Reactor Internals for Hydroprocessing Unit

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An Optimized Quench Zone Design for a Mixed-Phase Cocurrent Downflow Fixed-Bed Reactor

Reactor Internals for Hydroprocessing Unit

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• Inlet Diffuser

• Inlet Distributor

• Quench Zone including catalyst support, quench distributor, quench mixing chamber, flash tray, and re-distributor

• Outlet Collector

Reactor Internals Components

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• Distributor tray needs optimized

• Quench mixer needs to attain perfect thermal equilibrium

• Quench zone height needs shortened

Reactor InternalsObjective: Maximizing Catalyst Utilization

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TSC Reactor Internals Portfolio

Refinery Unit Process Licensor # Distributor # Quench ZonesTesoro Golden Eagle Hydrocracker MAK 15 12US refinery Hydrocracker Mobil 10 8US refinery Hydrocracker Mobil 5 4US refinery USA* CHD (DHT) Mobil 3 2Middle East Refinery* Hydrocracker MAK 6 4Asia refinery Lube Hydrocracker Mobil 10 8US refinery Isomerization Dewaxing Mobil 1US refinery Isomerization Dewaxing Mobil 1Middle East Refinery Octgain (FCC Gasoline HDT) Mobil 3 2Bayernoil CHD (DHT) H2Advance 3 2European refinery* DHT Topsoe 3 2US refinery Revamp HDC to DHT Topsoe 3US refinery DDU (DHT) Topsoe 2US refinery NHT (Naphtha Quench Zone) Topsoe 1US refinery DDS (DHT) Topsoe 3 2US refinery ISOM Topsoe 6US refinery BOU (DHT) Topsoe 2 1US refinery DHT Topsoe 2 1US refinery Kero hydrotreater Topsoe 1US refinery VGO hydrotreater Topsoe 1US refinery Hydrocracker Topsoe 2Total 82 49* designed but not implemented

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Distributor / QZ Performance

Reactor Temperature Profile

Tray (Distributor) Selection

• Low Sensitivity to Tray Unlevelness

• Low DP, Less Than 1 psi

• Good Spray Angle

• Dense Pack

• Easy Cleaning

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Liquid Distributor Type

• Downcomer with one size orifice to fit all conditions

• Downcomer with wide angle spray pattern

• Well engineered downcomer (H2Advance)

• Vapor Lift with poor element coverage on tray

• Vapor Lift with max drip density on tray

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U.S. Patent 4,126,540Grosboll et al (ARCO)

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U.S. Patent 6,098,965Jacobs et al (Fluor)Swirl Cap Distributor

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Distributor tray: Downcomer with slots

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Bubble-cap tray

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Vapor Lift Tray

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Uniformity of Flow Distribution

• H2Advance: Good spray angle with low

sensitivity to tray out-of-levelness

• vs. poor spray pattern and sensitive to tray out-

of-levelness

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H2Advance Downcomer Tray:RX Area Coverage

0

0.2

0.4

0.6

0.8

1

1.2

1.4

0 1 2 3 4 5 6 7 8

Frac

tion

of

RX A

rea

Cove

red

Tray to Inert Clearance, inch

Downcomer Spray Covered Area

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Distributor Tray, H2Advance Design

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Quench Zone Type

• Impingement Plate 1970 Unocal

• Improved Impingement Plate (Axens, PetroChina)

• Segregated Vapor/Liquid Mixer (Shell, Chevron)

• Mixed Phase Vortex Mixer (EM, UOP, Topsoe, H2Advance)

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Impingement Plate Quench

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Unocal 1970 Impingement Plate Quench boxUS Patent 3,502,445

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Unocal 1970 Impingement Plate Quench boxUS Patent 3,502,445

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PetroChina 2007 Upgrader

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PetroChina 2007 Upgrader Internals

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Segregated Vapor/Liquid Mixer

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Chevron “Nautilus” Quench Internals 2001

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Shell Quench Patent

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Mixed Phase Vortex Mixer

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Mobil Spider-Vortex

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UOP Quench Internals

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H2Advance Quench Internals 2006US Patent 7,112,312

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H2Advance: Quench Swirl Mixing Chamber

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H2Advance: Effective Quench Mixer

• H2Advance: Swirl mixing chamber provides an

excellent thermal efficiency

• vs. competitor’s poor thermal equilibrium with

segregated vapor/liquid mixing

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H2Advance: Compact Swirl Quench Zone Design

• Inert-to-inert height requirement: less than 4.5 ft

• vs. 5-7 ft required by competitors

• Integrated Quench Swirl Mixing Chamber and

Flash Tray: Compact Design

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H2Advance: Compact Quench zone withReduced # of Manway

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# of Manways per Quench Zone

• H2Advance design: 2 manways per quench zone

• Compared with 4 (+quench gas distributor)

• H2Advance: Use wedge pin for manway (not

nuts and bolts)

• Impact: shorten unit TAR time

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H2Advance Example: Bayernoil ULSD

• Installed in 2002 (18ft ID 3-bed RX) for ULSD

• Resulted in a higher unit throughput (revamped

at 53,000 BPD)

• And longer than anticipated catalyst cycle

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DHT Performance Post Revamp 2002

Radial Differential Temperature (Observed - Average)

-3

-2

-1

0

1

2

3

1 2 3 4 5 6

Location in Bed 1

Del

ta T

, deg

. C

Top-Inner C ircle Bottom-Inner Bottom-Outer C ircle

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DHT Performance Post Revamp 2002

Radial Differential Temperature (Observed - Average)

-3

-2

-1

0

1

2

3

1 2 3 4 5 6

Location in Bed 2

Del

ta T

, deg

. C

Top-Inner Circle Bottom-Inner Bottom-Outer Circle

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DHT Performance Post Revamp 2002

Radial Differential Temperature (Observed - Average)

-3

-2

-1

0

1

2

3

1 2 3 4 5 6

Location in Bed 3

Del

ta T

, deg

. C

Top-Inner Circle Bottom-Inner Bottom-Outer Circle

Internals Installation is important

Internals installation supervision to ensure good seal And tray levelness

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Well Designed Quench Box with poor Distributor Installation(2010 DHT)

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Poor Quench Zone Design (HDC 2002)

720730740750760770780790800

0 1 2 3 4 5

Rad

ial T

spr

ead,

F

Bed 1, 2, 3, 4, and 5

Functional Quench Box?

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Conclusions: State-of-the-art H2Advance Internals

• Min # of manways per Quench Zone

• Distributor provides uniformity of flow distribution

• Compact Design with excellent thermal equilibrium that reduces capital investment; good for revamp upgrading

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