Claims
- 1. A hydrocarbon conversion apparatus, comprising:
(a) a plurality of riser reactors, each having a first end into which a catalyst can be fed, and a second end through which the catalyst can exit; (b) a separation zone having a plurality of inlets, the separation zone being provided to separate the catalyst from products of a reaction conducted in the hydrocarbon conversion apparatus; (c) a plurality of deviating members, each deviating member being in fluid communication between the second end of a respective riser reactor and a respective inlet of the separation zone; (d) a catalyst retention zone provided to contain catalyst, which can be fed to the riser reactors; and (e) a catalyst return in fluid communication between the separation zone and the catalyst retention zone.
- 2. The apparatus of claim 1, wherein each of the plurality of riser reactors includes a center axis extending between the first and second ends thereof, and wherein the plurality of inlets are not oriented along the center axes of the riser reactors.
- 3. The hydrocarbon conversion apparatus of claim 2, wherein the apparatus further comprises:
(f) a plurality of arms, each arm in fluid communication between the catalyst retention zone and the first end of a respective riser reactor.
- 4. The hydrocarbon conversion apparatus of claim 2, wherein the apparatus further comprises:
(f) a feed distributor including a plurality of feed heads positioned adjacent to the first ends of the riser reactors.
- 5. The hydrocarbon conversion apparatus of claim 2, wherein the hydrocarbon conversion apparatus includes two riser reactors.
- 6. The hydrocarbon conversion apparatus of claim 2, wherein the hydrocarbon conversion apparatus includes three riser reactors.
- 7. The hydrocarbon conversion apparatus of claim 2, wherein the hydrocarbon conversion apparatus includes four riser reactors.
- 8. The hydrocarbon conversion apparatus of claim 2, wherein the hydrocarbon conversion apparatus includes five riser reactors.
- 9. The hydrocarbon conversion apparatus of claim 2, wherein the hydrocarbon conversion apparatus includes six riser reactors.
- 10. The hydrocarbon conversion apparatus of claim 2, wherein the hydrocarbon conversion apparatus includes more than six riser reactors.
- 11. The hydrocarbon conversion apparatus of claim 4, wherein the feed distributor provides feed to each of the riser reactors in substantially equal streams through the feed heads.
- 12. The hydrocarbon conversion apparatus of claim 2, wherein the apparatus further comprises:
(f) a fluidizing agent distributor in fluid communication with the catalyst retention zone, the fluidizing agent distributor being provided to feed a fluidizing agent to the catalyst retention zone to fluidize catalyst contained in the catalyst retention zone.
- 13. The hydrocarbon conversion apparatus of claim 12, wherein the apparatus further comprises:
(g) a disperser positioned in the catalyst retention zone, the disperser being provided to disperse the fluidizing agent in the catalyst retention zone to fluidize the catalyst.
- 14. The hydrocarbon conversion apparatus of claim 13, wherein the disperser is a device selected from the group consisting of a grid, a screen and a perforated plate.
- 15. The hydrocarbon conversion apparatus of claim 2, wherein the catalyst return is positioned centrally to the riser reactors.
- 16. The hydrocarbon conversion apparatus of claim 2, wherein the hydrocarbon conversion apparatus includes a plurality of catalyst returns.
- 17. The hydrocarbon conversion apparatus of claim 16, wherein the apparatus further comprises:
(f) a flow control device positioned on at least one of the catalyst returns.
- 18. The hydrocarbon conversion apparatus of claim 16, wherein the apparatus further comprises:
(f) a flow control device positioned on each of the plurality of catalyst returns.
- 19. The hydrocarbon conversion apparatus of claim 2, wherein the separation zone further comprises a quiescent zone in which catalyst can be retained until the catalyst moves from the separation zone to the catalyst return.
- 20. The hydrocarbon conversion apparatus of claim 2, wherein the apparatus further comprises:
(f) a catalyst regenerator in fluid communication with the hydrocarbon conversion apparatus.
- 21. The hydrocarbon conversion apparatus of claim 20, wherein the apparatus further comprises:
(g) a catalyst stripper in fluid communication with the hydrocarbon conversion apparatus and the catalyst regenerator.
- 22. The hydrocarbon conversion apparatus of claim 2, wherein the apparatus further comprises:
(f) at least one separation device positioned in the separation zone.
- 23. The hydrocarbon conversion apparatus of claim 22, wherein the at least one separation device is selected from group consisting of a cyclonic separator, a filter, an impingement device and combinations thereof.
- 24. The hydrocarbon conversion apparatus of claim 2, wherein each of the riser reactors has a cross sectional area of no greater than 12 m2.
- 25. The hydrocarbon conversion apparatus of claim 2, wherein each of the riser reactors has a cross sectional area of no greater than 7 m2.
- 26. The hydrocarbon conversion apparatus of claim 2, wherein each of the riser reactors has a cross sectional area or no greater than 3.5 m2.
- 27. The hydrocarbon conversion apparatus of claim 2, wherein each of the riser reactors has a height of from 10 meters to 70 meters.
- 28. The hydrocarbon conversion apparatus of claim 2, wherein each of the riser reactors has a width of from 1 meter to 3 meters.
- 29. The hydrocarbon conversion apparatus of claim 2, wherein each of the riser reactors has a cross sectional area and the cross sectional area of one of the riser reactors varies by no more than 20% from the cross sectional area of another of the riser reactors.
- 30. The hydrocarbon conversion apparatus of claim 29, wherein the cross sectional area of one of the riser reactors varies by no more than 10% from the cross sectional area of another of the riser reactors.
- 31. The hydrocarbon conversion apparatus of claim 30, wherein the cross sectional area of one of the riser reactors varies by no more than 1% from the cross sectional area of another of the riser reactors.
- 32. The hydrocarbon conversion apparatus of claim 2, wherein at least one of the deviating members comprises a tubular member providing a deviation angle of at least 45 degrees.
- 33. The hydrocarbon conversion apparatus of claim 2, wherein at least one of the deviating members comprises a tubular member providing a deviation angle of at least 90 degrees.
- 34. The hydrocarbon conversion apparatus of claim 2, wherein at least one of the deviating members comprises a 90 degree elbow.
- 35. The hydrocarbon conversion apparatus of claim 2, wherein the apparatus further comprises:
(f) a second plurality of riser reactors, each of the second plurality of riser reactors having first and second ends and a second center axis, wherein the separation zone includes a plurality of second inlets, each second inlet being oriented along a respective second center axis.
- 36. A hydrocarbon conversion apparatus, comprising:
(a) a plurality of riser reactors, each having a first end into which a catalyst can be fed and a second end through which the catalyst can exit the riser reactor; (b) a separation zone provided to separate the catalyst from products of a reaction conducted in the hydrocarbon conversion apparatus, the separation zone including a plurality of inlets; (c) a plurality of deviating members, each deviating member oriented to deviate a flow of material from the second end of a respective riser reactor toward a respective inlet; and (d) at least one catalyst return in fluid communication with the separation zone and the first ends of the riser reactors, the catalyst return being provided to transfer the catalyst from the separation zone to the first ends of the riser reactors.
- 37. The hydrocarbon conversion apparatus of claim 36, wherein each of the riser reactors has a height of from 10 meters to 70 meters.
- 38. The hydrocarbon conversion apparatus of claim 36, wherein each of the riser reactors has a width of from one meter to three meters.
- 39. The hydrocarbon conversion apparatus of claim 36, wherein each of the riser reactors has a cross sectional area of no greater than 12 m2.
- 40. The hydrocarbon conversion apparatus of claim 36, wherein each of the riser reactors has a cross sectional area of no greater than 7 m2.
- 41. The hydrocarbon conversion apparatus of claim 36, wherein each of the riser reactors has a cross sectional area or no greater than 3.5 m2.
- 42. The hydrocarbon conversion apparatus of claim 36, wherein each of the riser reactors has a cross sectional area and the cross sectional area of one of the riser reactors varies by no more than 20% from the cross sectional area of another of the riser reactors.
- 43. The hydrocarbon conversion apparatus of claim 42, wherein the cross sectional area of one of the riser reactors varies by no more than 10% from the cross sectional area of another of the riser reactors.
- 44. The hydrocarbon conversion apparatus of claim 43, wherein the cross sectional area of one of the riser reactors varies by no more than 1% from the cross sectional area of another of the riser reactors.
- 45. The hydrocarbon conversion apparatus of claim 36, wherein the apparatus further comprises:
(e) a catalyst retention zone provided to contain catalyst which can be fed to the riser reactors.
- 46. The hydrocarbon conversion apparatus of claim 45, wherein the apparatus further comprises:
(f) a feed distributor including a plurality of feed heads, each head being positioned adjacent to the first end of a respective riser reactor.
- 47. The hydrocarbon conversion apparatus of claim 36, wherein the apparatus further comprises:
(e) a fluidizing agent distributor in fluid communication with the catalyst return, the fluidizing agent distributor being provided to feed a fluidizing agent to the catalyst return to fluidize catalyst contained in the catalyst return.
- 48. The hydrocarbon conversion apparatus of claim 47, wherein the apparatus further comprises:
(f) a regeneration apparatus in fluid communication with the hydrocarbon conversion apparatus.
- 49. The hydrocarbon conversion apparatus of claim 48, wherein the apparatus further comprises:
(g) a catalyst stripper in fluid communication with the regeneration apparatus.
- 50. The hydrocarbon conversion apparatus of claim 36, wherein at least one of the deviating members comprises a tubular member providing a deviation angle of at least 45 degrees.
- 51. The hydrocarbon conversion apparatus of claim 36, wherein at least one of the deviating members comprises a tubular member providing a deviation angle of at least 90 degrees.
- 52. The hydrocarbon conversion apparatus of claim 36, wherein at least one of the deviating members comprises a 90 degree elbow.
- 53. The hydrocarbon conversion apparatus of claim 36, wherein the apparatus further comprises:
(e) a second plurality of riser reactors, each of the second plurality of riser reactors having a first end into which a catalyst can be fed, and a second end through which the catalyst can exit the riser reactor and directly enter the separation zone.
- 54. A hydrocarbon conversion process, comprising the steps of:
(a) contacting a fluidizable catalyst with a fluidizing agent to fluidize the fluidizable catalyst; (b) feeding the catalyst and a feed to a plurality of riser reactors, the plurality of riser reactors being part of a single hydrocarbon conversion apparatus; (c) contacting the feed with the catalyst in the plurality of riser reactors under conditions effective to convert the feed to a product; (d) directing the product and the catalyst through a plurality of deviating members each deviating member being positioned to deviate a flow of the product and the catalyst from an outlet of a respective riser reactor to a separation zone; (e) separating the catalyst from the product in the separation zone, the separation zone being in fluid communication with the plurality of deviating members; (f) returning the catalyst from the separation zone to the plurality of riser reactors; and (g) repeating steps (a) to (f).
- 55. The process of claim 54, wherein the feed is fed to each of the plurality of riser reactors in a substantially equal amount.
- 56. The process of claim 54, wherein the feed is fed to each of the plurality of riser reactors such that the flow of feed to each reactor varies by no more than 25%, by volume rate, from one riser reactor to another riser reactor.
- 57. The process of claim 56, wherein the feed is fed to each of the plurality of riser reactors such that the flow of feed to each reactor varies by no more than 10%, by volume rate, from one riser reactor to another riser reactor.
- 58. The process of claim 57, wherein the feed is fed to each of the plurality of riser reactors such that the flow of feed to each reactor varies by no more than 1%, by volume rate, from one riser reactor to another riser reactor.
- 59. The process of claim 54, wherein the feed is fed to each of the plurality of riser reactors such that the flow of feed to each reactor varies by no more than 25%, by mass percent for each component in the feed, from one riser reactor to another riser reactor.
- 60. The process of claim 59, wherein the feed is fed to each of the plurality of riser reactors such that the flow of feed to each reactor varies by no more than 10%, by mass percent for each component in the feed, from one riser reactor to another riser reactor.
- 61. The process of claim 60, wherein the feed is fed to each of the plurality of riser reactors such that the flow of feed to each reactor varies by no more than 1%, by mass percent for each component in the feed, from one riser reactor to another riser reactor.
- 62. The process of claim 54, wherein the fluidizing agent is selected from the group consisting of nitrogen, steam, carbon dioxide, hydrocarbons and air.
- 63. The process of claim 54, wherein the catalyst is separated from the product with a separation device selected from the group consisting of cyclonic separators, filters, screens, impingement devices, plates, cones and combinations thereof.
- 64. The process of claim 54, wherein the returning further comprises directing the catalyst from the separation zone to a catalyst return, which is in fluid communication with the separation zone and a plurality of arms.
- 65. The process of claim 64, wherein the returning further comprises directing the catalyst through the plurality of arms and to an inlet on each respective riser reactors.
- 66. The process of claim 64, wherein the catalyst is contacted with the fluidizing agent to fluidize the fluidizable catalyst in the catalyst return, in a catalyst retention zone or a combination of the catalyst return and the catalyst retention zone.
- 67. The process of claim 66, wherein the process further comprises the steps of:
(h) regenerating at least a portion of the catalyst in a catalyst regenerator after separating the catalyst from the products to produce a regenerated catalyst; and (i) returning the regenerated catalyst to at least one of the separation zone, the catalyst return, and the catalyst retention zone.
- 68. The process of claim 67, wherein the process further comprises the step of:
(j) stripping the at least a portion of the catalyst prior to regenerating the at least a portion of the catalyst.
- 69. The process of claim 54, wherein each of the riser reactors has a height of from 10 meters to 70 meters.
- 70. The process of claim 54, wherein each of the riser reactors has a width of from 1 meter to 3 meters.
- 71. The process of claim 54, wherein each of the riser reactors has a cross sectional area of no greater than 12 m2.
- 72. The process of claim 54, wherein each of the riser reactors has a cross sectional area of no greater than 7 m2.
- 73. The process of claim 54, wherein each of the riser reactors has a cross sectional area or no greater than 3.5 m2.
- 74. The process of claim 54, wherein each of the riser reactors has a cross sectional area and the cross sectional area of one of the riser reactors varies by no more than 20% from the cross sectional area of another of the riser reactors.
- 75. The process of claim 74, wherein the cross sectional area of one of the riser reactors varies by no more than 10% from the cross sectional area of another of the riser reactors.
- 76. The process of claim 75, wherein the cross sectional area of one of the riser reactors varies by no more than 1% from the cross sectional area of another of the riser reactors.
- 77. The process of claim 54, wherein the hydrocarbon conversion process is a reaction selected from the group consisting of an olefin interconversion reaction, an oxygenate to olefin conversion reaction, an oxygenate to gasoline conversion reaction, malaeic anhydride formulation, vapor phase methanol synthesis, phthalic anhydride formulation, a Fischer Tropsch reaction, and acrylonitrile formulation.
- 78. The process of claim 54, wherein the hydrocarbon conversion process is an oxygenate to olefin conversion reaction.
- 79. The process of claim 78, wherein the catalyst is a silicoaluminophosphate catalyst.
- 80. The process of claim 79, wherein the feed is selected from the group of methanol; ethanol; n-propanol; isopropanol; C4-C10 alcohols; methyl ethyl ether; dimethyl ether; diethyl ether; di-isopropyl ether; methyl formate; formaldehyde; di-methyl carbonate; methyl ethyl carbonate; acetone; and mixtures thereof.
- 81. The process of claim 54, wherein at least one of the deviating members deviates the flow of the product and the catalyst by at least 45 degrees.
- 82. The process of claim 54, wherein at least one of the deviating members deviates the flow of the product and the catalyst by at least 90 degrees.
- 83. The process of claim 54, wherein at least one of the deviating members comprises a 90 degree elbow.
- 84. A hydrocarbon conversion apparatus, comprising:
(a) a plurality of riser reactors, each having a first end for receiving catalyst and a second end through which the catalyst and a product can exit; (b) a plurality of deviating members, each associated with a respective riser reactor; (c) a separation zone having at least one side and provided to separate the catalyst from the product, wherein the separation zone includes a plurality of inlets, each inlet being associated with a respective deviating member, wherein the inlets are oriented on the side of the separation zone; and (d) a catalyst return coupled to a plurality of arms, the catalyst return and arms being in fluid communication between the separation zone and the first ends of the plurality of riser reactors.
Parent Case Info
[0001] This application claims priority to U.S. Ser. No. 60/419,408, filed Oct. 18, 2002, which is fully incorporated herein by reference. The present invention relates to a reactor useful in hydrocarbon conversion processes and particularly in oxygenate to olefin conversion reactions.
Provisional Applications (1)
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Number |
Date |
Country |
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60419408 |
Oct 2002 |
US |