GB2108871A - Apparatus for classifying catalyst particles and catalytic process employing catalyst particles thus classified - Google Patents

Apparatus for classifying catalyst particles and catalytic process employing catalyst particles thus classified Download PDF

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Publication number
GB2108871A
GB2108871A GB08231544A GB8231544A GB2108871A GB 2108871 A GB2108871 A GB 2108871A GB 08231544 A GB08231544 A GB 08231544A GB 8231544 A GB8231544 A GB 8231544A GB 2108871 A GB2108871 A GB 2108871A
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GB
United Kingdom
Prior art keywords
particles
conveyor belt
catalyst particles
outlet
catalyst
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Granted
Application number
GB08231544A
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GB2108871B (en
Inventor
Johannes Boom
Den Bosch Petrus Johannes Van
Pieter Visser
Dirk Wagenaar
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Shell Internationale Research Maatschappij BV
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Shell Internationale Research Maatschappij BV
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Priority to GB08231544A priority Critical patent/GB2108871B/en
Publication of GB2108871A publication Critical patent/GB2108871A/en
Application granted granted Critical
Publication of GB2108871B publication Critical patent/GB2108871B/en
Expired legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
    • B07B—SEPARATING SOLIDS FROM SOLIDS BY SIEVING, SCREENING, SIFTING OR BY USING GAS CURRENTS; SEPARATING BY OTHER DRY METHODS APPLICABLE TO BULK MATERIAL, e.g. LOOSE ARTICLES FIT TO BE HANDLED LIKE BULK MATERIAL
    • B07B15/00—Combinations of apparatus for separating solids from solids by dry methods applicable to bulk material, e.g. loose articles fit to be handled like bulk material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
    • B01J8/008—Details of the reactor or of the particulate material; Processes to increase or to retard the rate of reaction
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
    • B07B—SEPARATING SOLIDS FROM SOLIDS BY SIEVING, SCREENING, SIFTING OR BY USING GAS CURRENTS; SEPARATING BY OTHER DRY METHODS APPLICABLE TO BULK MATERIAL, e.g. LOOSE ARTICLES FIT TO BE HANDLED LIKE BULK MATERIAL
    • B07B13/00—Grading or sorting solid materials by dry methods, not otherwise provided for; Sorting articles otherwise than by indirectly controlled devices
    • B07B13/003—Separation of articles by differences in their geometrical form or by difference in their physical properties, e.g. elasticity, compressibility, hardness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
    • B07B—SEPARATING SOLIDS FROM SOLIDS BY SIEVING, SCREENING, SIFTING OR BY USING GAS CURRENTS; SEPARATING BY OTHER DRY METHODS APPLICABLE TO BULK MATERIAL, e.g. LOOSE ARTICLES FIT TO BE HANDLED LIKE BULK MATERIAL
    • B07B13/00—Grading or sorting solid materials by dry methods, not otherwise provided for; Sorting articles otherwise than by indirectly controlled devices
    • B07B13/10—Grading or sorting solid materials by dry methods, not otherwise provided for; Sorting articles otherwise than by indirectly controlled devices using momentum effects
    • B07B13/11—Grading or sorting solid materials by dry methods, not otherwise provided for; Sorting articles otherwise than by indirectly controlled devices using momentum effects involving travel of particles over surfaces which separate by centrifugal force or by relative friction between particles and such surfaces, e.g. helical sorters
    • B07B13/116—Grading or sorting solid materials by dry methods, not otherwise provided for; Sorting articles otherwise than by indirectly controlled devices using momentum effects involving travel of particles over surfaces which separate by centrifugal force or by relative friction between particles and such surfaces, e.g. helical sorters stratification of dry granular material on a continuously travelling surface, e.g. belt conveyor
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
    • C10G2300/10—Feedstock materials
    • C10G2300/107—Atmospheric residues having a boiling point of at least about 538 °C

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  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Devices And Processes Conducted In The Presence Of Fluids And Solid Particles (AREA)

Abstract

Apparatus for classifying catalyst particles comprises: a conveyor belt system for separating particles into two groups, said system including at least one conveyor belt (5, 8) in an inclined position, a first outlet for one group of particles and a second outlet for another group of particles; a vibrating table (9) for separating particles into two groups, a first outlet for one group of particles and a second outlet for another group of particles; means (4) for supplying particles to the conveyor belt system; and means (7) for passing particles emerging from one of the outlets of the conveyor system to the vibrating table. The apparatus is especially suited for a process to classify catalyst particles which can be used in a hydrodemetallization process. <IMAGE>

Description

SPECIFICATION Apparatus for classifying catalyst particles and catalytic process employing catalyst particles thus classified The present application relates to an apparatus for classifying catalyst particles especially suitable for use in moving beds, to a process for classifying catalyst particles using the apparatus according to the present invention and to catalytic processes employing beds of catalyst particles thus classified.
Processes employing moving beds of catalysts include for instance catalytic cracking, hydrotreating, hydrometallization, hydrodesulphurization, and the production of olefins. Generally in these processes catalyst particles are used having diameters of 0.1-10 mm, in particular 1-3 mm. Preferably the catalyst particles have a spherical shape, but cylindrical particles, e.g. extrudates, may be used too. A process for the preparation of spherical catalyst (carrier) particles is described e.g. in our British patent specification 1,525,386. In particular silica and alumina spheres, having diameters of a few millimetres, e.g. from 1.5 to 3.0 mm, can be prepared in this way, which when loaded with certain transition metai ions constitute excellent hydrodemetallization catalysts.The hydrodemetallization process is well known to experts in the oil processing industry and need not be described here. It is gaining in importance as increasingly heavier and more metal-containing crude oils are being processed and will be processed in the future.
The use of catalytic moving bed reactors appears to be quite satisfactory from a chemical point of view, but from a mechanical point of view some improvements could still be made. One of the problems encountered occasionally is that reactor outlet screens, which should retain the catalyst particles whilst letting the fluid reaction products pass through are plugged by chips and fines. Also, some fouling and erosion of fluid conduits, pumps and valves has been experienced.
An investigation into these problems showed that catalyst particles may collapse under the weight of the moving bed thereby producing irregularly shaped chips and fines. It appears in particular, tnat some particles, which at first sight seem to be spherical actually contain concealed cavities, which render them likely to collapse under pressure. The smallest chips and fines pass through the reactor outlet screens, and travel with the fluid reaction products to various pumps etc.
which is highly undesired. The larger chips do not pass through the reactor outlet screens, but they unfortunately get stuck in the screens' openings, thus obstructing the passage of fluids. The nature of the catalyst particles is thus very important. It will be clear that spherical and almost spherical particles are less likely to plug the reactor outlet screens since they are able to roll easily over the reactor outlet screens, provided their size exceeds the screens' openings.
It has now been found that these problems can be avoided by carefully picking out the suitable catalyst particles before supplying them to the reactor system, in order to provide an easily flowing catalyst mass possessing a high intrinsic crushing strength which makes them especially suitable for use in moving beds.
The invention therefore relates to an apparatus for classifying catalyst particles which comprises: a conveyor belt system for separating particles into two groups, said system including at least one conveyor belt in an inclined position, a first outlet for one group of particles and a second outlet for another group of particles; a vibrating table for separating particles into two groups, a first outlet for one group of particles and a second outlet for another group of particles; means for supplying particles to the conveyor belt system; and means for passing particles emerging frorn one of the outlets of the conveyor system to the vibrating table.
It should be noted that an inclined conveyor belt for separating spherically-shaped solids from irregularly-shaped solids is known from US patent specification 4,118,309. That specification, however, relates to an oil shale retorting process, which is quite distinct from (moving bed) catalytic processes.
The conveyor belt system which forms part of the apparatus according to the present invention comprises at least a during operation inclined ascending conveyor belt having a first outlet, preferably at the lower end of the belt to collect catalyst particles rolled down the conveyor belt during operation and a second outlet preferably at the upper end of the conveyor belt to collect the remaining particles. The particles emerging at the second outlet are passed on to the vibrating table.
The particles emerging at the first outlet are normally either stored for further usage or transported to a further conveyor belt. They could also be transported to a further or the same vibrating table.
The catalyst particles to be classified using the apparatus according to the present invention are normally transported to a moving conveyor belt so that piling-up of material does not occur. If one were processing only a small batch of particles one could of course use any steady, tilted plane to effect a separation between rolling and non-rolling particles, but for a continuous process some movement is necessary. The particles are fed to the conveyor belt using any conventional means, such as a tube or a slide-plate, but preferably feed nozzles are used to ensure an even deposition.
The catalyst particles are thus classified according to their rolling ability, a property which is closely related to their degree of "sphericality".
The latter is extremely hard to define, however, whereas the rolling ability can be related simply to the particle "roll angle", i.e. the inclination (in degrees) of a plane at which a particle starts to roll down when the inclination is increased slowly.
When a particle does not roll down, but rather starts to slide down, the inclination of the plane is called the "slip angle". The slip angle is also a function of the friction coefficient between particle and plane. The friction being a rolling particle and plane. The friction between a rolling particle and a plane is negligibly small, when compared to the friction of a sliding particle. and the roll angle is a good measure of the "sphericality" of a particle therefore. The smaller the roll angle, the better the rolling ability, and the better the sphericality. A batch of particles of varying roundness will thus give a range of roll angles, and specific curves showing the proportion of particles rolling down a slope at a given inclination can be drawn.
Depending on the nature of the particles, maximum roll angles for each batch of particles can thus be specified.
By varying the inclination and the speed of the conveyor belt the separation quality and the capacity, resp., for separating rolling particles from non-rolling or slightly-rolling particles can be adjusted. The inclination of the conveyor belt preferably lies in the range of from 0.5 to 300, and in particular between 5 and 1 80. The linear velocity of the conveyor belt preferably lies in the range of 0.01 to 1.0 m/sec, and in particular between 0.1 and 0.7 m/sec. The use of a conveyor belt results in rolling particles mainly emerging at the lower end of the conveyor belt and non-rolling or slightly-rolling particles at the upper end of the conveyor belt.
For some applications the use of only one conveyor belt is sufficient. If finer classifications are required, it may be advantageous to pass catalyst particles already classified again over the same or over another conveyor belt. The inclination and the linear velocity of any second, third, etc. conveyor belt need not necessarily be the same, nor equal to the settings of the first. To avoid any build-up of material, the capacity of each conveyor belt is at least similar to and preferably increased with respect to the preceding one. Preferably, therefore, the linear velocity of each inclined ascending conveyor belt is not smaller than the linear velocity of the preceding one(s).
Each conveyor belt is adjusted in such a way, that the rolling particles obtained at the last belt's lower end are almost exclusively spherical. It is normally accepted that the fraction(s), obtained at the belt's or belts' upper end, do(es) contain some spherical particles as well.
The mixture(s) of non-rolling and slightly-rolling particles obtained at the second outlet(s) of the conveyor belt(s) is (are) fed to an inclined vibrating table. The vibrations of this table may be perpendicular or parallel to the table's plane, or both. Those skilled in the art know how to adjust the vibration frequency and amplitude for an optimal separation of spherical and non-spherical particles. The non-spherical particles seem to "creep" upwards on the table, whereas the spherical particles quickly roll off.
An additional advantage of the inclined vibrating table is that it enables separation of particles containing (concealed) cavities from homogeneous particles. A possible explanation is that in particles containing cavities the centre of mass does not coincide with the geometrical centre, so that their behaviour on the inclined vibrating table becomes rather erratic as opposed to the regular behaviour of spherical and homogeneous particles. Since cavities may result in a decreased crushing strength of such catalyst particles, the removal of these particles is beneficial with respect to the flowing properties of a moving bed.
It would seem handy to process all catalyst particles to be classified over the inclined vibrating table, in other words to omit the ascending conveyor belt(s). However, this is not useful, since inclined vibrating tables have a very limited capacity and consume a iot of energy, whereas conveyor belts are cheap and suitable for preselecting the bulk of the catalyst particles that are to be classified. It appears that the few inhomogeneous, spherical particles obtained at the lower end of a conveyor belt do not normally impair the suitability of the catalyst particles finally obtained for use in a (moving) bed.
The inclination of the vibrating table also should be adjusted to the optimal value. Preferably the inclination of the vibrating table lies between 0 and 300. There are several ways to bring the table into vibration, of which one preferred way is to excite the table in the vicinity of its upper side by an electromagnetic vibrator. The main axis of this vibrator may make an angle with the horizontal plane of between 0 and 1800.
It may be advantageous to incorporate a sieve in the apparatus according to the invention, so that oversized particles are sieved out prior to classification but often, this will not be necessary.
As sieve can be used any conventional wire cloth or screen sieve, having the appropriate mesh, which is advantageously of the sealcleaning type. When catalyst particles of about 3 mm diameter are required, a mesh comparable to a US standard test sieve No. 8 may be used. In case many very small fines are present, it may be advantageous to use a pneumatic means of sieving, e.g. a wind-sifter or a cyclone.
It is further possible to perforate the material of the first conveyor belt or to use a belt of gridiron material. By choosing the appropriate size of perforation a simuitaneously sieving conveyor is obtained.
The particles emerging from the first (lower) outlet of the last conveyor belt (when more than one conveyor belt is applied) can be stored as such or they may be combined with particles emerging from the first (lower) outlet of the vibrating table depending on the degree of classification required.
It has been found that by using the apparatus according to the present invention substantially less plugging of reactor outlet screens and less fouling and erosion of conduits, valves and pumps occur. The down-time of (moving) bed reactors is thus shortened so that less cleaning of equipment is needed and more material can be put through the reactor per period of time.
The catalyst particles to be classified may have been freshly prepared or they may have been freshly prepared or they may have been regenerated one or more times. It will be clear that the apparatus and process of the invention can be used advantageously in a catalyst manufacturing plant, so that the catalyst particles produced meet certain specifications regarding roundness, homogeneity and crushing strength. It is also possible to use the apparatus process of the invention in chemical factories where catalyst regeneration processes are carried out. For instance, in a hydrodemetallization plant it would be possible to apply the process according to the invention subsequent to the catalyst regeneration step, i.e. before the supply of the catalyst to the hydrometallization reactor.
The present invention further relates to a process for classifying catalyst particles wherein use is made of the apparatus as described and claimed herein. The present invention relates in particular to a process for employing a bed of catalyst particles wherein the catalyst particles have been classified using the apparatus referred to hereinbefore. The apparatus and process are particularly advantageous in hydrodemetallization since in hydrodemetallization the catalyst particles are subjected frequently to mechanical handling, e.g. when transporting the particles to and from the regeneration unit.
The present invention will now be described in more detail with reference to the figure, schematically showing a preferred embodiment as used in a hydrodemetallization plant. The steps of the preferred process -- also constituting various parts of the apparatus -- are indicated by the letters (a) to (e) at the left hand side of the drawing.
Fresh and/or freshly regenerated catalyst particles, comprising spheres, chips and fines are introduced via a conduit 1 onto a vibrating sieve 2 (step a). The fines pass through the sieve and are removed via a conduit 3, whereas the chips and the spheres are led to a feed nozzle 4 which is located above a during operation ascending conveyor belt 5 (step b). Preferably, the feed nozzle is located half-way the conveyor belt. On the conveyor belt classification takes place. A first fraction (1) containing mainly rolling particles is obtained continuously at the lower end and led to a second feed nozzle 6, and a first fraction (2) containing mainly non-rolling or slightly-rolling particles is obtained continuously at the upper end and led to a slotted feed pipe 7.The first fraction (1) is classified on the second conveyor belt 8 into a second fraction (1) and a second fraction (2) (step c).
The second fraction (2) is combined with the first fraction (2), and both fractions are spread via the slotted feed pipe 7 on a vibrating table 9. On the vibrating table 9 classification takes place (step d) into spherical particles at the table's lower side, which may be combined with the second fraction (1) (step e) to yield the desired classified catalyst particles, and non-spherical particles, i.e.
the chips and some spheres containing cavities, which jump over the upper side of the vibrating table 9. The throughput of the illustrated system can be regulated by varying V and V', the velocities of the inclined conveyor belts, and by varying the size of the apertures of the feed pipes 4, 6 and 7. The inclinations of conveyor belts 5 and 8, are designated a and a' respectively, the inclination of the vibrating table 9 is called P and the inclination of vibrator 10 is called y. The fines and the chips that are removed via 3 and at the upper side of the vibrating table 9 may be collected for reprocessing to spherical catalyst particles.
EXAMPLE In a hydrodemetallization plant employing the apparatus and process of the invention in the way as illustrated in the drawing, 1000 kg/day regenerated and fresh catalyst particles were processed. The catalyst particles were required to be spherical, having a diameter greater than 1.5 mm. The particles were fed onto the sieve 2, having a mesh of 1.41 mm. 39 Kg/day of fines were removed and 961 kg/day of larger particles were fed on the first conveyor belt 5, having an inclination of 120 and a velocity of 0.2 m/sec.
909 Kg/day was removed as the first fraction (1) and 52 kg/day was removed as the first fraction (2). The first fraction (1) was further separated on conveyor belt 8, having an inclination of 90 and a velocity of 0.1 m/sec. Both fractions (2) were combined and separated into 29 kg/day spherical and 61 kg/day non-spherical particles on the vibrating table 9, yielding a total of 900 kg/day selected spherical particles. The inclination of table 9 was set at 3.50, and the vibrator 10 was inclined at 370, vibrating at 60 Hz. The catalyst particles obtained using the apparatus and process according to the invention were used in a hydrodemetallization process under standard conditions and the operation of the hydrodemetallization process appeared to be quite satisfactory, in that less plugging of reactor outlet screens and less fouling of fluid conduits and pumps was experienced, resulting in 5 to 10 times longer run times between scheduled shutdowns, as compared to a hydrodemetallization process wherein the catalyst applied had not been subjected to a classification process.

Claims (7)

1. Apparatus for classifying catalyst particles which comprises: a conveyor belt system for separating particles into two groups, said system including at least one conveyor belt in an inclined position, a first outlet for one group of particles and a second outlet for another group of particles; a vibrating table for separating particles into two groups, a first outlet for one group of particles and a second outlet for another group of particles; means for supplying particles to the conveyor belt system; and means for passing particles emerging from one of the outlets of the conveyor system to the vibrating table.
2. Apparatus according to claim 1, further comprising a sieve wherein one outlet of the sieve communicates with the means for supplying particles to the conveyor belt system.
3. Apparatus according to claim 1 or 2, wherein the first conveyor belt is perforated.
4. Apparatus according to any one of claims 1-3, comprising means to collect particles from one outlet of the conveyor belt system and one outlet of the vibrating table.
5. Process for classifying catalyst particles wherein use is made of an apparatus as claimed in any one of the preceding claims.
6. Process for employing a bed of catalyst particles wherein the catalyst particles have been classified according to a process as claimed in claim 5.
7. Process according to claim 6, wherein the classified particles are used in a hydrodemtallization process.
GB08231544A 1981-11-06 1982-11-04 Apparatus for classifying catalyst particles and catalytic process employing catalyst particles thus classified Expired GB2108871B (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB08231544A GB2108871B (en) 1981-11-06 1982-11-04 Apparatus for classifying catalyst particles and catalytic process employing catalyst particles thus classified

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB8133526 1981-11-06
GB08231544A GB2108871B (en) 1981-11-06 1982-11-04 Apparatus for classifying catalyst particles and catalytic process employing catalyst particles thus classified

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GB2108871A true GB2108871A (en) 1983-05-25
GB2108871B GB2108871B (en) 1985-06-05

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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2588783A1 (en) * 1985-10-23 1987-04-24 Eurecat Europ Retrait Catalys METHOD AND APPARATUS FOR REALIZING THE SEPARATION OF SPHERICAL MATERIALS WITH OR WITHOUT IMPERFECTIONS
FR2607733A1 (en) * 1986-12-09 1988-06-10 Eurecat Europ Retrait Catalys PROCESS FOR REALIZING THE SEPARATION OF EXTRUDED MATERIALS WITH OR WITHOUT IMPERFECTIONS
GB2198371A (en) * 1986-11-07 1988-06-15 Guillaume Patrice Sanson Process and apparatus for sorting spherical objects
FR2636863A1 (en) * 1988-09-29 1990-03-30 Becker Arnaud Installation for separating and cleaning ground products
WO2005049231A2 (en) * 2003-11-05 2005-06-02 select Ingenieurgesellschaft für Optoelektronik, Bilderkennung und Qualitätsprüfung mbH Method and device for separating foreign admixtures from a product flow

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2588783A1 (en) * 1985-10-23 1987-04-24 Eurecat Europ Retrait Catalys METHOD AND APPARATUS FOR REALIZING THE SEPARATION OF SPHERICAL MATERIALS WITH OR WITHOUT IMPERFECTIONS
EP0223639A1 (en) * 1985-10-23 1987-05-27 EUROPEENNE DE RETRAITEMENT DE CATALYSEURS (en abrégé EURECAT) Method of and device for putting apart spherical materials possibly showing imperfections
US4986424A (en) * 1985-10-23 1991-01-22 Europeenne De Retraitement Process and apparatus for separating materials of different shapes or sizes
GB2198371A (en) * 1986-11-07 1988-06-15 Guillaume Patrice Sanson Process and apparatus for sorting spherical objects
FR2607733A1 (en) * 1986-12-09 1988-06-10 Eurecat Europ Retrait Catalys PROCESS FOR REALIZING THE SEPARATION OF EXTRUDED MATERIALS WITH OR WITHOUT IMPERFECTIONS
EP0274924A1 (en) * 1986-12-09 1988-07-20 EUROPEENNE DE RETRAITEMENT DE CATALYSEURS (en abrégé EURECAT) Method for separating extruded materials with or without defects
US4839031A (en) * 1986-12-09 1989-06-13 Europeenne De Retraitement De Catalyseurs Eurecat Process for performing the separation of extruded materials which may or may not show imperfections
FR2636863A1 (en) * 1988-09-29 1990-03-30 Becker Arnaud Installation for separating and cleaning ground products
WO2005049231A2 (en) * 2003-11-05 2005-06-02 select Ingenieurgesellschaft für Optoelektronik, Bilderkennung und Qualitätsprüfung mbH Method and device for separating foreign admixtures from a product flow
WO2005049231A3 (en) * 2003-11-05 2005-09-29 Select Ingenieurgesellschaft F Method and device for separating foreign admixtures from a product flow

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Effective date: 19921104