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Application of Shell Reactor Internals in Huizhou Refinery
Application of Shell Reactor Internals in Huizhou Refinery
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Manag
Sunil C
It enters the top distribution plate via a circular channel at the filter center while most of the
gas is routed through the large circular channel. Such design can ensure that the pressure
drop is very low and can be negligible when the oil-gas mixture passes through the filter. Shell
compared the following three cases,
a) Oil and gas from the reactor top enter the catalyst bed directly
b) A scale basket is installed on the reactor top
c) A Shell proprietary filter is installed at the reactor top.
Shell analysed the relationship between the catalyst bed pressure drop and catalyst operation
time (results shown in Fig 1). Pressure drop with Shell proprietary filter is more stable and
rises slowly, which extends the catalyst operation cycle to a great extent. With Shell
proprietary filter on the top, the Huizhou Refinery HP HCU has been operating since its
startup on April 24, 2009 and has processed 7.6 million tonnes of feedstock. The catalyst bed
pressure drop is basically stable as depicted in Fig. 2.
Before July 2010 pressure drop of catalyst bed #1 was basically stabilised at 0.05MPa but Karnata
after July 2010 the total pressure drop of catalyst beds #1, #2 and #3 raised slightly; however
the trend was slow. Current total pressure drop in the three catalyst beds is stabilised around • India E
0.22MPa under full-load production. This demonstrates that besides performing the function of • OIL Pu
top bed grading materials, the Shell proprietary reactor filters play a significant role in
mitigating the pressure drop across the catalyst beds and also increasing the catalyst cycle • ONGC
life.
• India's
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High-speed gas flow breaks liquid into liquid drops which are carried to the central tube for
spraying across the next catalyst bed. In general, large viscosity feed and small hydrogen-oil
ratio always result in small oil-gas spraying angle, which would lead to uneven distribution of
gas and liquid across the bed. This will cause poor utilisation of catalysts or even catalyst
coking because of excessively large radial temperature difference.
Patented Shell “HD” distribution plate is used at the Huizhou Refinery HP HCU. Most oil and
gases flow through the center of the HD tube while liquid oil flows into the tube through small
holes on the “HD” tube side. Meanwhile, high speed gas that flows within the “HD” tube forms
the suction force to break liquid within the holes into atomized drops. The oil-gas mixture flows
downward quickly to collide with the baffle at the bottom of the “HD” tube and splash mist so
that the distribution of reaction oil and gas across the catalyst bed is uniform, thus avoiding
uneven fluid distribution.
Shell tested “HD” bubble cap and ordinary sieve plate to study the type with the best oil-gas
distribution effect. Results depicted in Fig 3 indicate that the HD distribution plate is better
than the others. The reactor at HP HCU at the refinery has large inner diameter of 4.4m.
Large inner diameter results in poor distribution of oil and gas across the catalyst bed and
occurrence of large radial temperature difference. Six flexible E+H thermocouples are
installed at the inlet of each of the catalyst beds. Since the startup, with patented Shell “HD”
distribution plate, the radial temperature difference of most catalyst beds is less than 2
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degrees and an individual one is more than 2 degrees but still less than 3 degrees, Table 1
(on the next page) shows the temperature distribution at the inlets of the first and last beds of
reactors in Row A, which demonstrates that “HD” distribution plate has better oil and gas
distribution effect.
In addition, as the oil and gas in the reactor, are heavy and viscosity is high at the upper bed
of the reactor a bigger HD tube is designed. Since hydrocracking reaction occurs on the
catalyst bed, a smaller HD tube is designed for the bottom of the reactor which has low
viscosity, light oil and gas.
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Note that for three different quench hydrogen flows, the radial temperature difference of the
bed is within 3 degrees, which indicates that the quench hydrogen injected into the reactor
can be fully mixed with hot fluid from the upper catalyst bed.
Like HD, “Oxhorn” tube is on the upper bed of the reactor. As the oil and gas in the reactor are
heavy and viscosity is high, “oxhorn” nozzles are designed bigger in size for the upper bed.
However, since hydrocracking reaction takes place on the catalyst bed and the oil and gas are
light and viscosity is low at the bottom of the reactor, the nozzles that are designed are
smaller in size.
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Conclusion
Huizhou Refinery's 4 MTPA HP HCU currently has the largest domestic single-processing
loading capacity, loading of about 353 tonnes catalyst per reactor. Shell patented reactor
internals are very essential in ensuring uniform distribution of reaction materials across the
catalyst bed, full catalyst activity, safety and stability when raising the reactor catalyst bed
temperature for uniform mixture of hot and cold fluids and avoiding large radial temperature
difference of the bed.
Since the startup of Huizhou Refinery HP HCU, the radial temperature distribution across the
catalyst bed is uniform without obvious rill flow or hot spot, and the catalyst activity is fully
indicated.
These demonstrate the successful application of Shell proprietary reactor internals in Huizhou
Refinery HP HCU.
Another significant characteristic of Shell proprietary reactor internals is that filter, distribution
plate and quench hydrogen box are connected through wedges for convenient assembly and
disassembly, while domestic bolts are generally used for the connection. When unloading
internal passage plates of the reactor, bolt seizure always hinders the normal removal. In
short, the unique design and excellent performance of Shell proprietary reactor internals play
a very important role in the safe, smooth and long-cycle operation of Huizhou Refinery HP
HCU.
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