h2advance • downcomer with one size orifice to fit all conditions • downcomer with wide angle...
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Reactor Internals for Hydroprocessing Unit
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An Optimized Quench Zone Design for a Mixed-Phase Cocurrent Downflow Fixed-Bed Reactor
Reactor Internals for Hydroprocessing Unit
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• Inlet Diffuser
• Inlet Distributor
• Quench Zone including catalyst support, quench distributor, quench mixing chamber, flash tray, and re-distributor
• Outlet Collector
Reactor Internals Components
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• Distributor tray needs optimized
• Quench mixer needs to attain perfect thermal equilibrium
• Quench zone height needs shortened
Reactor InternalsObjective: Maximizing Catalyst Utilization
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TSC Reactor Internals Portfolio
Refinery Unit Process Licensor # Distributor # Quench ZonesTesoro Golden Eagle Hydrocracker MAK 15 12US refinery Hydrocracker Mobil 10 8US refinery Hydrocracker Mobil 5 4US refinery USA* CHD (DHT) Mobil 3 2Middle East Refinery* Hydrocracker MAK 6 4Asia refinery Lube Hydrocracker Mobil 10 8US refinery Isomerization Dewaxing Mobil 1US refinery Isomerization Dewaxing Mobil 1Middle East Refinery Octgain (FCC Gasoline HDT) Mobil 3 2Bayernoil CHD (DHT) H2Advance 3 2European refinery* DHT Topsoe 3 2US refinery Revamp HDC to DHT Topsoe 3US refinery DDU (DHT) Topsoe 2US refinery NHT (Naphtha Quench Zone) Topsoe 1US refinery DDS (DHT) Topsoe 3 2US refinery ISOM Topsoe 6US refinery BOU (DHT) Topsoe 2 1US refinery DHT Topsoe 2 1US refinery Kero hydrotreater Topsoe 1US refinery VGO hydrotreater Topsoe 1US refinery Hydrocracker Topsoe 2Total 82 49* designed but not implemented
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Distributor / QZ Performance
Reactor Temperature Profile
Tray (Distributor) Selection
• Low Sensitivity to Tray Unlevelness
• Low DP, Less Than 1 psi
• Good Spray Angle
• Dense Pack
• Easy Cleaning
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Liquid Distributor Type
• Downcomer with one size orifice to fit all conditions
• Downcomer with wide angle spray pattern
• Well engineered downcomer (H2Advance)
• Vapor Lift with poor element coverage on tray
• Vapor Lift with max drip density on tray
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U.S. Patent 4,126,540Grosboll et al (ARCO)
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U.S. Patent 6,098,965Jacobs et al (Fluor)Swirl Cap Distributor
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Distributor tray: Downcomer with slots
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Bubble-cap tray
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Vapor Lift Tray
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Uniformity of Flow Distribution
• H2Advance: Good spray angle with low
sensitivity to tray out-of-levelness
• vs. poor spray pattern and sensitive to tray out-
of-levelness
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H2Advance Downcomer Tray:RX Area Coverage
0
0.2
0.4
0.6
0.8
1
1.2
1.4
0 1 2 3 4 5 6 7 8
Frac
tion
of
RX A
rea
Cove
red
Tray to Inert Clearance, inch
Downcomer Spray Covered Area
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Distributor Tray, H2Advance Design
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Quench Zone Type
• Impingement Plate 1970 Unocal
• Improved Impingement Plate (Axens, PetroChina)
• Segregated Vapor/Liquid Mixer (Shell, Chevron)
• Mixed Phase Vortex Mixer (EM, UOP, Topsoe, H2Advance)
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Impingement Plate Quench
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Unocal 1970 Impingement Plate Quench boxUS Patent 3,502,445
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Unocal 1970 Impingement Plate Quench boxUS Patent 3,502,445
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PetroChina 2007 Upgrader
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PetroChina 2007 Upgrader Internals
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Segregated Vapor/Liquid Mixer
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Chevron “Nautilus” Quench Internals 2001
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Shell Quench Patent
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Mixed Phase Vortex Mixer
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Mobil Spider-Vortex
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UOP Quench Internals
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H2Advance Quench Internals 2006US Patent 7,112,312
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H2Advance: Quench Swirl Mixing Chamber
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H2Advance: Effective Quench Mixer
• H2Advance: Swirl mixing chamber provides an
excellent thermal efficiency
• vs. competitor’s poor thermal equilibrium with
segregated vapor/liquid mixing
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H2Advance: Compact Swirl Quench Zone Design
• Inert-to-inert height requirement: less than 4.5 ft
• vs. 5-7 ft required by competitors
• Integrated Quench Swirl Mixing Chamber and
Flash Tray: Compact Design
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H2Advance: Compact Quench zone withReduced # of Manway
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# of Manways per Quench Zone
• H2Advance design: 2 manways per quench zone
• Compared with 4 (+quench gas distributor)
• H2Advance: Use wedge pin for manway (not
nuts and bolts)
• Impact: shorten unit TAR time
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H2Advance Example: Bayernoil ULSD
• Installed in 2002 (18ft ID 3-bed RX) for ULSD
• Resulted in a higher unit throughput (revamped
at 53,000 BPD)
• And longer than anticipated catalyst cycle
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DHT Performance Post Revamp 2002
Radial Differential Temperature (Observed - Average)
-3
-2
-1
0
1
2
3
1 2 3 4 5 6
Location in Bed 1
Del
ta T
, deg
. C
Top-Inner C ircle Bottom-Inner Bottom-Outer C ircle
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DHT Performance Post Revamp 2002
Radial Differential Temperature (Observed - Average)
-3
-2
-1
0
1
2
3
1 2 3 4 5 6
Location in Bed 2
Del
ta T
, deg
. C
Top-Inner Circle Bottom-Inner Bottom-Outer Circle
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DHT Performance Post Revamp 2002
Radial Differential Temperature (Observed - Average)
-3
-2
-1
0
1
2
3
1 2 3 4 5 6
Location in Bed 3
Del
ta T
, deg
. C
Top-Inner Circle Bottom-Inner Bottom-Outer Circle
Internals Installation is important
Internals installation supervision to ensure good seal And tray levelness
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Well Designed Quench Box with poor Distributor Installation(2010 DHT)
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Poor Quench Zone Design (HDC 2002)
720730740750760770780790800
0 1 2 3 4 5
Rad
ial T
spr
ead,
F
Bed 1, 2, 3, 4, and 5
Functional Quench Box?
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Conclusions: State-of-the-art H2Advance Internals
• Min # of manways per Quench Zone
• Distributor provides uniformity of flow distribution
• Compact Design with excellent thermal equilibrium that reduces capital investment; good for revamp upgrading
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