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Reactor Design
Reactor Chemistry
Folowing are key Hydrotreating and Hydrocracking reactions
Reactor Design
73
Actually reaction chemistry doesnt ends here. Following figure shows the extent of
hydroracking reactions.
Catalyst selection
Reactor Design
74
Hydrocracking catalysts are dual functional, (having metallic and acidic sites) promoting
cracking and hydrogenation reactions
Acidic Support
Metallic Support
Hydrogenation Function is
provided by this support
2. Base Metals
(Group VIII A: Cobalt , Nickel)
(Group VI A: Molybdenum, Tungsten)
Metal Sulfides (NiS,
WS2)
Ni-Mo,Co-Mo, MoS2,
2. Noble Metals
(Pt , Pd )
Amorphous Silica-Alumina
Zeolite Catalyst
Have large pores which permit bulky feed stock Zeolites also need lower temperatures to achieve a
molecules to acidic sites
specified conversion
Have Moderate activity and makes metal-acid
balance
Based on above features and our chemistry we selected zeolite bed for hydrocracking
reactor and amorphous for hydrotreating reactor. And for Metalic sites Ni-Mo catalyst.
Catalyst specs are as folows
Catalyst Shape
Reactor Design
150 or more
75
Pore volume (ml/g)
0.6 - 1
30 100
881
Average Length
1/8
b. Disadvantages
Reactor Design
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At low liquid flow rates, flow maldistributions such as channeling, bypassing and
incomplete catalyst wetting may occur. This adversely affects the reactor
performance.
The catalyst particles cannot be very small. The intra-particle diffusion effects can
be significant. The catalyst pore-mouth plugging can cause rapid deactivation.
b. Disadvantages
Table 8.3: Comparison of Trickle bed reactor And Ebullated bed reactor
Characteristics
Trickle Bed Reactor
Ebullated Bed Reactor
Liquid flow
Reactor Design
77
Conversion
Mixing
Heat control
Liquid/solid
ratio
Catalyst
wetting
Catalyst
separation
Pressure drop
Catalyst
attrition
Application
Maximum
volume
Maximum
working
pressure
Investment
costs
Operating costs
maldistributions.
High conversion can be achieved
owing to plug flow behavior of fluid
in the reactor
Poor radial mixing.
Relatively difficult, usually provided
by additional quench streams.
Ratio is less.
Partial wetting is a serious
shortcoming.
Not required as fixed beds of
catalysts are used.
It is higher.
Not a problem, as catalyst particles
are fixed.
Used where Gas/liquid ratio is very
high.
300 m3
10 MPa
Low.
High.
Low.
High.
As 2431 SCF of hydrogen is required per barrel of oil, so the reactor flow regime
is trickle flow regime and Trickle flow reactor is selected for the service
Reactor Design
78
reactant to the catalyst surface. High liquid-to-solid ratio will give more
importance to the role of possible homogeneous reactions.
At low liquid flow rates, up-flow will provide better distribution of liquid and,
thus, in many cases, better performance of the reactor than the down-flow reactor
under similar operating conditions.
If reaction is rapid and highly exothermic, heat transfer between liquid and solid
is more effective in an up-flow reactor.
In an up-flow reactor, the catalyst must be kept in place by suitable mechanical
methods; otherwise the bed will be fluidized. In a down-flow reactor, the catalyst
is held in place tightly by the flow. This may cause undesired cementation of the
soft catalyst particles.
In an up-flow reactor, the catalyst particles are more likely to fill completely with
the liquid than in a down-flow reactor. The catalyst effectiveness factor is lower
when the catalyst pores are completely filled with liquid compared to the case
when they are only partially filed with the liquid.
Better sweeping of the catalyst by liquid in an up-flow reactor may sometimes
give better aging of the catalyst. If a solid reactant is used, then an up-flow would
cause less solids plugging problem than the down-flow operation.
In an up-flow reactor, flooding may be a problem.
The relative direction of flow of the liquid and gaseous phases is important.
Counter-current operation is mostly preferred for the gas-liquid-solid inert (GLSI)
reactors. In these units, the solid is used as a packing to increase the contact of the
liquid and gas phases, but it remains inert in the reaction.
Co current mode of operation is best suited for the (GLSC) gas liquid-solid
catalytic reactors where the solid acts as a catalyst
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Selected data, equations for calculations and calculated results are as follows
LHSV = Volumetric Feed Rate (m3/h)
Catalyst Volume (m3)
Selected value from hydrocracking studies is 2 hr-1
Catalyst Volume (m3) = Volumetric Feed Rate (m3/h)
LHSV (hr-1)
Reactor Volume (m3) = Catalyst Volume (m3) (1 + )
%age of Reactor Volume the catalyst volume is
Reactor 1
Feed Rate (kg/hr)=
Avg Density (kg/m3) =
LHSV (hr-1) =
Bed Porousity =
L/D =
%age of reactor volume =
the catalyst volume is
Catalyst density (kg/m3) =
CALCULATIONS
Vol. Feed Rate (m3/hr) =
Catalyst volume (m3) =
Actual Catalyst volume (m3) =
(accounting porousity)
Volume of Reactor (m3) =
Dr (m) =
Lr (m) =
Remaining volume (m3) =
154187
802
2
0.2
6
70
881
192.25
96.13
115
165
3.3
19.6
49.4
101625
3
30
80
B (% by wt of catalyst )
C (% by wt of catalyst )
D (% by wt of catalyst )
40
30
0
P
G 1 150(1 )
( 3 )
1.75G
L
D p
Dp
Equation Parameters
Values
5.1
Viscosity (Pa-s)
0.000283
Density (kg/m3)
802
0.003
Bed Porousity
0.2
13 m
0.60
81
6.Support Selection
Following table shows the results of Mechanical Design
Operating Conditions
T= 400 oC
P= 99 Barabs
Design Conditions
T= 440 oC
(20% allowance)
P= 109 Barabs
(10% allowance)
Material of Construction
SS-347 (2.25Cr-1Mo)
Reactor Design
Pi Di
c
2 Jf Pi
Wv 240Cv Dm ( H v 0.8 Dm )t
1452kN
20
82
Reactor Design
83
Reactor Design
84
Specification sheet:
Equipment
Function
Type
Operation
Reactor Volume
165 m3
Reactor Height
20 m
Reactor Diameter
3m
No. of Beds
No. of Quenches
Operating T
400 oC
Operating P
99 Bar
Design T
440 oC
Design P
109 Bar
Reactor Design