Abstract:
The invention relates to distributing reactants more evenly across the interior space of a reactor vessel utilizing a distributor at the inlet end that initially directs the flow of reactants through a series of circumferential nozzles. The nozzles are physical spaced such that the first nozzle provides the reactants into the vessel to spread radially and broadly outwardly into the vessel and each successive circumferential nozzle to deliver reactants in a less broadly distribution or dispersion where the interior space is filled with reactants without broadly diverse velocities that may create hot spots within the catalyst bed.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    None. 
       STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    None. 
       FIELD OF THE INVENTION 
       [0003]    This invention relates to reactor design and especially to the design of inlets to reactors. 
       BACKGROUND OF THE INVENTION 
       [0004]    There are many sizes and designs for reactors for converting reactants to desirable intermediates and final products. Chemical engineers expend many hours designing reactor systems to optimize reactor production considering pressure, temperature, flow rates, catalyst cost, reaction kinetics along with balancing many other issues and concerns. 
         [0005]    It is generally understood that a generally uniform distribution of reactants in a catalyst reactor is preferred to avoid hot spots and to avoid the underutilization of catalyst in the reactor. Many inlet designs have been created to improve the distribution of reactants within reactors such as where the reactants are vaporous and have higher velocities along the outside of a bend in the piping leading to the reactor. In a reactor arrangement that is fed by a conduit with a significant bend leading into the top or bottom of a reactor, the higher velocities tend to follow the outside of the bend and concentrate along one side of the reactor. Baffles and vanes have been used for years to create back pressure on the inlet stream and cause the reactants to distribute themselves across the reactor. 
         [0006]    Another common technique is to provide an inert support bed with a thick layer of inert support that create tortuous paths to the catalyst and causing mixing and back pressure to create a level of balance across the body of the reactor. 
         [0007]    What is desired is a technique for creating a balanced distribution of the reactants across a rector body without significantly enlarging the size of the reactor and without creating significant back pressure on the flow of reactants. 
       BRIEF SUMMARY OF THE DISCLOSURE 
       [0008]    The invention more particularly relates to a reactor inlet distributor for delivering a feedstream of reactants into a reactor vessel. The reactor inlet distributor includes a generally cylindrical body with an inlet end and an outlet end. A first deflector ring with an integrally attached first neck attached to but spaced from the outlet end of the generally cylindrical body is attached to the generally cylindrical body by stanchions such that a circumferential nozzle is defined between the deflector ring and the outlet end of the generally cylindrical body where the neck extends from the first deflector ring away from the generally cylindrical body. The reactor inlet distributor further includes at least one additional deflector ring having an integrally attached additional neck attached to but spaced from the first neck by stanchions such that an additional circumferential nozzle is defined between the additional deflector ring and the first neck. Finally, a deflector plate is attached to the additional deflector ring by stanchions, but spaced from said additional neck to define a last circumferential nozzle. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    A more complete understanding of the present invention and benefits thereof may be acquired by referring to the follow description taken in conjunction with the accompanying drawings in which: 
           [0010]      FIG. 1  is an elevation cross section of a spherical reactor showing an inventive distributor and reactor fixed valve tray; 
           [0011]      FIG. 2  is a perspective view of a cross section of the first embodiment of the inventive distributor; 
           [0012]      FIG. 3  is an elevation cross section of the first embodiment of the distributor; 
           [0013]      FIG. 4  is an elevation cross section of the first embodiment of the distributor showing the aerodynamics of the distributor; 
           [0014]      FIG. 5  is an elevation cross section of the second embodiment of the distributor; 
           [0015]      FIG. 6  is an elevation cross section of the second embodiment of the distributor showing the aerodynamics of the distributor; 
           [0016]      FIG. 7  is a perspective view of a third embodiment of the inventive distributor; 
           [0017]      FIG. 8  is an elevation cross section of the third embodiment of the inventive distributor showing the aerodynamics of the distributor; 
           [0018]      FIG. 9  is a top view of the reactor fixed valve tray; 
           [0019]      FIG. 10  is perspective view of the reactor fixed valve tray; and 
           [0020]      FIG. 11  is a perspective view of an alternative installation where the valve tray is installed on the top of the outlet device sometimes called an elephant stool. 
       
    
    
     DETAILED DESCRIPTION 
       [0021]    Turning now to the detailed description of the preferred arrangement or arrangements of the present invention, it should be understood that the inventive features and concepts may be manifested in other arrangements and that the scope of the invention is not limited to the embodiments described or illustrated. The scope of the invention is intended only to be limited by the scope of the claims that follow. 
         [0022]    As shown in  FIG. 1 , an example reactor system is shown generally indicated by the numeral  10  comprising a reactor vessel  12  that is shown having the shape of a sphere. The example reactor vessel  12  includes a catalyst bed  13  within the reactor intermediate from the inlet and outlet and having inert materials positioned above and below the catalyst bed. The example reaction vessel  12  receives reactants at the inlet end  14  from an inlet conduit  15  and delivers the reactants into the reactor vessel  12 . It is noted that the illustrated reactor  12  is arranged to have the reactants flow from the top down through the catalyst to exit at the bottom while the invention may work equally well with reactors that are arranged to direct the flow from the bottom up or have a horizontal flow or have the flow in other orientations. Most reactors are top down or bottom up, but the other arrangements are possible. It should also be understood that although the reactor vessel  12  is near spherical, some reactors are also elongated with somewhat spherically shaped upper and lower portions and the present invention may be useful in all of these various reactors. Continuing with the description of the reactor system  10 , the products of the reaction are conveyed to the exit end  18  at the bottom of the reactor where the products are conveyed away by an outlet conduit  19 . 
         [0023]    In one aspect of the invention, a distributor  30  is positioned at the inlet end  14  of the reactor  12  to distribute the reactants flowing into the interior of the reactor vessel  12  to spread out and more evenly disperse. The distributor  30  has a configuration that imposes a very modest or low back pressure on the flow of the reactants and, at the same time, splits and directs the flows of the reactants in a manner that more evenly disperses the reactants. Turning to  FIGS. 2 and 3 , the distributor  30  includes a generally cylindrical shell  31  extending along the inlet conduit  15  and extending into the interior of the reactor vessel  12 . The generally cylindrical shell  31  is generally about the same length as its diameter, although it is preferred that it be slightly shorter in length than its diameter. 
         [0024]    At about a midpoint along its length (vertically) of the generally cylindrical shell  31  is an inset perforated baffle ring  32  supported by brackets  33 . The inset perforated baffle ring  32  has a large, generally circular opening in the middle thereof and a generally circular outer diameter that is less than the diameter of the interior of the generally cylindrical shell  31  and spaced from the interior of the generally cylindrical shell by a generally uniform spacing around the perimeter thereof. The inset perforated baffle ring is also relatively thin compared to its diameter with holes  34 . The inset perforated baffle ring is preferably constructed from flat sheet metal stock with holes punched through from top to bottom. The inset perforated baffle ring  32  is intended to obstruct between about 5% and 15% of the passage within the generally cylindrical shell  31  creating some turbulence and mixing of the reactants entering the reactor vessel  12 . In particular, inset perforated baffle ring  32  provides some modest resistance to the flow of reactants into the reactor vessel  12  and divide the flow within the generally cylindrical shell  31  into two large flow paths and a plurality of smaller flow paths. The first large flow path being in the center of the inset perforated baffle ring  32  and the second large flow path being around the perimeter of the inset perforated baffle ring  32 . The smaller flow paths are through the numerous holes  34 . 
         [0025]    A series of stanchions  36  are attached vertically to the interior surface of the generally cylindrical shell  31  and arranged to extend downwardly beyond the lower edge of the generally cylindrical shell  31  for supporting a first perforated deflector ring  40 . The first perforated deflector ring  40  is constructed in a manner similar to the construction of the inset perforated baffle ring  32  where it is generally flat with through holes  41 . The outer diameter of the first perforated deflector ring  40  is slightly less than the diameter of the generally cylindrical shell  31  and the inner diameter provides for a rather large circular opening to allow most of the reactants flowing down through the distributor  30  to continue to flow downwardly. The first perforated deflector ring reduces the area for the free flow of reactants by between 5% and 20% and more preferably between 10% and 15%. However, it should be noted that the space between the lower edge of the generally cylindrical shell  31  defines a first radial nozzle  42  that allows for reactants to exit from the distributor  30  radially outwardly. While some flow of the reactants may pass through the holes  41  in the first perforated deflector ring and thereby exit the distributor  30 , the first radial nozzle  42  provides a substantial path for the reactants to enter the reactor vessel  12 . As such, a first portion of the reactants are deflected radially outwardly into the upper portions of the reactor vessel  12 . 
         [0026]    A second perforated deflector ring  50  is positioned in a similar manner below the first perforated deflector ring  40 . In particular, the first perforated deflector ring  40  includes a generally cylindrical first neck  45  extending down from the interior diameter of the first perforated deflector ring  40 . The first neck  45  directs reactants that pass through the large circular opening further into the reactor vessel  12  and within the distributor  30  toward the second perforated deflector ring  50 . Stanchions  46  are attached to the interior surface of the first neck  45  and extend downwardly beyond the lower edge of the first neck  45 . As such, the second perforated deflector ring  50  is spaced from the lower edge of the first neck  45  defining a second radial nozzle  52 . The outer edge of the second perforated ring  50  is slightly smaller than the inner diameter of the first neck  45 . 
         [0027]    A third perforated deflector ring  60  is positioned in a similar manner below the second perforated deflector ring  50  and continues a stair step pattern of reducing diameter generally circular central openings with successive radially oriented nozzles of reduced diameter along the periphery of the distributor  30 . The second perforated deflector ring  50  includes a generally cylindrical second neck  55  extending down from the interior diameter of the second perforated deflector ring  50  in a manner similar to the first neck and the first perforated deflector ring  40 . The second neck  55  conveys reactants that pass through the large central circular opening further into the reactor vessel  12  and within the distributor  30  toward the third perforated deflector ring  60 . Stanchions  56  are attached to the interior surface of the second neck  55  and extend downwardly beyond the lower edge of the first neck  55 . As before, the third perforated deflector ring  60  is spaced from the lower edge of the second neck  55  defining the third radial nozzle  62 . Again, the outer edge of the third perforated ring  60  is slightly smaller than the inner diameter of the second neck  55 . 
         [0028]    While additional deflector rings may be incorporated into the design, two three or four are generally preferred, but ultimately, the bottom of the deflector  30  is defined by a deflector plate  70 . Deflector plate  70  is mounted to the third deflector ring  60  in a manner similar to the deflector rings  40 ,  50  and  60 . A third neck  65 , having a generally cylindrical design, is attached to the inner edge of the third perforated deflector ring  60  and arranged to extend further into the reactor vessel  12 . Stanchions  66  are attached to the inner surface of the third neck  65  and arranged to extend below the lower edge of the third neck  65 . The deflector plate  70  being spaced below the lower edge of the third neck  65  defines the fourth generally radial nozzle  72 . 
         [0029]    The deflector plate  70 , similar to the deflector rings  40 ,  50  and  60 , has through holes  71  to allow reactants to pass down through the middle of the distributor  30  and enter into the middle of the reactor vessel  12 . However, as shown in  FIG. 4 , the nozzles direct a significant portion of the reactants radially outward, or with a significant radially outward direction component along with some downward direction of flow with the through holes  41 ,  51 ,  61  and  71  to permit a smaller amount of flow to fill in between the primary flows through the nozzles  42 ,  52 ,  62  and  72 . 
         [0030]    There are many variations on the preferred arrangements for the distributor  30 , one of which includes that the inset perforated baffle ring  32  is coaxial to the generally cylindrical shell  31  such that the vertically oriented generally cylindrical shell  31  has inset perforated baffle ring  32  generally horizontally arranged therein. Through holes  34  comprise between about 5% and 15% of the top surface of the inset perforated baffle ring  32 . The distance between the inner edge of the inset perforated baffle ring  32  and its outer edge is approximately the same dimension as the space from the outer edge of the inset perforated baffle ring  32  and the interior surface of the generally cylindrical shell  31 . The large generally circular opening within the inner edge of inset perforated baffle ring  32  comprises between 50% and 90% of the diameter of the interior of the generally cylindrical shell  31 . 
         [0031]    The drawings show three perforated deflector rings, however, it should be understood that the invention may comprise two deflector rings, three deflector rings, four deflector rings and even more perforated deflector rings, although between two and four are preferred. 
         [0032]    In  FIG. 5 , another arrangement of the distributor  30  is shown using the same numbering as in  FIGS. 1-4 , but adding “100” so that the second embodiment of the distributor has the number  130 . In this second arrangement, the generally cylindrical shell  131  has a more complex form with a first cylindrical section  131 A connected to an inverted conical section  131 B forming a reducing cross section for the distributor  130  and then continuing with a smaller, but generally cylindrical second cylindrical section  131 C. In this arrangement, the first perforated deflector ring  140  has an outer diameter that is larger than the diameter of the second cylindrical section  130 . As such, the first circumferential nozzle  142  is oriented to provide a much more radial orientation to the flow of reactants entering the reactor vessel  12  than the circumferential nozzle  42  and perhaps with some upward direction. Similarly, the second perforated deflector ring  150  has an outer diameter that is slightly larger than the diameter of the first neck  145 . As such, the second circumferential nozzle  152  also provides a more radial orientation to the flow of the reactants than the second circumferential nozzle  52  in the first described embodiment although it should appear from the drawing that it will not impose as much of an upward flow as the first circumferential nozzle  142 . The third circumferential nozzle  162  is constructed and oriented in a manner very comparable to the circumferential nozzles of the first described embodiment, however, the last circumferential nozzle  172  has a much more axially orientation to due to the deflector plate  170  being smaller than the third neck  165  and with the deflector plate being much closer in proximity to the bottom edge of the third neck. In this arrangement, each successive circumferential nozzle directs the flow of reactants radially outwardly and somewhat upwardly nearest the top of the reactor vessel  12  and in successively and progressively downward angles as shown in  FIG. 6 . 
         [0033]    A third variation of the distributor is shown as  230  in  FIGS. 7 and 8 . This third embodiment includes two baffle rings  232 A and  232 B mounted generally concentrically and high in the distributor  230  near the level of the flange  237 . These are somewhat smaller baffle rings than the baffle ring  32  in the first described embodiment and they are also perforated. However, these two baffle rings are designed to obstruct about the same percentage of the flow path through the generally cylindrical shell  231 . Again, the baffle rings  232 A and  232 B create some turbulence and mixing and thereby create a more uniform flow across the width of the generally cylindrical shell as opposed to a flow characterized by a faster rate at the center and a slower rate along the walls. A second different aspect is that the support structure for the deflector rings is arranged on the outside of the generally cylindrical shell  231  and along the outside of the deflector rings and necks. The stanchions  236  and smaller than the flange  237  so as to allow the distributor  230  to be mounted to the reactor vessel  12  and extend down into the reactor vessel at the inlet end  14 . The first perforated deflector ring  240  of this third embodiment, similar to the first deflector ring  140  in the second embodiment, has a larger diameter than the generally cylindrical shell  231  and thereby form a first circumferential nozzle  242  that provides some portion of upwards or backwards flow while primarily delivering the reactants in a very radial orientation into the reactor vessel  12 . Focusing on  FIG. 8 , like the distributor  130  of the second embodiment, the successive circumferential nozzles to have a progressively more downward orientation. In this third embodiment, the through holes  271  in the deflector plate  270  are larger than the through holes through the deflector rings to allow more of the reactants to flow through the deflector plate. At the same time, the last or fourth circumferential nozzle  272  in the third embodiment is oriented more radial and less axial than the last or fourth circumferential nozzle  172  of the second embodiment. Another noteworthy difference is that the necks are slightly longer and are also perforated in this third embodiment. While the majority of the reactants are passing through the circumferential nozzles, flow is also emanating from the numerous through holes in the deflector rings, necks and deflector plate. 
         [0034]    In conjunction with the distributor  30 , one aspect of the present invention is to make sure that the flow of the reactants, and eventually the products, is distributed across reactor vessel  12  as evenly as practical by using a fixed valve tray  20  positioned under the catalyst bed, but on top of the inert material. The fixed valve tray  20  is constructed of a generally circular plate having the diameter to match the portion of the reactor vessel  12  at the level to which it is to be installed. The fixed valve tray  20  includes spaced apart openings. As seen in  FIGS. 9 and 10 , the openings are formed to allow flow of products but prevent passage of the catalyst. With an even spacing across the fixed valve tray  20 , velocity differences across the width of the reactor vessel  12  would be suppressed by the size and spacing of the openings so as to restrict the localized rate at which the products may leave the catalyst bed  13 . This provides another basis for forcing a more balanced rate of flow through the reactor vessel  12 . 
         [0035]    As seen in  FIG. 11 , the flow may also be restricted at the middle of the vessel by using a plate similar to the valve tray installed at the top of the outlet of the reactor vessel  12  to prevent the flow from taking the most direct path down the middle of the reactor vessel  12 . In this location, sometimes described as an elephant stool, an open mesh-like material surrounds the perimeter that is less restrictive of flow while the top surface is more restrictive of flow. 
         [0036]    In closing, it should be noted that the discussion of any reference is not an admission that it is prior art to the present invention, especially any reference that may have a publication date after the priority date of this application. At the same time, each and every claim below is hereby incorporated into this detailed description or specification as an additional embodiment of the present invention. 
         [0037]    Although the systems and processes described herein have been described in detail, it should be understood that various changes, substitutions, and alterations can be made without departing from the spirit and scope of the invention as defined by the following claims. Those skilled in the art may be able to study the preferred embodiments and identify other ways to practice the invention that are not exactly as described herein. It is the intent of the inventors that variations and equivalents of the invention are within the scope of the claims while the description, abstract and drawings are not to be used to limit the scope of the invention. The invention is specifically intended to be as broad as the claims below and their equivalents.