessel throughout the cross-section of the reactor vessel.

9. The hydrocracking process as claimed in claim 7 wherein the pre-determined droplet size is in a range of 50 μm to 500 μm.

10. The hydrocracking process as claimed in claim 7 comprising continuously stripping off at least a portion of the one or more hydrocarbons by the gaseous feed during downstream flow of the dispersed droplets in the reactor vessel.

11. The hydrocracking process as claimed in claim 7 comprising introducing an asphaltene stabilizer into the reactor vessel.

12. The hydrocracking process as claimed in claim 7 further comprising collecting the dispersed droplets and redistributing the collected dispersed droplets during downstream flow of the dispersed droplets at one or more collection and redistribution points in the reactor vessel.

13. The hydrocracking process as claimed in claim 12 comprising introducing an asphaltene stabilizer at the one or more collection and redistribution points in the reactor vessel.

14. The hydrocracking process as claimed in claim 7 , wherein the gaseous feed comprising hydrogen is having a hydrogen partial pressure in the range of 70 barg to 220 barg inside the reactor vessel.

15. The hydrocracking process as claimed in claim 7 , wherein the liquid feedstock having conradson carbon content more than 15 percent weight and asphaltene content more than 5 percent weight.

16. The hydrocracking process as claimed in claim 7 , wherein the catalyst pre-mixed in the liquid feedstock is either in a dissolved form or uniformly distributed in the liquid feedstock droplet.

Assignees

• Indian Oil Corp Ltd

Inventors

• Sarkar Mainak
• Dave Darshankumar Manubhai
• Karumanchi Ramesh
• Sau Madhusudan
• Butley Ganesh Vitthalrao
• Vishwakarma Nepal
• Kumar Kamal
• Kumar Pravesh
• Kumar Sarvesh
• Bhattacharyya Debasis
• Mazumdar Sanjiv Kumar
• RAMAKUMAR Sankara Sri Venkata

Classifications

• B01J2219/1943

  cylindrical · CPC title

• C10G47/00

  Cracking of hydrocarbon oils, in the presence of hydrogen or hydrogen- generating compounds, to obtain lower boiling fractions (C10G15/00 takes precedence; destructive hydrogenation of non-melting solid carbonaceous or similar materials C10G1/06) · CPC title

• B01J2208/00911

  Sparger-type feeding elements · CPC title

• C10G47/24 Primary

  with moving solid particles · CPC title

• B01J4/004

  Sparger-type elements · CPC title