WO2021011768A1 - Sondes multisensorielles et systèmes de surveillance de fluidisation - Google Patents

Sondes multisensorielles et systèmes de surveillance de fluidisation Download PDF

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Publication number
WO2021011768A1
WO2021011768A1 PCT/US2020/042324 US2020042324W WO2021011768A1 WO 2021011768 A1 WO2021011768 A1 WO 2021011768A1 US 2020042324 W US2020042324 W US 2020042324W WO 2021011768 A1 WO2021011768 A1 WO 2021011768A1
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WIPO (PCT)
Prior art keywords
body member
reactor
probe
elongate body
disposed
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PCT/US2020/042324
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English (en)
Inventor
Mohammed S. CHEHAB
Billy D. MCMILLAN
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Exxonmobil Research And Engineering Company
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Application filed by Exxonmobil Research And Engineering Company filed Critical Exxonmobil Research And Engineering Company
Publication of WO2021011768A1 publication Critical patent/WO2021011768A1/fr

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    • 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
    • B01J8/18—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles
    • B01J8/1809—Controlling processes
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01K—MEASURING TEMPERATURE; MEASURING QUANTITY OF HEAT; THERMALLY-SENSITIVE ELEMENTS NOT OTHERWISE PROVIDED FOR
    • G01K1/00—Details of thermometers not specially adapted for particular types of thermometer
    • G01K1/02—Means for indicating or recording specially adapted for thermometers
    • G01K1/026—Means for indicating or recording specially adapted for thermometers arrangements for monitoring a plurality of temperatures, e.g. by multiplexing

Definitions

  • the present disclosure relates generally to measuring process parameters in reactors.
  • Fluidized bed reactors operating at elevated pressure and temperature experience complex hydrodynamic patterns.
  • Gas-solid fluidized bed reactors are nonlinear and chaotic dynamic systems with both non-random and irregular flow characteristics and thermal patterns, which influence the interactions among the constituents in the reactor.
  • Monitoring process parameters in such dynamic environments are necessary and beneficial to normal operation of the reactors and to the development of performance improvements.
  • a fluidized bed reactor is used for polymer production.
  • process parameter sensors are installed through the reactor wall to measure parameters such as temperature.
  • the sensors only extend a few inches into the reactor from the reactor wall. With the reactors typically being six to twenty feet in diameter, the sensors can be monitoring less than 15% of the entire cross-sectional area of the reactor, which leaves the central 85% or more of reactor contents unmonitored.
  • the present disclosure relates generally to measuring process parameters in reactors. More specifically, the present disclosure relates to measuring temperature, electrostatic charge, and optionally pressure in the central portion of fluidized bed reactors.
  • a multi-sensory probe for measuring temperature and electric field within a reactor in accordance with this disclosure may comprise: an elongate body member extending between a first end and a second end along a longitudinal axis; a plurality of temperature sensors spaced apart along the body member and disposed to measure temperatures external to the body member; and an electrostatic sensor disposed to measure an electrostatic field external to the body member.
  • a method for operating a fluidized bed reactor in accordance with this disclosure may comprise: contacting a catalyst and a monomer in a fluidized bed reactor under polymerization conditions; and measuring with a multi-sensory probe an electric field in the fluidized bed reactor and temperatures at a plurality of radially spaced apart locations in the fluidized bed reactor.
  • a fluidization monitoring system in accordance with this disclosure may comprise: a multi-sensory probe comprising: an elongate body member extending between a first end and a second end along a longitudinal axis; a plurality of temperature sensors spaced apart along the body member and disposed to measure temperatures external to the body member; and an electrostatic sensor disposed to measure an electrostatic field external to the body member.
  • the fluidization monitoring system further comprises a fluidized bed reactor comprising: a central axis; a sidewall disposed about the central axis; an annular outer zone extending inward from the sidewall toward the central axis; and an internal zone extending inward from the intermediate zone toward the central axis; wherein, the fluidized bed reactor is configured to be operable in a mode such that during operation a solids fraction of catalyst with respect to a fluidizing gas increases from the wall toward the central axis in the outer zone, reaches a maximum value between the outer zone and the internal zone, and decreases toward the central axis in the internal zone; and wherein a temperature sensor of the plurality of temperature sensors and the electrostatic sensor are disposed in a location within the internal zone.
  • FIG. 1 illustrates, in partial cross-section, an example reactor system comprising a fluidized bed reactor having a fluidization monitoring system and a plurality of catalyst injection tubes installed therein.
  • FIG. 2 illustrates, in partial cross-section, a non-limiting example of a multi-sensory probe of a fluidization monitoring system.
  • FIG. 3 shows a graph of the concentration of catalyst particles in a fluidized mixture of catalyst particles and a fluidizing gas during an operation of the fluidization monitoring system and reactor system of FIG. 1.
  • FIG. 4 illustrates, in partial cross-section, another non-limiting example of a multi- sensory probe of a fluidization monitoring system.
  • FIG. 5 illustrates, in partial cross-section, another non-limiting example of a multi- sensory probe of a fluidization monitoring system. DESCRIPTION
  • the present disclosure relates generally to measuring process parameters in reactors. More specifically, the present disclosure relates to measuring temperature and electrostatic charge in the central portion of fluidized bed reactors. Monitoring the conditions in the central portion of a fluidized bed reactor may enable identifying temperature variations within the reactor, better mapping of particle flow characteristics (e.g., velocities and directions), and identifying reaction rate variations. With knowledge such as this, catalyst utilization and development may be improved, reactor conditions may be fine-tuned, and upset conditions minimized or mitigated.
  • particle flow characteristics e.g., velocities and directions
  • fluidization monitoring systems having instrumentation on a multi-sensory probe to evaluate performance of fluidized bed reactors.
  • fluidization monitoring systems can include multi-sensory probes configured to measure temperature and electrostatic charge.
  • Some of these multi-sensory probes may utilize an existing catalyst injection port in a fluidized bed reactor disposed at the catalyst injection level. Improvements to the monitoring of temperature and static charge in fluidized bed reactors may help operators better understand temperature variations and build-up of static charge within fluidized bed reactors and may lead to discoveries that reduce fouling and sheeting events within these reactors. The additional process data or the resulting improvements may improve the speed that new products can be produced economically at a commercial scale and may reduce the frequency of reactor outages.
  • ordinal numbers such as first, second, third, etc. do not indicate a quantity but are used for naming and reference purposes.
  • ordinal numbers used in the claims in reference to a component or feature may differ from the ordinal numbers used in the written description for the corresponding component or feature. For example, a“second object” in a claim might be described as a“third object” or may be described without an ordinal number in the written description.
  • FIG. 1 illustrates, in partial cross-section, an example reactor system 100 comprising a fluidized bed reactor 104 having a fluidization monitoring system 102 and a plurality of catalyst injection tubes 106 installed therein.
  • the fluidized bed reactor 104 is a cylindrical vessel that includes a sidewall 110 extending lengthwise along a central axis 111 from a bottom 112 to a top 114.
  • the reactor 104 is characterized by a reactor height H104 measured axially and by a diameter ID104.
  • the reactor height HI 04 and diameter ID 104 are shown as internal measurements, meaning ID 104 is an inside diameter in this example, but reactor 104 may also be characterized by external height and diameter.
  • the reactor 104 may have a diameter ID 104 in the range of six feet to twenty feet although smaller and larger diameters are contemplated.
  • the reactor 104 also includes an inlet port 118 disposed in or adjacent to the bottom 112, a plurality of side ports 120A, 120B, 120C, 120D disposed in the reactor sidewall 110, and an exit port 126 disposed in or adjacent to the top 114.
  • the reactor 104 is shown with four side ports 120A, 120B, 120C, 120D.
  • reactors can have any number of side ports to accommodate the desired number of catalyst injection tubes and the desired number of fluidization monitoring systems.
  • the number of side ports may range from 2 to 10, or preferably 2 to 6.
  • the side ports 120A-D are typically located closer to the bottom 112 than to the top 114 of the reactor 104. Preferably, the side ports 120A-D are located within the lower 1/3 of the reactor height HI 04 or within the lower 1/3 of the portion of reactor height HI 04 that is disposed above a distribution member 130. As illustrated, the first and second side ports 120A, 120B are axially spaced apart, and the third and fourth side ports 120C, 120D are axially spaced apart. Further, the first and second side ports 120 A, 120B are circumferentially spaced apart from the third and fourth side ports 120C, 120D. An axial location 128 of the first side port 120A is indicated in FIG. 1 for reference.
  • the axial location 128 corresponds a radially extending plane that passed through the center of the first port 120 A.
  • the reactor 104 includes one inlet port 118 and one exit port 126.
  • reactors can have any number of inlet ports and any number of exit ports.
  • the inlet port(s) are used to provide fluidizing gas and chemical feedstock (e.g., monomers), separately or together.
  • the inlet port(s) 118 may be fluidically coupled to an inlet line for a fluidizing gas (not shown) or a feed line for chemical constituents (not shown), and the exit port(s) 126 may be coupled to an exit line (not shown).
  • a fluidizing gas not shown
  • the exit port(s) 126 may be coupled to an exit line (not shown).
  • reactor 140 may be described as a vertical vessel with central axis and sidewall 110 extending vertically, and inlet 118 is vertically below exit port 126.
  • inlet line “exit line”
  • related types of“line” encompass any of piping, hoses, connections, and the like.
  • the fluidized bed reactor 104 includes the distribution member 130 that extends across the body of reactor 104 at an axial location between inlet port 118 and the lowermost side ports 120A, 120C.
  • the distribution member 130 may be a plate, screen, wire mesh, and the like, or any combination thereof.
  • the distribution member 130 is substantially horizontal.
  • An inlet chamber 132 fed by the inlet port 118 is defined between the bottom 112 and the distribution member 130.
  • a reaction chamber 134 is defined between the distribution member 130 and the top 114.
  • the reaction products, unreacted feedstock, catalyst particles, gas, and other constituents may be discharged from reaction chamber 134 through exit port 126.
  • the reaction chamber 134 may be divided into multiple, concentric zones located about the central axis 111.
  • FIG. 1 presents three zones 140, 142, 144.
  • the size and position of the zones 140, 142, 144 may be based on flow patterns, material distribution patterns (e.g., variations in solids fractions across an area), or variation in localized reaction rates that are anticipated to develop in the reactor 104 during operation. Knowledge of these zones can be used to design the dimensions and configurations of a probe 160 of the fluidization monitoring system 102.
  • reaction chamber 134 When reaction chamber 134 has a selected amount of catalyst and a flow rate of fluidizing gas is supplied through port 118 to fluidize the catalyst, an annular outer zone 140, an annular intermediate zone 142, and an annular or cylindrical internal zone 144 may be established in chamber 134.
  • the approximate boundaries between zones 140, 142, 144 are shown with dashed lines in FIG. 1.
  • the outer zone 140 extends inward from reactor sidewall 110 toward the central axis 111 ; the intermediate zone 142 extends from the outer zone 140 inward toward the central axis 111; and the internal zone 144 extending inward from the intermediate zone toward the central axis 111.
  • intermediate zone 142 is disposed radially inside the outer zone 140
  • internal zone 144 is disposed radially inside the outer zone 140 and the intermediate zone 142.
  • the sizes of zones 140, 142, 144 may vary based on the quantities or conditions of solids and fluids constituents within reactor 104. Even without constituents or without operational conditions in reactor 104, these zones are understood to exist and their locations, e.g., the interfaces between the zones, may be predicted based on a selected or an anticipated set of operational conditions.
  • a support tube 150 is installed in each of second, third, and fourth side ports 120B, 120C, 120C, and a catalyst injection tube 106 is installed in each support tube 150. While FIG. 1 illustrates all support tubes 150 associated with catalyst injection tube 106, support tubes may be installed without including a catalyst injection tube.
  • the catalyst injection tubes 106 extend into the internal zone 144 of reactor chamber 134 to inject catalyst into this zone.
  • the catalyst injection tubes 106 may be connected to additional a catalyst equipment and a reservoir of catalyst (not shown).
  • the first side port 120A is likewise configured to receive a support tube 150 and a catalyst injection tube 106, but instead, a multi-sensory probe 160 is installed in port 120A.
  • the probe 160 may be installed from the exterior of reactor 104 without a person entering into reactor 104.
  • the multi-sensory probe 160 is a member of the fluidization monitoring system 102, which may also include instrumentation, control components, a processor, or machine executable code that are not shown in FIG. 1.
  • the multi-sensory probe 160 extends into internal zone 144 to measure within the internal zone 144 a plurality of parameters associated with the operation of reactor 104.
  • the multi-sensory probe 160 may also be configured to measure parameters associated with the operation of reactor 104 within zones 140, 142.
  • the probe 160 is configured to measure temperature and an electric field within a reactor such as reactor 104.
  • the probe 160 includes a temperature sensor 162 and an electrostatic sensor 164 and optionally a pressure sensor (not illustrated in FIG. 1 but rather illustrated in multi-sensory probe 500 of FIG. 5).
  • the probe 160 includes ten temperature sensors 162 space apart and located along the probe 160.
  • the multi-sensory probe of the fluidization monitoring system may include any number of temperature probes including, for example, from 1 to 100, or 2 to 50, or 5 to 25, or 10 to 50, or 25 to 100.
  • a temperature sensor 162 is located in each of the zones 140, 142, 144 with multiple sensors 162 being disposed within internal zone 144.
  • temperature sensors may be located in one, two, or three of the zones.
  • the probe 160 extends substantially horizontally and in this example extends in a substantially radial direction.
  • the innermost temperature sensor 162A is located at an insertion distance 166 relative to sidewall 110, and the electrostatic sensor 164 is located at an insertion distance 168.
  • the larger of the two intersection distances 166, 168 are referred to as the intersection distance of the multi-sensory probe 160. Accordingly, in this example, insertion distance 168 is the intersection distance of the multi-sensory probe 160.
  • the insertion distance 168 of the multi-sensory probe 160 may be equal to or greater than 7% of the reactor diameter ID 104. Preferably, the insertion distance 168 of the multi-sensory probe 160 is also less than one-half of diameter ID 104. However, the multi-sensory probe 160 may extend past the central axis 111 of the reactor 104, giving the insertion distance 168 a value that is greater than one-half of diameter ID 104.
  • the insertion distance 168 of the multi-sensory probe 160 may be equal to or greater than 7% of the reactor diameter ID 104 to less than one-half of diameter ID104, or equal to or greater than 15% of the reactor diameter ID104 and less than 40% of diameter ID 104, or equal to or more than one-half of diameter ID 104 and less than diameter ID 104.
  • the insertion distance 168 of the multi-sensory probe 160 may be from 0.30 m to 1.8 m (1 foot to 6 feet), or from 1 m to 2 m (3.28 feet to 6.56 feet) or from 0.60 m to 1.2 m (2 feet to 4 feet), or from 3.7 m to 4.9 m (12 feet to 16 feet), or less than 3.7 m (12 feet), or greater than 4.9 m (16 feet) up to a suitable size for catalytic polymer processing.
  • the reactor system 100 can also include a conventional temperature probe 152 including a temperature sensor and a separate, conventional electrostatic sensor 154, which both extend into outer zone 140 to measure process conditions in outer zone 140.
  • the temperature probe 152 and the electrostatic sensor 154 are not located in and do not extend into internal zone 144.
  • the temperature probe 152 and the electrostatic sensor 154 are independently mounted in separate ports through sidewall 110. Data from the temperature probe 152 and the electrostatic sensor 154 may be compared to data from multi-sensory probe 160.
  • FIG. 2 illustrates, in partial cross-section, a non-limiting example of multi-sensory probe 160 suitable for use in a fluidization monitoring system.
  • the probe 160 includes an elongate body member 202 extending between a leading end 204 and a trailing end 206 along a longitudinal axis 208.
  • the body member 202 further includes an outer surface 210 and a first channel 212 and a second channel 214, which are formed in surface 210.
  • the channels 212, 214 extend between ends 204, 206.
  • a mounting feature illustrated as a flange 216 in this example, is coupled at a trailing end 206, and an end cap 218 is coupled to flange 216 or body member 202.
  • the plurality of temperature sensors 162 are spaced apart along the body member 202 within first channel 212 and are arranged to measure temperatures external to the body member. Temperature sensors 162 are shown axially spaced apart along the body member 402 with the innermost sensor 162A disposed proximal leading end 204. The plurality of temperature sensors 162 electrically couple to and thereby include wires or cable 224 to deliver signals or data from the sensors.
  • sensors 162 are housed together in a sheath 226, forming a temperature sensor assembly. Sheath 226 is retained in channel 214, being coupled to the body member 202. Temperature sensors 162 may be exposed through the outer surface of sheath 226 or may be protected inside, beneath the outer surface of sheath 226. Wires or cable 224 is disposed in and extends through sheath 226 and therefore in channel 212, extending through trailing end 204.
  • the electrostatic sensor 164 is coupled to body member 202 to measure an electrostatic charge or an electrostatic field external to the body member.
  • the electrostatic sensor 164 is disposed proximal or beyond the leading end 204.
  • the electrostatic sensor 164 is electrically coupled to and thereby includes wires or a cable 244 that extends into the second channel 214 and through trailing end 204.
  • a length L 160 for probe 160 may be defined from the inner face of flange 216 to the center or tip of electrostatic sensor 164. Other lengths may be considered when designing or using probe 160, such as the length that leading end 204 of body member 202 extends beyond flange 216, or the length that the innermost temperature sensor 162A extends beyond flange 216.
  • the length L160 may be selected to be a value from 0.30 m to 1.8 m (1 to 6 feet), or from 0.60 m to 1.2 m (2 to 4 feet) or from 1 m to 2 m (3.28 feet to 6.56 feet).
  • a length for probe 160 may be chosen so that the first end 204 of elongate body member 202 extends into internal zone 144 when probe 160 is installed in fluidized bed reactor 104.
  • the temperature sensors 162 may be circumferentially spaced from one another and may be disposed in another location, possibly spaced apart from channel 212 and may be disposed in another channel. As illustrated, the temperature sensors 162 lack a sheath and may be housed within channel 212 in another manner, such as using an adhesive or potting compound, as examples. Alternatively, the cables 224, 244 are routed in the same channel, and body member 202 may have only one channel, e.g., channel 212 or channel 214.
  • FIG. 3 shows a graph 300 of the concentration of catalyst particles in a fluidized mixture of catalyst particles and a fluidizing gas during an operation of reactor 104.
  • the concentration of catalyst particles may also be called the solids concentration or solids fraction and is shown by curve 302.
  • Curve 302 may include data representing a moment in time or may include data collected on a time-averaged basis, as examples.
  • FIG. 3 plots the solids fraction 302 along a radial line 304 from sidewall 110 to centerline 111 at the location 128 for a selected operation mode or an operation condition of reactor 104.
  • Location 128 and therefore the radial line 304 define a radial plane, a plane that is perpendicular to axis 111.
  • Each point on radial line 304 beyond axis 111 represents a circle in that radial plane.
  • the centerline 208 of multi-sensory probe 160 lies on the radial plane defined by location 128.
  • annular outer zone 140, annular intermediate zone 142, and internal zone 144 are shown on graph 300 of FIG. 3.
  • Zone 144 may extend to centerline 111 or may be defined for a smaller volume. Zone 144 spans rightward to include or to extend beyond the insertion distance 168 of probe 160, a location that is plotted on graph 300.
  • the size and locations of concentric zones 140, 142, 144 in reactor chamber 134 may be characterized or defined based on an operational characteristic, such as flow patterns, material distribution patterns, or localized reaction rates that develop in reactor 104 during operation.
  • Zones 140, 142, 144 may be described as reaction zones, being distinguished by different reaction characteristics. For example, the spatial distribution of the solids fraction of fluidized catalyst (e.g., curve 302) may be used to define these zones, as will be explained with graph 300.
  • Flow characteristics in a reactor may be indicative of reaction rate patterns within the reactor.
  • curve 302 (i.e., the solids fraction of catalyst) rises as radial line 304 is traversed from wall 110 toward central axis 111. Traveling on the same path and in the same direction, within intermediate zone 142, curve 302 rises, reaches a maximum value and begins to decline. Location 308 along radial line 304 is where curve 308 reaches a maximum value for the selected operational mode. Continuing into internal zone 144, curve 302 declines towards central axis 111. Thus, as shown in FIG.
  • the fluidized bed reactor is configured to be operable in a mode such that during operation a solids fraction (e.g., curve 302) of catalyst with respect to a fluidizing gas increases from the wall toward the central axis in the outer zone 140, reaches a maximum value at a location 308 between the outer zone 140 and the internal zone 144, and decreases toward the central axis in the internal zone 144.
  • a solids fraction e.g., curve 302
  • the solids fraction 302 rises to a maximum value, which is achieved at location 308, and decreases toward the central axis.
  • Location 308 may fluctuate radially between central axis 111 and sidewall 110 when flow conditions naturally fluctuate or change due to an operation decision.
  • the radial span of intermediate zone 142 may be selected in order to accommodate different operational conditions or different modes of operation in reactor 104 while consistently including location 308. Predicting or establishing the location 308 of maximum solids fraction and margins for its variation (e.g., inner and outer boundaries of intermediate zone 142) may help when selecting a length for multi- sensory probe 160 to ensure that the probe may be sufficiently inserted into reactor 104 to get the desired data.
  • a preferred length for probe 160 would allow electrostatic sensor 164 and at least one temperature sensor 162 to be disposed beyond location 308, e.g., further from sidewall 110 of FIG. 1 and closer to central axis 111.
  • preferred length for probe 160 would allow electrostatic sensor 164 and at least one temperature sensor 162 to be disposed beyond location 308 and on or along a path where the solids fraction of catalyst with respect to a fluidizing gas decreases toward the central axis, e.g., within in the internal zone 144.
  • the length or the insertion distance of probe 160 may be selected so that electrostatic sensor 164 and a temperature sensor 162 are disposed to take measurements at a location that is beyond location 308, and where the solids fraction is approximately less than 60% of the maximum value at location 308.
  • the length or the insertion distance of probe 160 may be selected so that electrostatic sensor 164 and a temperature sensor 162 are disposed to take measurements at a location that is beyond location 308 and has a solids fraction approximately less than 20% of the maximum value at location 308.
  • the solids fraction value used to evaluate the placement of probe 160 may be an historic, a predicted, an anticipated, or a measured value, as examples.
  • a reason for targeting internal zone 144 for measurement relates to chemical interactions that transpire in that portion of the reactor 104, chemical interactions between the catalyst and the polymer that is fed to the reactor.
  • the flow characteristics may be indicative of reaction rate patterns within the reactor.
  • probe 160 may be installed in reactor 104 without knowledge of or without consideration of the location 308.
  • reactor chamber 134 may be divided into an outer zone 140 and an inner zone 144 without consideration of an intermediate zone 142.
  • the boundary between zones 140, 144 in such situations is the location 308, the location of maximum solids fraction.
  • Location 308 represents a circle in the radial plane disposed at axial location 128 or at another axial location.
  • a length for multi-sensory probe 160 may be selected to be sufficiently long so that electrostatic sensor 164 and at least one temperature sensor 162 are disposed where the solids fraction of catalyst with respect to a fluidizing gas decreases toward the central axis during a range of anticipated operational modes or conditions.
  • the selected length may be insertion distance 166 of temperature sensor 162A (FIG. 1).
  • the selected length may be probe length LI 60 (FIG.
  • FIG. 4 illustrates, in partial cross-section, a multi-sensory probe 400 that is compatible with fluidization monitoring system 102 and may be installed in reactor 104 as a member of fluidization monitoring system 102 replacing or complementing probe 160 (FIG. 1).
  • FIG. 4 illustrates, in partial cross-section, a multi-sensory probe 400 that is compatible with fluidization monitoring system 102 and may be installed in reactor 104 as a member of fluidization monitoring system 102 replacing or complementing probe 160 (FIG. 1).
  • probe 400 includes an elongate, tubular body member 402 extending between a leading end 404 and a trailing end 406 along a longitudinal axis 408. Trailing end 406 is closed, and leading end 404 may be closed.
  • Body member 402 includes an outer surface 410 and axial channel or central cavity 412.
  • Probe 400 further includes a mounting feature, which in this example is a flange 216, and an end cap 218, both coupled at trailing end 406.
  • a plurality of temperature sensors 162 are axially spaced apart along the body member 402 and are arranged to measure temperatures external to the body member. Innermost sensor 162A is disposed proximal leading end 404. Temperature sensors 162 are mounted along outer surface 410 or may be mounted under surface 410.
  • Temperature sensors 162 include wires that extend inward through the wall of body member 402 into central cavity 420, joining together to form or to connect to a cable 224. Cable 224 extends through central cavity 420 and trailing end 404. Alternatively or in addition to the foregoing, some sensors 162 may be circumferentially spaced from other sensors 162.
  • An electrostatic sensor 164 is coupled to body member 402 to measure an electrostatic charge or an electrostatic field external to the body member.
  • the electrostatic sensor 164 is disposed proximal or beyond the leading end 204.
  • Sensor 164 is electrically coupled to and thereby includes wires or a cable 244 that extends into central cavity 412 and through trailing end 404.
  • multi-sensory probe 400 and its temperature sensors 162 and its electrostatic sensor 164 may be disposed within the reactor in the same arrangement as was described for the multi-sensory probe 160 with respect to FIGS. 1, 3.
  • the diameter and length L400 of probe 400 or an insertion depth of sensor 162 A, 164 of probe 400 may be selected using the same basis or may be selected to have the same value as was discussed for the diameter or length LI 60 of probe 160 or the insertion depths of its sensor 162A, 164.
  • Body member 402 may be, for example, a modified support tube, such as support tube 150 of FIG. 1, or end cap 218 may be replaced by a blind or blank flange that accommodates cables 224, 244.
  • FIG. 5 illustrates, in partial cross-section, a multi-sensory probe 500 that is compatible with fluidization monitoring system 102 and may be installed in reactor 104 as a member of fluidization monitoring system 102 replacing or complementing probe 160 (FIG. 1) or probe 400.
  • Probe 500 includes an elongate body member 402, a plurality of temperature sensors 162 disposed along body member 402, an electrostatic sensor 164 coupled to body member 402, and a plurality of pressure sensors 562 disposed along body member 402.
  • body member 402 is tubular and extends between a leading end 404 and a trailing end 406 along a longitudinal axis 408. Trailing end 406 of body member 402 is closed, and leading end 404 may be closed.
  • Body member 402 includes an outer surface 410 and axial channel or central cavity 412.
  • Probe 500 further includes a mounting feature, which in this example is a flange 216, and an end cap 218, both coupled at trailing end 406.
  • the plurality of temperature sensors 162 are spaced apart along the body member 402 and are arranged to measure temperatures external to the body member. Temperature sensors 162 are shown axially spaced apart along the body member 402 with the innermost sensor 162A disposed proximal leading end 404.
  • Temperature sensors 162 are mounted along outer surface 410 or may be mounted under surface 410. Temperature sensors 162 include wires that extend inward through the wall of body member 402 into central cavity 420, joining together to form or to connect to a cable 224. Cable 224 extends through central cavity 420 and trailing end 404. Alternatively or in addition to the foregoing, some sensors 162 may be circumferentially spaced from other sensors 162.
  • Electrostatic sensor 164 is coupled to body member 402 to measure an electrostatic charge or an electrostatic field external to the body member.
  • the electrostatic sensor 164 is disposed proximal or beyond the leading end 204.
  • Sensor 164 is electrically coupled to and thereby includes wires or a cable 244 that extends into central cavity 412 and through trailing end 404.
  • the plurality of pressure sensors 562 are spaced apart along the body member 402 and are arranged to measure pressure external to the body member. Innermost sensor 562A is disposed proximal leading end 404. Pressure sensors 562 include an active element that is in fluid communication with the outer surface 410 or with a fluid located outside the outer surface 410. Pressure sensors 562 wires extend into central cavity 420 of body member 402. The wires of the pressure sensors 562 may join together to form or to connect to a cable 564. Cable 224 extends through central cavity 420 and trailing end 404. Alternatively or in addition to the foregoing, some pressure sensors 562 may be circumferentially spaced from other pressure sensors 562. Pressure sensors 562 may be axially spaced apart along the body member 402.
  • Pressure sensors 562 may be circumferentially spaced apart from temperature sensors 162 by 180 degrees about axis 408, as may be viewed from the perspective of end 406. Pressure sensors 562 may be circumferentially spaced apart from temperature sensors 162 by less than 180 degrees. Various of the individual pressure sensors 562 may be axially aligned with various temperature sensors 162 or may be axially offset from various temperature sensors 162.
  • a pressure sensor 562 may comprise a sensing element embedded in body member 402 adjacent the outer surface 410.
  • a pressure sensor 562 may comprise a sensing element located in chamber 412 or in end cap 218 and a tube or a hole that extends from the sensing element through the wall of body member 402 to outer surface 410. Cable 562 may be replaced by a group of fluidically parallel tubes.
  • multi-sensory probe 500 and its temperature sensors 162, its electrostatic sensor 164, and its pressure sensors 562 may be disposed within the reactor in an arrangement similar to the arrangement as was described for the multi- sensory probe 160 with respect to FIGS. 1, 3.
  • the diameter and length L500 of probe 500 or an insertion depth of sensor 162A, 164 of probe 500 may be selected using the same basis or may be selected to have the same value as was discussed for the diameter or length LI 60 of probe 160 or the insertion depths of its sensor 162A, 164.
  • the inmost pressure sensor 562A may be inserted to an insertion depth equal to the insertion depth of inmost temperature sensor 162A.
  • Body member 402 of probe 500 may be, for example, a modified support tube, such as support tube 150 of FIG. 1, or end cap 218 may be replaced by a blind or blank flange that accommodates cables 224, 244, 564.
  • the multi-sensory probe 500 having a plurality of temperature sensors 162, an electrostatic sensor 164, and a plurality of pressure sensors 562 may have a generally solid body member 202 like the body member of probe 160 instead of a tubular body member 402.
  • the wires or cables 224, 244, 564 for the various sensors 162, 164, 562 may be routed in one or more channels or holes extending axially within the body member 202.
  • a multi-sensory probe extending radially or horizontally through a reactor sidewall.
  • a multi-sensory probe may be installed through an end wall, such as a bottom or top of a reactor, and extends axially or vertically therein.
  • vertical reactors were discussed and shown in various examples, a fluidization monitoring system 102 or a multi-sensory probe in accordance with the principles disclosed herein may be integrated with or installed in a horizontal reactor or another type of vessel.
  • a multi-sensory probe 160, 400 were described in terms of a reactor in which the probe might be used. It is to be understood that a multi-sensory probe that is in accordance with the principles defined herein may be designed or build independently from any reactor.
  • a multi-sensory probe described herein is preferably received in a spare port in a reactor, a port that might otherwise be used for catalyst injection.
  • a multi-sensory probe may utilize a spare support tube in the port or may be inserted into a port without a support tube.
  • Other injection ports in the reactor may hold a support tube and a catalyst injection tube.
  • a multi-sensory probe may include a temperature sensor and an electrostatic sensor.
  • the multi-sensory probe will protrude into a fluidized reaction chamber further than convention temperature sensors extend and further than convention electrostatic sensors extend.
  • convention temperature sensors may be installed in a thermowell and may extend 0.18 m (6 inches) into the reactor bed in the reaction chamber, not reaching certain hydrodynamic or reaction zones within the chamber, which may be, for example, 4.6 m (15 feet) in diameter.
  • the disclosed probes may extend to an insertion distance of 0.91 m to 1.2 m (3 feet to 4 feet) from the reactor sidewall into the reaction chamber, for example. Additional, non- exhaustive examples are given below.
  • the multi-sensory probe may be designed such that installation can be accomplished from the outside of the reactor, therefore avoiding entering the reactor and the risks associated with doing so.
  • the electrostatic sensor of the probe can be used to monitor static buildup in the reactor. With this knowledge, process operators or experts can modify process variables for the reactor such as catalyst feed to mitigate the scenario of a sheeting event or other difficulties.
  • the temperature and electrostatic sensors will be used to measure data where it would be unknown in a conventional reactor.
  • the added data from otherwise unsupervised locations in a reactor may help process operators or experts understand hot, slow-moving bands of catalyst particles which are understood to cause polymer agglomerations.
  • Extended reach into the fluidized polymer bed may allow improved profiling of physical conditions and flow patterns and may allow for determination of shifts in circulation patterns and solids concentrations within the fluidized polymer bed.
  • the result may allow corrective actions to improve fluidization parameters and overall bed continuity, increased service factor, minimized or eliminated lengthy treatments of the internal wall of reactors, and enhanced commercialization of new catalyst/product development.
  • Improved ability to detect and discern bed hydrodynamic changes within the fluidized bed core may lead to control capabilities to mitigate adverse effects during reactor operation.
  • a fluidization monitoring system comprising a multi-sensory probe may be used in methods of operating a fluidized bed reactor.
  • a polymerization reaction may be carried out in the fluidized bed reactor while measuring the temperature and the electric field of the fluidized bed.
  • the data received from the multi-sensory probe may be used to adjust the conditions within the fluidized bed reactor.
  • Such conditions may include, but are not limited to, reaction temperature, catalyst flow rate, catalyst concentration, monomer flow rate, monomer concentration, fluidizing gas flow rate, reactor pressure, and the like, and any combination thereof.
  • the conditions in the fluidized bed reactor and any changes to such conditions will depend on the reaction being carried out and the design of the reactor.
  • Methods of the present disclosure can include contacting one or more catalysts and one or more monomers in a fluidized bed reactor under polymerization conditions; and measuring with a multi-sensory probe an electric field in the fluidized bed reactor and temperatures at a plurality of radially spaced apart locations in the fluidized bed reactor. Then, the polymerization conditions can be adjusted based on the electrical field and/or the temperatures measured with the multi- sensory probe.
  • a first nonlimiting example embodiment is a multi-sensory probe for measuring temperature and electric field within a reactor, the probe comprising: an elongate body member extending between a first end and a second end along a longitudinal axis; a plurality of temperature sensors spaced apart along the body member and disposed to measure temperatures external to the body member; and an electrostatic sensor disposed to measure an electrostatic field external to the body member.
  • Embodiment B is a fluidization monitoring system comprising: a fluidized bed reactor extending a reactor height from a bottom to a top and comprising a central axis extending through the bottom and the top, a wall, an inside diameter, a first port and a second port; a multi-sensory probe according to Embodiment A; wherein, the multi-sensory probe is installed in the first port with the first end of the elongate body member extending into an internal zone of the fluidized bed reactor within which solids fraction of catalyst with respect to the fluidizing gas decreases in a direction toward the central axis during at least one mode of operation; and a catalyst injection tube installed in the second port and extending into the fluidized bed reactor.
  • Embodiment C is a method for operating a fluidized bed reactor, the method comprising: contacting a catalyst and a monomer in a fluidized bed reactor under polymerization conditions; and measuring with a multi-sensory probe an electric field in the fluidized bed reactor and temperatures at a plurality of radially spaced apart locations in the fluidized bed reactor.
  • Embodiment D is a fluidization monitoring system comprising: a multi-sensory probe comprising: an elongate body member extending between a first end and a second end along a longitudinal axis; a plurality of temperature sensors spaced apart along the body member and disposed to measure temperatures external to the body member; and an electrostatic sensor disposed to measure an electrostatic field external to the body member.
  • the fluidization monitoring system further comprises a fluidized bed reactor comprising: a central axis; a sidewall disposed about the central axis; an annular outer zone extending inward from the sidewall toward the central axis; and an internal zone extending inward from the intermediate zone toward the central axis; wherein, the fluidized bed reactor is configured to be operable in a mode such that during operation a solids fraction of catalyst with respect to a fluidizing gas increases from the wall toward the central axis in the outer zone, reaches a maximum value between the outer zone and the internal zone, and decreases toward the central axis in the internal zone; and wherein a temperature sensor of the plurality of temperature sensors and the electrostatic sensor are disposed in a location within the internal zone.
  • Embodiments A, B, and D may have one or more of the following additional elements in any combination: Element 1 : wherein the elongate body member is 0.30 m to 1.8 m (e.g., 1 foot to 6 feet) long; and wherein the plurality of temperature sensors are spaced apart axially along the body member; Element 2: wherein the plurality of temperature sensors are housed together in a sheath coupled to the body member; Element 3: wherein the body member comprises an outer surface and a first channel in the outer surface, the first channel extending between the first and second ends; and wherein at least some of the plurality of temperature sensors are disposed in the first channel; Element 4: wherein the body member further comprises an outer surface and a second channel in the outer surface; wherein the second channel extends between the first and second ends; and wherein the electrostatic sensor comprises a cable that extends into the second channel; Element 5: wherein the electrostatic sensor is disposed beyond the first end; Element 6: wherein the
  • Versions of embodiment D may include first and second ports as does embodiment B.
  • Each of embodiments B and D may have one or more of the following additional elements in any combination.
  • Element 7 wherein the first and second ports extend through a sidewall of the reactor and are disposed within the lower 1/3 of the reactor’s height;
  • Element 8 wherein the first and second ports each comprise a support tube that extends into the reactor; wherein the multi-sensory probe extends through a first support tube in the first port; and wherein the catalyst injection tube extends through a second support tube in the second port;
  • Element 9 wherein the multi-sensory probe extends into the reactor for an insertion distance equal to or greater than 7% of the inside diameter;
  • Element 10 The multi-sensory probe further comprising a plurality of pressure sensors spaced apart along the body member and disposed to measure pressure external to the body member;
  • Element 11 wherein the plurality of pressure sensors are spaced apart axially along the body member and are circumferentially spaced 180 degrees from the plurality
  • Embodiment C may have one or more of the following additional elements in any combination: Element 13: adjusting the polymerization conditions based on the electric field and/or the temperatures; Element 14: wherein the polymerization conditions comprise a parameter selected from the group consisting of: a reaction temperature, a catalyst flow rate, a catalyst concentration, a monomer flow rate, a monomer concentration, a fluidizing gas flow rate, a reactor pressure, and any combination thereof; Element 15: supplying a flow rate of fluidizing gas to the fluidized bed reactor; wherein the fluidized bed reactor includes a central axis, a sidewall, and a reaction chamber that receives the catalyst and a fluidizing gas; wherein the reaction chamber is characterized by a solids fraction of catalyst with respect to the fluidizing gas; wherein the solids fraction at a selected axial location in the reaction chamber, varies radially with respect to the central axis; wherein supplying a flow rate of fluidizing gas includes establishing in the reaction chamber an annular outer zone
  • Examples of combinations applicable to embodiments A, B, and D include, but are not limited to, Element 1 in combination with one or more of Elements 2-6; Element 2 in combination with one or more of Elements 3-6; Element 3 in combination with one or more of Elements 4-6; Element 4 in combination with one or more of Elements 5 and 6; Element 5 in combination with Element 6.
  • Examples of combinations applicable to embodiments B and D also include, but are not limited to, Element 7 in combination with one or more of Elements 9-12; Element 8 in combination with one or more of Elements 9-12; Element 9 in combination with one or more of Elements 10- 12; Element 10 in combination with one or more of Elements 11-12; Element 11 in combination with Element 12.
  • Examples of combinations applicable to embodiment C include, but are not limited to: Element 13 in combination with one or more of Elements 14-17; Element 14 in combination with one or more of Elements 15-17; Element 15 in combination with one or more of Elements 16-17.
  • compositions and methods are described in terms of“comprising,”“containing,” or“including” various components or steps, the compositions and methods can also“consist essentially of’ or“consist of’ the various components and steps. All numbers and ranges disclosed above may vary by some amount. Whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range is specifically disclosed. In particular, every range of values (of the form,“from about a to about b,” or, equivalently,“from approximately a to b,” or, equivalently,“from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values.

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Abstract

Une sonde multisensorielle pour mesurer la température et le champ électrique à l'intérieur d'un réacteur peut comprendre un élément de corps allongé s'étendant entre une première extrémité et une seconde extrémité le long d'un axe longitudinal ; une pluralité de capteurs de température espacés le long de l'élément de corps allongé et disposés pour mesurer des températures externes à l'élément de corps allongé ; et un capteur électrostatique disposé pour mesurer un champ électrostatique extérieur à l'élément de corps allongé.
PCT/US2020/042324 2019-07-18 2020-07-16 Sondes multisensorielles et systèmes de surveillance de fluidisation WO2021011768A1 (fr)

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EP4389273A1 (fr) * 2022-12-20 2024-06-26 ExxonMobil Chemical Patents Inc. Réacteur tubulaire comprenant un thermocouple pour mesurer une température à l'intérieur du réacteur tubulaire

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WO2008100368A1 (fr) * 2007-02-16 2008-08-21 Univation Technologies, Llc Procédé de surveillance et de contrôle en continu de procédés de polymérisation et de réacteurs pour empêcher des événements associés à une discontinuité
WO2009014682A2 (fr) * 2007-07-24 2009-01-29 Univation Technologies, Llc Procédé de surveillance d'une réaction de polymérisation
US20090163748A1 (en) * 2007-12-20 2009-06-25 Man Dwe Gmbh Tube bundle reactor

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Publication number Priority date Publication date Assignee Title
WO2005068507A1 (fr) * 2004-01-02 2005-07-28 Univation Technologies, Llc Procede de maitrise de la formation de depots dans des reacteurs en phase gazeuse
WO2008100368A1 (fr) * 2007-02-16 2008-08-21 Univation Technologies, Llc Procédé de surveillance et de contrôle en continu de procédés de polymérisation et de réacteurs pour empêcher des événements associés à une discontinuité
WO2009014682A2 (fr) * 2007-07-24 2009-01-29 Univation Technologies, Llc Procédé de surveillance d'une réaction de polymérisation
US20090163748A1 (en) * 2007-12-20 2009-06-25 Man Dwe Gmbh Tube bundle reactor

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Publication number Priority date Publication date Assignee Title
EP4389273A1 (fr) * 2022-12-20 2024-06-26 ExxonMobil Chemical Patents Inc. Réacteur tubulaire comprenant un thermocouple pour mesurer une température à l'intérieur du réacteur tubulaire

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