CN116867564A - 用于在催化裂化反应器中进行混合的设备 - Google Patents

用于在催化裂化反应器中进行混合的设备 Download PDF

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CN116867564A
CN116867564A CN202280011071.4A CN202280011071A CN116867564A CN 116867564 A CN116867564 A CN 116867564A CN 202280011071 A CN202280011071 A CN 202280011071A CN 116867564 A CN116867564 A CN 116867564A
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reactor
feed
fluidized
stream
catalyst particles
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R·A·鲁道夫
M·A·巴斯登
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Shell Internationale Research Maatschappij BV
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Abstract

本发明提供了一种催化裂化反应器，所述催化裂化反应器包括导管和注入区，所述导管被构造成允许催化剂颗粒流通过，所述注入区包括从所述反应器的壁向内延伸并倾斜以将进料注入到所述催化剂颗粒流中的进料注入器环，其特征在于所述反应器还包括从所述注入区上游的所述反应器的内壁突出到所述反应器中的接触装置。本发明还提供了一种将催化剂颗粒的流化料流与烃进料混合的方法，所述方法包括以下步骤：a)在反应器中产生流化催化剂颗粒料流；b)使所述流化催化剂颗粒料流经过从所述反应器的内壁突出到所述反应器中的接触装置；c)随后使所述流化催化剂颗粒料流通过包括从所述反应器的壁向内延伸的进料注入器环的注入区，并使所述流化催化剂颗粒料流与通过所述进料注入器提供的烃进料接触；d)将与烃进料接触的所述流化催化剂颗粒料流送入所述反应器的下游段，以在所述催化剂颗粒的存在下将所述烃进料转化成转化产物。

Description

用于在催化裂化反应器中进行混合的设备
技术领域
本发明涉及改善液体在反应器中分散成流化固体的设备和方法。更具体地，本发明涉及用于将烃分散到流化催化剂颗粒料流中的设备和方法。
背景技术
在使用流化固体催化剂床技术的方法中，含碳材料通常沉积在床内的催化剂颗粒上。通常这些方法在循环基础上进行，其中将废催化剂固体从反应器中除去并输送到另一容器中，在该容器中通过在含氧环境下燃烧除去含碳材料。这允许催化剂一旦返回到反应器中就被再利用。
具有这种性质的重要方法是流化催化裂化(FCC)方法，其用于将相对高沸点的烃转化为沸点在加热油或汽油(或更轻)范围内的较轻烃。在该方法中，使烃进料与颗粒裂化催化剂在流化催化剂床中在适于烃转化的条件下接触。
现代FCC单元通常使用大的、通常垂直的提升管形式的管式反应器，其中气态介质向上传输流化态的催化剂。然而，在一些情况下，类似地使用垂直式反应器，但具有向下的流动。
对于有效的方法，希望烃进料瞬时分散在移动通过反应器的整个催化剂料流中。进料在反应器的整个横截面上的完全和瞬时分散是不可能的，但是通过将高度雾化的进料注入预加速的催化剂颗粒料流中已经获得了良好的结果。然而，进料在整个催化剂颗粒中的分散需要一些时间，使得如前所述在进料和催化剂之间存在一些不均匀的接触。进料和催化剂的非均匀接触使部分进料暴露于催化剂持续更长时间段，这继而可产生热裂化并降低反应产物的质量。
使用许多不同的方法来使烃进料在颗粒催化剂悬浮液中的分散最大化。将进料分成小液滴通过增加液体和固体之间的相互作用改善了进料的分散。优选地，液滴尺寸变得足够小以允许液体在接触固体之前气化。还已知在使催化剂颗粒与烃进料接触之前预加速催化剂颗粒，诸如在US4479870中。
将烃进料通过多个成角度的进料喷嘴注入反应器中，该进料喷嘴通常布置在围绕反应器的周向带中并且将进料朝向提升管的中心注入。所述喷嘴通常突出到反应器中。
US5554341、US5173175、US4832825和US3654140都显示使用径向指向的进料注入喷嘴将进料引入FCC提升管中。喷嘴的布置在进料注入区和下游提升管段上方保持基本开放的提升管横截面。成角度的进料喷嘴是用于在提升管导管中的中间部分处注入进料或其它流体的典型喷嘴。
然而，成角度的进料喷嘴通常远离反应器的壁延伸并进入催化剂的流动路径中。使颗粒以高速通过喷嘴可导致腐蚀。此外，喷嘴突出到反应器中可产生静态区，催化剂在该静态区中流动但在进料注入区内提供有限的烃进料。
不希望使喷嘴完全凹入反应器的壁中并将它们从催化剂流动路径中除去。该解决方案不令人满意，因为进料注入器尖端被特别设计成通过在烃进料从喷嘴离开时扩展进料注入模式而在反应器的横截面上提供烃进料的相对均匀的覆盖。使注入器喷嘴的尖端在反应器的壁内完全凹陷破坏了在大部分提升管横截面积上获得喷雾图案的能力。
US7101474描述了一种修改的FCC提升管，其中增加进料注入区域下方的提升管壁的厚度以提供通过喷嘴的更窄的催化剂颗粒流。这需要新的提升管构造。
本发明的一个目的是提供一种简单的设备和方法以在反应器的横截面上更均匀地分布催化剂和油。
附图说明
图1示出了FCC提升管中现有技术注入区的示例。
图2a和图2b示出了根据本发明的接触装置。
图3和图4示出了合适的接触装置。
图5示出了本发明的催化裂化提升管反应器的一部分。
发明内容
本发明提供了一种催化裂化反应器，所述催化裂化反应器包括导管和注入区，所述导管被构造成允许催化剂颗粒流通过，所述注入区包括从所述反应器的壁向内延伸并倾斜以将进料注入到所述催化剂颗粒流中的进料注入器环，其特征在于所述反应器还包括从所述注入区上游的所述反应器的内壁突出到所述反应器中的接触装置。
本发明还提供了将流化催化剂颗粒料流与烃进料混合的方法，所述方法包括以下步骤：
a)在反应器中产生流化催化剂颗粒料流；
b)使所述流化催化剂颗粒料流经过从所述反应器的内壁突出到所述反应器中的接触装置；
c)随后使所述流化催化剂颗粒料流通过包括从所述反应器的壁向内延伸的进料注入器环的注入区，并使所述流化催化剂颗粒料流与通过所述进料注入器提供的烃进料接触；
d)将与烃进料接触的所述流化催化剂颗粒料流送入所述反应器的下游段，以在所述催化剂颗粒的存在下将所述烃进料转化成转化产物。
具体实施方式
本发明人已经确定，在进料注入器环上游的反应器中提供接触装置，通过该接触装置将烃进料提供至反应器，导致烃进料与流化的催化剂颗粒流的改善的混合。本发明提供了一种简单的解决方案，解决了使烃进料快速且均匀地分散到流化的催化剂颗粒流中的问题。
该反应器是用于流化催化裂化(FCC)方法的合适的反应器。在这种方法中，向反应器中提供细分的催化剂颗粒并通过添加流化介质使其流化。催化剂颗粒可以是新鲜催化剂颗粒或再生催化剂颗粒或它们的混合物。流化介质可以是烃料流的稀释材料，通常是蒸气或低分子量流化气体。流化的催化剂料流流过反应器。反应器可以是“下行”反应器，其中流化的催化剂料流向下流过反应器。优选地，反应器是提升管反应器，并且流化催化剂料流向上流过提升管反应器。
在本发明中，在反应器中在进料注入器环的上游提供接触装置。因此，使流化催化剂料流在送入注入区中之前与所述接触装置接触。
接触装置包括牢固地紧固到反应器的壁上的插入件。典型地，接触装置包括外径等于反应器内径的环形元件。
该接触装置可以包括金属、陶瓷、陶瓷金属或它们的混合物。在本发明的一个实施方案中，接触装置包括耐火材料和金属结构的复合物。在该实施方案中，金属结构可以连接到反应器的外壁以确保接触装置的位置在操作期间不改变，尽管存在温度冲击。
此外，金属结构增强金属结构和耐火材料的组合，使得其变得更坚固并且更不易于腐蚀。当反应器设置有内部耐火衬里时，这是特别有利的。
考虑到反应器混合物的腐蚀性质，适当地选择耐火材料以使得其高度耐磨。该材料优选地还为可浇铸的，以便于接触装置的成形。合适地，耐火材料选自氧化铝、二氧化硅、氧化钙、氧化钛、氧化镁、氧化铁以及它们的混合物。耐火材料也可以含有氧化磷。
接触装置可以具有本领域技术人员认为适于特定用途的任何横截面形状。本领域技术人员将优化这些优点，特别是湍流效应，同时最小化任何缺点，诸如压降。在某些实施方案中，接触装置可具有矩形的横截面轮廓。在其它实施方案中，非矩形横截面可能是期望的。例如，从反应器的内壁向外倾斜的锥形形状可能是合适的。合适的装置描述于US9283532、WO2017/003991和WO2008017660中。
当接触装置为环形物的形状时，整个环形物可以组装成一体式。然而，在多于一个模块中组装这样的环形物是有利的。这不仅更易于组装，而且还提供了局部修理的可能性。在该实施方案中，模块的数量适当地在4至25的范围内。
本发明的一个特别的优点是以这种方式构造的接触装置可以被改装到反应器上，允许改善现有的反应器而不需要大的改造。接触装置位于进料注入器环的上游。典型地，接触装置将直接放置在进料注入器环的上游。优选地，接触装置的下游边缘与进料注入器的上游边缘之间的距离不超过25英寸(63.5cm)。接触装置的下游边缘与进料注入器的上游边缘或下侧之间的距离将取决于反应器的几何形状以及反应器是否被型锻，并且可以取决于反应器内的几何形状和流动条件两者而改变。
接触装置在进料注入器环上游的位置使催化剂颗粒流转向以更紧密地匹配来自进料注入器的烃进料的分散。接触装置将减少反应器中的通道。优选地，基于接触装置上游的反应器的通道，通道减少不超过35％。合适地，基于接触装置上游的反应器的通道，通道的减少为至少10％。
接触装置在进料注入器环上游的位置提供了保护进料注入器本身免受由催化剂颗粒流引起的腐蚀和损坏的额外优点。
进料注入器可包括任何合适的进料注入喷嘴。在典型的FCC实践中，进料以扇形图案喷雾离开喷嘴。喷嘴通常成一定角度以使扇形图案沿下游方向倾斜。相对于穿过喷嘴、液体进入注入器的横向平面，喷嘴的角度通常在至少20°且小于70°的范围内。
在注入区内，流化催化剂颗粒与通过进料注入器提供的烃进料接触。本发明允许进料极好地快速分散在整个催化剂颗粒中。
然后使与烃进料接触的流化催化剂颗粒料流通过注入区的下游，并在催化剂颗粒的存在下将烃进料转化成转化产物。这可以作为通过反应器的流的一部分而发生，或者在一些实施方案中，可以至少部分地在设置于反应器下游段内的催化剂床内发生。
附图说明
现在将参考以下示例性的非限制性附图来进一步描述本发明。
图1示出了本发明要克服的问题。图1显示了提升管反应器在注入区的横截面。多个进料注入器(1)从提升管反应器(2)的内壁突出。示出了典型反应器装置中的组合喷雾图案(3)。这导致静态区(4)，在该静态区中向上通过注入区的流化催化剂颗粒料流接触降低水平的进料。
图2a和图2b示出了本发明。接触装置(5)设置在注入区的上游。在图2a中，基于接触装置上游的提升管反应器的通道，接触装置使用于流化催化剂颗粒的通道的面积减少23％。在图2b中，基于接触装置上游的提升管反应器的通道，接触装置使用于流化催化剂颗粒的通道的面积减少31％。在这两个图中，可以清楚地看出，当与图1相比时，静态区(4)的面积显著减小。
图3示出了接触装置(5)，其包括由耐火材料构成的区段(5a)，该区段经由金属结构(5b)通过提升管反应器的内壁(6)连接到所述反应器的金属外壁(7)。
图4中示出了相同接触装置的不同横断面视图。
图5示出了反应器内的视图，其示出了在进料注入器(1)上游突出到反应器中的接触装置(5)。流化催化剂颗粒料流(8)的流动通过注入区上游的接触装置。在注入区内，进料注入器(1)提供烃进料，并且所述烃进料与所述流化催化剂颗粒接触。
实施例
提供以下非限制性实施例作为本发明的进一步描述。
使用计算流体动力学(CFD)模拟来测试本发明。模型被构造成代表标准提升管反应器构造和工艺条件。对于每种场景使用相同的基本提升管反应器和工艺条件，除了对于每种场景描述的修改。对四种不同的场景进行建模。在场景1中(基本情况；对比)模拟未经修改的提升管反应器。在场景2中，在进料注入器的上游添加接触装置。场景3(对比)包括降低进料喷嘴上游的提升管反应器的直径。场景4适用于场景3，其中在进料喷嘴的上游添加接触装置。该模拟的结果示于表1中。
表1
在场景2中在进料喷嘴的上游添加接触装置在这些模拟中清楚地显示，当与场景1相比时，通过注入的油与热流动催化剂的更好接触，将原料气化增加超过2重量％。这种改善中的一些但不是全部可以通过用具有更小直径的提升管替换提升管的下段来实现(场景3)。然而，添加接触装置(例如场景2)不需要替换提升管的下段，并且可以改装到现有反应器上。
更进一步的益处由更小的下部提升管和接触装置的组合证明(场景4)。

Claims (7)

1.一种催化裂化反应器，所述催化裂化反应器包括导管和注入区，所述导管被构造成允许催化剂颗粒流通过，所述注入区包括从所述反应器的壁向内延伸并倾斜以将进料注入到所述催化剂颗粒流中的进料注入器环，其特征在于所述反应器还包括从所述注入区上游的所述反应器的内壁突出到所述反应器中的接触装置。
2.根据权利要求1所述的催化裂化反应器，其中所述接触装置包括耐火材料和金属结构的复合物。
3.根据权利要求1或权利要求2所述的催化裂化反应器，其中所述接触装置的下游边缘与所述进料注入器的上游边缘或下侧之间的距离不超过25英寸(63.5cm)。
4.根据权利要求1至3中任一项所述的催化裂化反应器，其中基于所述接触装置上游的所述反应器的横截面积，所述催化剂颗粒流的横截面积减少至少10％且不超过35％。
5.根据权利要求1至4中任一项所述的催化裂化反应器，其中所述反应器是提升管反应器，所述提升管反应器被构造成允许催化剂颗粒流向上通过。
6.一种将催化剂颗粒的流化料流与烃进料混合的方法，所述方法包括以下步骤：
a)在反应器中产生流化催化剂颗粒料流；
b)使所述流化催化剂颗粒料流经过从所述反应器的内壁突出到所述反应器中的接触装置；
c)随后使所述流化催化剂颗粒料流通过包括从所述反应器的壁向内延伸的进料注入器环的注入区，并使所述流化催化剂颗粒料流与通过所述进料注入器提供的烃进料接触；
d)将与烃进料接触的所述流化催化剂颗粒料流送入所述反应器的下游段，以在所述催化剂颗粒的存在下将所述烃进料转化成转化产物。
7.根据权利要求6所述的方法，其中烃料流包含高沸点烃，并且所述转化产物包含沸点在燃料油、汽油或更轻范围内的较轻烃。
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