CA1182984A - Packed bed reactor for solids containing feeds - Google Patents

Packed bed reactor for solids containing feeds

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Publication number
CA1182984A
CA1182984A CA000407162A CA407162A CA1182984A CA 1182984 A CA1182984 A CA 1182984A CA 000407162 A CA000407162 A CA 000407162A CA 407162 A CA407162 A CA 407162A CA 1182984 A CA1182984 A CA 1182984A
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Canada
Prior art keywords
packed bed
particles
inches
diameter
packed
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
CA000407162A
Other languages
French (fr)
Inventor
David C. Kramer
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Chevron USA Inc
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Chevron Research and Technology Co
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J8/00Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
    • B01J8/008Details of the reactor or of the particulate material; Processes to increase or to retard the rate of reaction
    • B01J8/0085Details of the reactor or of the particulate material; Processes to increase or to retard the rate of reaction promoting uninterrupted fluid flow, e.g. by filtering out particles in front of the catalyst layer
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J8/00Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
    • B01J8/02Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds
    • B01J8/04Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds the fluid passing successively through two or more beds
    • B01J8/0446Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds the fluid passing successively through two or more beds the flow within the beds being predominantly vertical
    • B01J8/0449Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds the fluid passing successively through two or more beds the flow within the beds being predominantly vertical in two or more cylindrical beds
    • B01J8/0453Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds the fluid passing successively through two or more beds the flow within the beds being predominantly vertical in two or more cylindrical beds the beds being superimposed one above the other
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2208/00Processes carried out in the presence of solid particles; Reactors therefor
    • B01J2208/02Processes carried out in the presence of solid particles; Reactors therefor with stationary particles
    • B01J2208/023Details
    • B01J2208/024Particulate material
    • B01J2208/025Two or more types of catalyst

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  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Devices And Processes Conducted In The Presence Of Fluids And Solid Particles (AREA)
  • Exhaust Gas Treatment By Means Of Catalyst (AREA)
  • Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)

Abstract

ABSTRACT OF THE DISCLOSURE
A packed bed reactor and method of use is provided. The reactor comprises:
(a) a first packed bed of particles in fluid com-munication with a feed inlet to said reactor, said first packed bed extending at least 3 inches in the direction of flow and comprising predominantly particles at least about 3/3 inched in diameter;
(b) a second packed bed of particles in fluid com-munication with said first packed bed and downstream of said first packed bed; said second packed bed extending at least 10 inches in the direction of flow and comprising predominantly particles having diameters within the range of 3/16 to 5/16 inches and smaller than the average diameter of particles in said first bed; and (c) a third packed bed of particles in fluid com-munication with said second packed bed and downstream of said second packed bed, said third packed bed comprising predominantly particles having diameters below 1/8 inch.

Description

~1 PACRED BED REACTOR FOR SOLIDS CONTAINING FEEDS

BACKGROUND OF THE INVENTXON
This invention relates to the chemical processing of fluid feeds containing suspended solids and more particularly to processing in packed bed reactorsO
Packed bed reactors are employed in a number of industries for converting fluid feedstocks. The packing can be reactive material, catalytic material, or inert material and can also act as deposition sites for reactants or products.
Plugging problems can occur when packed bed reactors are used to process fluids which contain suspend-ed solids. Plugging is manifested by an unacceptable pressure drop across the reactor causing premature shut-down, for example, the shutdown of catalytic reactors while usable catalytic activity remains.
Plugging is particularly troublesome in downflow packed bed reactors. In the hydrocarbon processing indus-try plu~ging is often encountered in downflow reac~ors that e~ploy catalysts about l/8 inch in diameter or below, e~g., l/32 to 3/32 inches in diameter.
One technique used in the hydrocarbon processing industry is to employ one or more guard beds above active catalyst particles in order to protect the catalyst from incoming particulates in the feed. Such guard beds have had only limited success, however. Even when multiple guard beds are used, catalytic reactors often experience unacceptable plugging, causing premature shutdown.
One guard bed configuration is described in U.S.
Patent 3,562,800 wherein layers of l/2 inch and l/~ inch aluminum balls are used above a l/32 inch catalyst bed.
The depths of the beds are unspecified, however~ Table l depicts several guard bed sequences which have been used for downflow packed catalyst beds in ~he hydrocarbon processing industry.
~Q

Particle Depth Diameters Confi~uration (inches) ~inches) Type A 6-12 1/2~3/4 spheres B 6 1 1~2 saddles .
6 1/2-3/4 spheres C 12 1/4 rings 24 3/16 tablets 24 1/5 tr ilobes D 12 1/3 spheres 12 1/6 spheres E 4 1/2 saddles 3 3/4 spheres 3 1/2 spheres 3 1/4 spheres 4 1/2 saddles SUMMARY OF THE INV~NTION
2~ According to this invention a systematic method is provided for the design of guard beds~ The method results in novel packed bed reactor designs and novel processes for contacting solids-containing fluids.
In its apparatus aspects this invention comprises a packed bed reactor for treating a fluid feed containing suspended solids which comprises:
(a) a first packed bed of particles in fluid communication with a feed inlet to said reactor, said first packed bed extending at least. 3 inches in the direction of flow and comprising predominantly par~icles at least about 3/8 inches in diameter;
(b) a second packed bed of particles in fluid communica~ion with the first packed bed and downs~ream of the first packed bed, said second packed bed extendlng at least 10 inches in the direction of flow and comprising f~

~l -3-predominantly particles having diameters within the range of 3/16 to 5/16 inches and smaller than the average ~5 diameter of particles in the first bed;
(c) a third packed bed of particles in fluid communica~i~n ~Jith the second packed bed and downstream o the second packed bed said third packed bed comprising predominantly particles having diameters below l/3 inch.
l~ In some applications an additional bed can be placed downstream of the second packed bed and in fluid communication therewith. This additional packed bed will comprise particles having diameters within the range of 1/16 and 3/16 inches and smaller than the average diameter - 15 of particles in the second packed bed~ The third packed bed will be followed by a fourth packed bed in fluid communication with the third packed bed and downstream of the third packed bed and comprising predominantly parti-cles having diameters below l/8 inch, and smaller than the average diameter of the particles in the third packed bed.
In its process aspects this invention comprises a process for contacting a fluid feed containing suspended solids which comprises passing the feed through the above-described packed bed reactors.
~5 BRIEF D~SCRIPTION OF THE DRAWI~IGS
Figures l and 2 are schematic depictions of a reactor with the guard bed configuration of the invention.
D ~
According to this invention it has been found that a packed bed o~ particles less than l/8 inch in diameter can be protected from plugging by di~posing guard beds upstream of the packed bed o particles and which have a graded particle size, which decreases in the direction of flow. The maxim~n particl~ size in the guard beds is typically 3/3 to l l/2 inch, however, larger particles can be used if desiredr The minimum particle size is sllghtly above the average par~icle size of the principal contact particles or catalyst.
~0 Particles will be described herein in terms of diameters. While spherical particles are very much pre-05 ferred for use in the guard bed, the guard bed ~articlescan be in other configurations. For non-spherical particles, the diameter is defined as the smallest diameter, i.e., the smallest surface-to-surface dimension through the center or axis of the particle, re~ardless of the shape of the particle.
This invention is primarily applicable in down-flow packed bed systems. The packed bed can be any gravity-packed bed configuration, for example, a fixed bed, a moving bed, or a bed which permits incremental addition of fresh particles.
The feeds can be liquid-solids, gas-solids, or gas-liquid-solids, and will generally contain no more than about 0.1 weighk percent particles. The most preferr~d application ~or this invention is the processing of fluids ~ containing less than 10 ppmw of solids, which is typical of petroleum refinery streams. The optimum guard bed design will depend upon the particle size distribution in the eedstream. Typical particle distributions of interest have an average particle diameter between about 5 and liOOO micrometers. Particles smaller than about 5 micrometers generally do not cause plugging problems in small concentrations~ Rarticles above 1,000 micrometers . in diameter generally are easily filtered by conventional means, prior to treatment in packed bed reactors.
Particle distributions suitable for this invention are found in a variety of feed in the hydrocarbon processing industry. For example, naphthas, vacuum and atmospheric residua, vacuum gas oils; diese] and medium distillate streams, and a variety of other feedstocks, including certain so:Lids lean synthetic oils derived from coal, oil shale and tar sands, etc. The suspended particles in petroleum-derived streams are primarily iron sulfide particles from scaling of upstream equipment and piping, however, other particles may be present as well.

This invention employs in part the theory of irnpaction in packed beds which is described in Jackson et al "Entrained Particle Collection in Packed Beds" AICHE Journal, November 1966, pages 1075-1078. According to this invention, however, it is found that impaction alone was not adequate to describe the behavior of particles in packed beds. While impaction theory might predict substantially al] particles of a certain size should be trapped within the first ~ew inches of a particle bed, it has been discovered that in practlcal applications particles which have impacted become re-entrained and travel further into the bed to impact other particles. Consequently, the guard beds for trapping the particles need to be significantly deeper than would be expected from impaction theory.
It has been found that with typical feed particle size distributions~ at least about 10 inches of 3/16 to 5/16 inch particles are needed in the guard bed. If the depth of the
3/16 to 5/16 inch diameter particle bed is insufficient, particles will pass through and tend to agglomerate at the interface between that bed and the adjacent bed.
In the ideal situation, a guard bed would have a continuously decreasing particle size including a region 10 inches or deeper of particles in the 3/16 to 5/16 inch diameter range~ In practice, however, such continuously decreasing size is difficult to achieve. Satisfactory results can be obtained with a plurality of discrete guard beds with each bed containing particles of predominantly the same size. Consequently, the term "bed" as used herein will include a region of particles of varying particle size within the particle size limits defined for the bed.
It is conceivable that thin intermediate beds or screens may be disposed between one or more of the guard beds.

`~
~, ~2~

While the reactor should preferably comprise particles whose diameter decreases essentially monotonic]y in the direction o~ ~low, the thin intermediate beds may -5a~

~`

~1 -6-contain particles larger than those in one or more of the upstream beds. ~he thin intermediate beds should not, ~5 however, comprise particles smaller than downstream beds, as this will promote uneven solids capture, leading to premature pressure drop build-up.
The number of guard beds and the size of the bed particles will depend upon the characteristics of the feed. The following examples describe the cases of 1 i qu id - so 1 id, g a s- solid, and gas-liquid-solid eedsO The examples will illustrate the use of inert guard bed parti-cles above catalyst beds, however, it should be understood that the guard bed particles may themselves contain active catalyst materials such as transition metals, etc. The guard bed particles may~ in fact, be of the same composi-tion as the main catalyst or contact particles.
The ~uard bed designs depicted herein are suitable for processing a wide variety of fluids under a wide variety of conditions. The designs depicted in the following examples are suitable for processing hydrocarbo-naceous feedstocks at typical refinery processing condi-tions, for example, pressures of 0-3S00 psig. and tempera-tures of 50-1500F~
Example l Liquid-Solid Feed Referring to FIG. l the feed enters the reactor l through an inlet and encounters a first packed bed 3 containing particles above 3/~ inch, preferably 3/8 to l inch, and most preferably about l/2 inch in diameter. The first packed bed is at leas~ about 3 inches deep and can extend up l:o about 18 inches or more in depth~ e.g., 24, 36 inches, etc~ The preferred depth of the first packed bed is 6 inches~ The fun~tion of the first bed is to trap large particles and to stabilize the lower beds and protect them from inlet surges r etc. The second packed bed 2 contains predominantly particles in the range of 3/16 to 5~l6 inches in diameter, preferably about 1/4 inch in diameter. The second packed bed is at least about 1 O
inches deep and can be 48 or more inches deep, preferably ~1 -7-about 2 ft. deep. The main catalyst bed contains cylin-drical extrudate catalyst 1/32 to 3/32 inches in diameter, S preferably about 1/16 inch in diameter and with a length to diameter ratio of from 2 to 10, The main catalyst bed can be any depth. Preferably the first and second beds contain spherical particles. This design is especially well s~ited for capturing particles with an average diameter of about 5 to 1,000 micrometers, preferably 25 to 250 micrometers average diameter. If most of the feed solids by weight are present as particles smaller than 50 microns in diameter, the second catalyst bed can be replaced by about 12 inches of 3/16 to 5/16 inch diameter spheres on top of about 12 inches of 1/16 to 3/16 inch diarneter spheres. The additional 1/16 to 3/16 inch spheres should also be used where the main catalyst bed contains catalyst smaller than about 1/16 inch in diam-eter. If most of ~he feed solids by weigh~ are present as particles larger than 300 microns in diameter, the first catalyst bed should be increased in depth.
Example 2 G~ c~l~
Again referring to FIG~ 1 the first particulate bed 3 in this case should contain spheres above 3/8 inch, preferably 1/2 to 1~1/2 inches in diameter, and most pref-erably about 3/4 inches in diameterO The first packed bed is at least about 3 inches deep ar.d can extend up to 18 or more inchesl e.g., 24, 36 inches, etc. The first packed bed is preferably about 9 inches deep. The second packed bed contains predominantly particles diame~er 3/16 to 5/16 inches, preferably about 1/4 inches, and should extend from about 10 inches to 4~ or more inches in depth, pref-erably about 24 inches. The main catalyst bed ls again a cylindrica:L extrudate catalyst 1/32 to 3/32 inches in diameter, preferably 1/16 inch in diameter and having a length to diameter ratio of 2 to 10. Again, this design is suited for capturing particles of 5 to 1, noo microm-eters in diameter, preferably with an average parti~le diameter of 2S to 250 micrometers. If most particles to 01 -~ -be captured by weight are smaller than 50 micrometers, the second packed bed can be replaced by 18 inches of 3/16 to 05 5/16 inch spheres followed by about 6 inches of 1jl6 ~o 3/16 inch spheres. Also the Eirst catalyst bed can be replaced by about ~ inches of about 1/2 inch diameter spheres. In gas phase reactors a nu~ber of flakes of sulfides from upstream equipment can be much larger than the remainder of the feed particles. When this condition is encountered or when most of the feed solids by weight are present as particles larger than 300 micrometers in diameter, the first particulate bed should contain about 12 inches of spheres of about 1 inch in diameter.
If severe plugging problems are expectedl an additional bed, about 12 inches deep, of spheres 1/1~ to 3/16 inches in diameter can be employed between the second packed bed and the main catalyst bed. The additional bed of 1/16 to 3/16 inch spheres should also be used when the main catalyst bed contains catalyst smaller than about 1/16 inch in diameter.
Example 3 _ _ ~ Gas-Liquid-Solid Feed __ Referring to FIG. 2, the feed to the reactor 1 encounters the first packed bed 6 which contains particles of diameter above 3/~ inches, preferably 3/8 to 1 inch, and most preferably about 1/2 inch. The depth of ~he first packed bed is at least about 3 inchesl and can be up to 18, 24, 36 or more inches, preferably about 6 inches. The second packed bed 5 contains spheres predominant:ly 3/16 to 5/16 inches in diameter and is 10-48 or more inches in depth, preferably about 13 inches in depth. The third packed bed 4 contains particles of 1/16 to 3/16 inches in diameter, preferably abou~ inch in diameter. The third packed bed i5 at least about 3 inches to 18 or ~ore inches in depthl preferably about 6 inches in depth~ The main catalyst bed i6 preferably cylindri~al extrudate catalyst 1/32 to 3/32 inches in diameter, preferably about 1/16 inch in diameter and having a length to diameter ratio of about 2 to 10. Again, this example 9_ is well suited for capturing particles with an average size in the range of 5 to 1,000 microrneters, preferably 25 to 250 micrometers in diameter. If most of the particles to be captured by weight are smaller than about 50 microm~
eters in diameter, the third packed bed 4 should be increased in depth to about 12 inches and the second pac~ed bed 5 can be reduced in diameter to about 12 1~ inches. If most of the particles to be captured by weight are larger than about 300 micrometers, the first catalyst bed should be about 12 inches in depth. Where the main catalyst bed contains particles smaller than about 1/16 inches in diameter, the third packed bed should be at lS least about 12 inches deep.
The confiyurations described in Examples 1 through 3 are primarily suited for reactors which in the absence o the guard bed form undesirable plugs when less than 20% of their normal catalyst life would be utilized.
If the reactors would operate substantially more than about 20% of their normal catalyst run life without the guard beds, then the guard bed design could be modified to reduce the depth of particles in the second packed bed, i,e., the 3~16 to 5/16 inch particles.
The following experimental results illustrate the drastically improved performance o a downflow cold mo~el pilot plant reactor 4 inches in diameter containing 1/16 diameter extrudate catalyst~ The feed was hexane containing 1/2 to 1~ solids which had been collected from a fo~led reactor and which comprised essentially iron sulfide particles. These particles are representative of the partic:Les encountered in commercial practice. ~exane was chosen to approximate the density and viscosity of liquid naphtha at normal process temperature and pressure D
The concentration of the feed particles was deliberately much higher than ordinarily encountered in practice in order to r,educe the time of the experiment. The results are depicted in Table 2. The reactor loading is in the downward direction.
4~

TABLE ~

Coll.ected Pressure Length ReactorSolids Drop of Run Loadin~ _ ~lbs./~q. ft) (psi) _ (mln,3 12 inches of 1/16 3~,4* 10 6 inch d.iameter cylin-drical extrudate 12 inches of 1/2 2.1* 10 inch spheres ~ 12 inches of 1/16 inch diameter cylindrical extrudate : 12 inches of 1/4 7.6 0~3 15 - 15 inch spheres + 12 inches of l/16 inch diameter cylindrical extrudate 24 inches of 1/4 13.9 U.4 21 inch spheres ~ 12 inches of 1/16 inch ~ diameter cylin-drical extrudate 6 inches of 1/2 22,8 1.5 43 inch spheres + 12 inches of 1/4 inch spheres + 6 inche s 25 of 1/8 inch spheres + 12 inches of 1/16 inch diameter cylin-drical extrudate *most solids collected in First 2-3 inches of 1/16 inch catalyst bed~

It is seen that when no guard bed is used a very low solids loading was obtained, and ~he 10 psi pressure drop occurred after only 6 minutes of operation~ With a guard bed containing only 12 inches of l/2 inch spheres, the solid loadi.ng was al50 low and the 10 psi pressure drop occurred after only 4 minutes. With guard beds containing 12 or ~4 inches of 1/4 inch sp}leres, the solids collection was signif:Lcantly increased with only a very low pressure drop after much longer run times. The triple guard bed ~18Z~

was allowed to operate to a hi.gher solids loadiny and pressure drop.
Those skilled in the art will recognize that the guard bed design depicted herein can be modified to account for differences in eed solids, etc. without departin~ from ~he spirit and scope of this invention.
Such modifications are contemplated as equivalent of the embodiments particularly described herein.

4a

Claims (35)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A packed bed reactor for treating a fluid feed containing suspended solids which comprises:
(a) a first packed bed of particles in fluid communication with a feed inlet to said reactor, said first packed bed extending at least 3 inches in the direction of flow and comprising predominantly particles at least about 3/8 inches in diameter, (b) a second packed bed of particles in fluid communication with said first packed bed and downstream of said first packed bed, said second packed bed extending at least 10 inches in the direction of flow and comprising predominantly particles having diameters within the range of 3/16 to 5/16 inches and smaller than the average diameter of particles in said first bed; and (c) a third packed bed of particles in fluid communication with said second packed bed and downstream of said second packed bed, said third packed bed comprising predominantly particles having diameters below 1/8 inch.
2. A packed bed reactor according to Claim 1 wherein at least one of said first or second packed bed comprises substan-tially spherical particles.
3. A packed bed reactor according to Claim 1 wherein said first packed bed extends 3 to 18 inches in the direction of flow and said second packed bed extends 12 to 1/8 inches in the direction of flow.
4. A packed bed reactor according to Claim 1 wherein said reactor is adapted for downflow operation, said first packed bed comprises predominantly particles within the range of 3/8 to 5/8 inches in diameter, and said third packed bed comprises predomin-antly particles 1/32 to 3/32 inches in diameter.
5. A packed bed reactor according to Claim 4 wherein said first and second packed beds comprise substantially spherical particles.
6. A packed bed reactor according to Claim 5 wherein said first packed bed comprises predominantly particles about 1/2 inch in diameter, said second packed bed comprises particles about 1/4 inch in diameter.
7. A packed bed reactor according to Claim 1 wherein said reactor is adapted for downflow operation, said first packed bed comprises predominantly particles within the range of 5/8 to 1 inch in diameter, and said third packed bed comprises predominantly particles within the range of 1/32 to 3/32 inches in diameter.
8. A packed bed reactor according to Claim 7 wherein said first and second packed beds comprise substantially spherical particles.
9. A packed bed reactor according to Claim 8 wherein said first packed bed comprises predominantly particles about 3/4 inch in diameter, and said second packed bed comprises predominantly particles about 1/4 inch in diameter.
10. A packed bed reactor for treating fluid feeds containing suspended solids which comprises:
(a) a first packed bed of particles in fluid communication with a feed inlet to said reactor said first packed bed extend-ing at least 3 inches in the direction of flow and comprising predominantly particles at least about 3/8 inches in diameter;
(b) a second packed bed of particles in fluid communication with said first packed bed and downstream of said first packed bed, said second packed bed extending at least 10 inches in the direction of flow and comprising predominantly particles having diameters within the range of 3/16 to 5/16 inches and smaller than the average diameter of particles in said first bed;
(c) a third packed bed of particles in fluid communication with said second packed bed and downstream of said second packed bed, said third packed bed comprising predominantly particles having diameters within the range of 1/16 to 3/16 inches and smaller than the average diameter of particles in said second bed;
(d) a fourth packed bed of particles in fluid communication with said third packed bed and downstream of said third packed bed, said fourth packed bed comprising predominantly particles having diameters below 1/8 inch and smaller than the average diameter of particles in said third packed bed.
11. A packed bed reactor according to Claim 10 wherein at least one of said first, second and third packed beds comprises substantially spherical particles.
12. A packed bed reactor according to Claim 10 wherein said first packed bed extends 3 to 18 inches in the direction of flow, said second packed bed extends 12 to 48 inches in the direction of flow, and said third packed bed extends 3 to 18 inches in the direction of flow.
13. A packed bed reactor according to Claim 10 wherein said reactor is adapted for downflow operation, said first packed bed comprises predominantly particles within the range of 3/8 to 5/8 inches in diameter, said third packed bed comprises predominantly particles within the range of 1/16 to 3/16 inches in diameter, and said fourth packed bed comprises predominantly particles 1/32 to 3/32 inches in diameter.
14. A packed bed reactor according to Claim 13 wherein said first, second and third packed beds comprise substantially spherical particles.
15. A packed bed reactor according to Claim 14 wherein said first packed bed comprises predominantly particles about 1/2 inch in diameter, said second packed bed comprises predominantly particles about 1/4 inch in diameter, and said third packed bed comprises predominantly particles about 1/16 inch in diameter.
16. A process for contacting a fluid feed containing suspended solids comprising passing said feed through a packed bed reactor comprising:
(a) a first packed bed of particles in fluid communication with a feed inlet to said reactor, said first packed bed extending at least 3 inches in the direction of flow and comprising predominantly particles at least about 3/8 inches in diameter;
(b) a second packed bed of particles in fluid communication with said first packed bed and downstream of said first packed bed, said second packed bed extending at least 10 inches in the direction of flow and comprising predominantly particles having diameters within the range of 3/16 to 5/16 inches and smaller than the average diameter of particles in said first bed; and (c) a third packed bed of particles in fluid communication with said second packed bed in downstream of said second packed bed, said third packed bed comprising predominantly particles having diameters below 1/8 inch.
17. A process according to Claim 16 wherein at least one of said first or second packed beds comprise substantially spherical particles.
18. A process according to Claim 16 wherein said first packed bed extends 3 to 18 inches in the direction of flow and said second packed bed extends 12 to 48 inches in the direction of flow.
19. A process according to Claim 16 wherein said feed contains liquid and solids, is passed downwardly through said reactor, said first packed bed comprises predominantly particles within the range of 3/8 to 5/8 inches in diameter and said third packed bed comprises predominantly particles 1/32 to 3/32 inches in diameter.
20. A process according to Claim 19 wherein said first and second packed beds comprise substantially spherical particles.
21. A process according to Claim 16 wherein said feed comprises gas and solids and is passed downwardly through said reactor, said first packed bed comprises substantially particles within the range of 5/8 to 1 inch in diameter, and said third packed bed comprises particles predominantly within the range of 1/32 to 3/32 inches in diameter.
22. A process according to Claim 21 wherein said first and second packed beds comprise substantially spherical particles.
23. A process according to Claim 22 wherein said first packed bed comprises predominantly particles about 3/4 inches in diameter and second packed bed comprises predominantly particles about 1/4 inch in diameter.
24. A process for contacting a fluid feed containing suspended solids comprising passing said feed through a packed bed reactor comprising:
(a) a first packed bed of particles in fluid communication with a feed inlet to said reactor, said first packed bed extend-ing at least 3 inches in the direction of flow and comprising predominantly particles within the range of 3/8 to 1-1/2 inches in diameter;
(b) a second packed bed of particles in fluid communication with said first packed bed and downstream of said first packed bed, said second packed bed extending at least 10 inches in the direction of flow and comprising predominantly particles having diameters within the range of 3/16 to 5/16 inches and smaller than the average diameter of particles in said first bed;
(c) a third packed bed of particles in fluid communication with said second packed bed and downstream of said second packed bed, said third packed bed comprising predominantly particles having diameters within the range of 1/16 to 3/16 inches and smaller than the average diameter of particles in said second bed;
(d) a fourth packed bed of particles in fluid communication with said third packed bed and downstream of said third packed bed, said fourth packed bed comprising predominantly particles having diameters below 1/8 inch and smaller than the average diameter of particles in said third packed bed.
25. A process according to Claim 24 wherein at least one of said first or second packed beds comprises substantially spherical particles.
26. A process according to Claim 24 wherein said first packed bed extends 3 to 18 inches in the direction of flow and said second packed bed extends 12 to 48 inches in the direction of flow and said third packed bed extends 3 to 18 inches in the direction of flow.
27. A process according to Claim 24 wherein said feed comprises liquids, gas and solids and is passed downwardly through said reactor, said first packed bed comprises predomin-antly particles within the range of 3/8 to 5/8 inches in diameter, said third packed bed comprises predominantly particles within the range of 1/16 to 3/16 inches in diameter and said fourth packed bed comprises particles predominantly within the range of 1/32 to 3/32 inches in diameter.
28. A process according to Claim 27 wherein said first, second and third packed beds comprise substantially spherical particles.
29. A process according to Claim 28 wherein said first packed bed comprises predominantly particles about 1/2 inch in diameters said second packed bed comprises predominantly particles about 1/4 inch in diameter and said third packed bed comprises predominantly particles about 1/8 inch in diameter.
30. A process according to Claim 19 wherein said fluid feed contains less than 0.1% by weight solids and said solids in said feed have an average diameter in the range of 25 to 250 micrometers.
31. A process according to Claim 21 wherein said fluid feed contains less than 0.1% by weight solids and said solids and said feed have an average particle diameter within the range of 25 to 250 micrometers.
32. A process according to Claim 27 wherein said feed contains less than 0.1% by weight solids and said solids in said feed have an average particle diameter within the range of 25 to 250 micrometers.
33. A process according to Claim 30 wherein said feed contains less than 10 ppm by weight solids.
34. A process according to Claim 31 wherein said feed contains less than 10 ppm by weight solids.
35. A process according to Claim 32 wherein said feed contains less than 10 ppm by weight solids.
CA000407162A 1981-10-29 1982-07-13 Packed bed reactor for solids containing feeds Expired CA1182984A (en)

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US31638781A 1981-10-29 1981-10-29
US316,387 1981-10-29

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CA1182984A true CA1182984A (en) 1985-02-26

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JP2730696B2 (en) * 1989-05-22 1998-03-25 日本ケッチェン株式会社 Hydrocarbon oil descaling agent and hydrotreating catalyst
EP1001837B1 (en) * 1997-07-18 2010-06-30 Crystaphase International Inc. Filtration and flow distribution method for chemical reactors
EP1293246B1 (en) * 1997-07-18 2015-08-19 Crystaphase International, Inc. Flow distribution method for chemical reactors
DE19858974B4 (en) * 1998-12-19 2006-02-23 Daimlerchrysler Ag Process for the catalytic conversion of a starting material, in particular a gas mixture
DE10002333A1 (en) * 2000-01-20 2001-07-26 Linde Ag Process for carrying out catalytic reactions e.g. exothermic or endothermic reactions, oxidation reactions and hydrogenations using a wire catalyst
US7722832B2 (en) 2003-03-25 2010-05-25 Crystaphase International, Inc. Separation method and assembly for process streams in component separation units
US10744426B2 (en) 2015-12-31 2020-08-18 Crystaphase Products, Inc. Structured elements and methods of use
US10054140B2 (en) 2016-02-12 2018-08-21 Crystaphase Products, Inc. Use of treating elements to facilitate flow in vessels
MX2022007367A (en) 2019-12-20 2022-07-12 Crystaphase Products Inc Resaturation of gas into a liquid feedstream.
WO2022056154A1 (en) 2020-09-09 2022-03-17 Crystaphase Products, Inc. Process vessel entry zones

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US3694351A (en) * 1970-03-06 1972-09-26 Gulf Research Development Co Catalytic process including continuous catalyst injection without catalyst removal
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