Catalyst transfer method for moving-bed reactors

Claim 2

A PROCESS FOR WITHDRAWING SOLID CATALYST FROM A PRESSURIZED, MIXED-PHASE HYDROPROCESSING REACTION ZONE WHICH COMPRISES THE STEPS OF: A. PASSING A QUANTITY OF CATALYST DOWNWARD FROM SAID REACTION ZONE, THROUGH EACH OF A PLURALITY OF CONDUITS INTO A LIQUID FILLED, VERTICALLY SEGMENTED CATALYST COLLECTION HOPPER, SAID COLLECTION HOPPER BEING FILLED WITH A RELATIVELY LIGHT LIQUID HYDROCARBON STREAM AS COMPARED TO SAID EFFLUENT STREAM; B. PASSING A LIQUID HYDROCARBON STREAM UPWARD THROUGH EACH OF SAID CONDUITS AND INTO SAID REACTION ZONE AT A RATE SUFFICIENT TO PREVENT THE FURTHER PASSAGE OF CATALYST DOWNWARD THROUGH SAID CONDUITS; C. EQUALIZING THE HYDROSTATIC PRESSURE IN THE LIQUID FILLED CATALYST COLLECTION HOPPER AND IN A LIQUID FILLED LOCK HOPPER MEANS, AND COMMUNICATING THE CATALYST COLLECTION HOPPER AND LOCK HOPPER MENS THROUGH A CATALYST TRANSFER CONDUIT HAVING A POSITIVE SEALING VALVE MEANS AND EFFECTING THE TRANSFER OF CATALYST CONTAINED WITHIN THE CATALYST COLLECTION HOPPER INTO THE LOCK HOPPER MEANS; D. CLOSING SAID POSITIVE SEALING VALVE MEANS AND ISOLATING THE LOCK HOPPER MEANS FROM THE CATALYST COLLECTION HOPPER; AND, E. REDUCING THE FLOW RATE OF SAID LIQUID HYDROCARBON STREAM THROUGH SAID CONDUITS TO EFFECT THE PASSAGE OF ADDITIONAL QUANTITIES OF CATALYST INTO THE SEGMENTED CATALYST COLLECTION HOPPER.

Claim 3

The catalyst withdrawal process of claim 1 further characterized in that the hydrostatic pressure of the catalyst collection hopper and lock hopper are equalized by pressurizing liquid contained in the lock hopper up to the pressure of the catalyst collection hopper.

Claim 4

The catalyst withdrawal process of claim 2 further characterized in that said catalyst collection hopper and said lock hopper are connected by a pressure equalization line having a normally closed positive sealing valve means, and said positive sealing valve means in the pressure equalization line is opened subsequent to the pressurizing of the liquid contained in the lock hopper and is closed prior to transferring the catalyst from the lock hopper.

Claim 5

A process for hydroprocessing a hydrocarbon charge stream which comprises the steps of: a. passing a hydrocarbon charge stream into an upper portion of a reaction vessel maintained at reaction conditions in admixture with hydrogen; b. withdrawing an effluent stream from a lower portion of said reaction vessel; c. passing quantities of used hydroprocessing catalyst downward from the lower portion of said reaction vessel into a liquid filled, vertically segmented catalyst collection hopper through a plurality of catalyst withdrawal conduits, the catalyst collection hopper being filled with a relatively light liquid hydrocarbon stream as compared to said effluent stream; d. passing a liquid hydrocarbon stream upward through each of said conduits and into said reaction vessel at a rate sufficient to prevent the further passage of catalyst downward through said catalyst withdrawal conduits, and equalizing the hydrostatic pressure in the liquid filled catalyst collection hopper and in a liquid filled lock hopper means; e. communicating the catalyst collection hopper and said lock hopper means through a catalyst transfer conduit having a positive sealing valve means to effect the transferring of catalyst contained within the catalyst collection hopper into the lock hopper means; f. closing said positive sealing valve means and isolating the lock hopper means from the catalyst collection hopper; g. reducing the flow rate of said liquid hydrocarbon stream through said conduits to effect the passage of additional quantities of catalyst into the segmented catalyst collection hopper; and, h. effecting the tranfer of catalyst into said reaction vessel by first transferring a relatively large amount of catalyst, as compared to said quantities of used hydroprocessing catalyst sequentially passed from the lower portion of the reaction vessel, into a catalyst feed hopper located above the reaction vessel and isolated from the reaction vessel by a positive sealing valve means, and then opening said positive sealing valve means to allow passage of the catalyst into the reaction vessel until said relatively large amount of catalyst has emptied from the catalyst feed hopper.

Claim 6

A process for hydroprocessing a hydrocarbon charge stream which comprises the steps of: a. passing a hydrocarbon charge stream into an upper portion of a reaction vessel maintained at reaction conditions in admixture with hydrogen; b. withdrawing an effluent stream from a lower portion of said reaction vessel; c. passing quantities of used hydroprocessing catalyst downward from the lower portion of said reaction vessel into a liquid filled, vertically segmented catalyst collection hopper through a plurality of catalyst withdrawal conduits, the catalyst collection hopper being filled with a relatively light liquid hydrocarbon stream as compared to said effluent stream; d. passing a liquid hydrocarbon stream upward through each of said conduits and into said reaction vessel at a rate sufficient to prevent the further passage of catalyst downward through said catalyst withdrawal conduits, and equalizing the hydrostatic pressure in the liquid filled catalyst collection hopper and in a liquid filled lock hopper means; e. communicating the catalyst collection hopper and said lock hopper means through a catalyst transfer conduit having a positive sealing valve means to effect the transferring of catalyst contained within the catalyst collection hopper into the lock hopper means; f. closing said positive sealing valve means and isolating the lock hopper means from the catalyst collection hopper; g. reducing the flow rate of said liquid hydrocarbon stream through said conduits to effect the passage of additional quantities of catalyst into the segmented catalyst collection hopper; and, h. effecting the tranfer of catalyst into said reaction vessel by first transferring a relatively large amount of catalyst, as compared to said quantities of used hydroprocessing catalyst sequentially passed from the lower portion of the reaction vessel, into a catalyst feed hopper located above the reaction vessel and isolated from the reaction vessel by a positive sealing valve means, and then opening said positive sealing valve means to allow passage of the catalyst into the reaction vessel until said relatively large amount of catalyst has emptied from the catalyst feed hopper.

Claim 7

The process of claim 4 further characterized in that said catalyst feed hopper is filled with a liquid hydrocarbon before said relatively large amount of catalyst is transferred into said catalyst feed hopper.

Claim 8

The process of claim 5 further characterized in that said transferring of a relatively large amount of catalyst into said catalyst feed hopper comprises the steps of passing catalyst into a lock hopper separated from the catalyst feed hopper by a positive sealing valve means, and purging the catalyst in the lock hopper with a liquid.

Claim 9

The process of claim 5 further characterized in that said hydrocarbon charge stream comprises crude column bottoms.

Claim 10

The process of claim 5 further characterized in that said hydrocarbon charge stream comprises material derived by the further fractionation of crude column bottoms material.

Claim 11

A process for hydroprocessing a hydrocarbon charge stream which comprises the steps of: a. passing said hydrocarbon charge stream into an upper portion of a reaction vessel maintained at reaction conditions in admixture with hydrogen; b. withdrawing an effluent stream from a lower portion of said reaction vessel; c. effecting the transfer of catalyst into said reaction vessel by first transferring a large amount of catalyst, as compared to the quantities of used hydroprocessing catalyst sequentially passed from the lower portion of the reaction vessel as hereinafter set out, into a catalyst feed hopper located above the reaction vessel and isolated from the reaction vessel by a positive sealing valve means while the catalyst feed hopper is at a pressure lower than the reaction vessel, then raising the pressure of catalyst feed hopper to the pressure of the reaction vessel while the catalyst feed hopper is filled with a liquid, and then opening said positive sealing valve means to allow passage of the catalyst into the reaction vessel; d. passing quantities of used hydroprocessing catalyst downward from the lower portion of said reaction vessel into a vertically segmented catalyst collection hopper through a plurality of conduits; e. passing a relatively light liquid hydrocarbon stream, as compared to said hydrocarbon charge stream, into said catalyst collection hopper and upwardly into said lower portion of the reaction vessel to effect the removal of hydroprocessed charge stream material from said hydroprocessing catalyst; f. passing quantities of used hydroprocessing catalyst from the catalyst collection hopper into a liquid filled lock hopper; and, g. isolating said liquid filled lock hopper from the catalyst collection hopper by a second positive sealing valve means and reducing the pressure of said lock hopper to effect a depressurizing of the used hydroprocessing catalyst.

Claim 12

A process for hydroprocessing a hydrocarbon charge stream which comprises the steps of: a. passing said hydrocarbon charge stream into an upper portion of a reaction vessel maintained at reaction conditions in admixture with hydrogen; b. withdrawing an effluent stream from a lower portion of said reaction vessel; c. effecting the transfer of catalyst into said reaction vessel by first transferring a large amount of catalyst, as compared to the quantities of used hydroprocessing catalyst sequentially passed from the lower portion of the reaction vessel as hereinafter set out, into a catalyst feed hopper located above the reaction vessel and isolated from the reaction vessel by a positive sealing valve means while the catalyst feed hopper is at a pressure lower than the reaction vessel, then raising the pressure of catalyst feed hopper to the pressure of the reaction vessel while the catalyst feed hopper is filled with a liquid, and then opening said positive sealing valve means to allow passage of the catalyst into the reaction vessel; d. passing quantities of used hydroprocessing catalyst downward from the lower portion of said reaction vessel into a vertically segmented catalyst collection hopper through a plurality of conduits; e. passing a relatively light liquid hydrocarbon stream, as compared to said hydrocarbon charge stream, into said catalyst collection hopper and upwardly into said lower portion of the reaction vessel to effect the removal of hydroprocessed charge stream material from said hydroprocessing catalyst; f. passing quantities of used hydroprocessing catalyst from the catalyst collection hopper into a liquid filled lock hopper; and, g. isolating said liquid filled lock hopper from the catalyst collection hopper by a second positive sealing valve means and reducing the pressure of said lock hopper to effect a depressurizing of the used hydroprocessing catalyst.

Claim 13

The process of claim 9 further characterized in that said hydrocarbon charge stream comprises crude column bottoms.

Claim 14

The process of claim 9 further characterized in that said hydrocarbon charge stream comprises material derived by the further fractionation of crude column bottoms material.

Claim 15

A process for hydroprocessing a hydrocarbon charge stream which comprises the steps of: a. passing said hydrocarbon charge stream into an upper portion of a reaction vessel in admixture with hydrogen; b. withdrawing an effluent stream from a lower portion of said reaction vessel; c. passing quantities of solid hydroprocessing catalyst downward into said upper portion of said reaction vessel; d. passing quantities of used hydroprocessing catalyst downWard from the lower portion of said reaction vessel into a vertically segmented catalyst collection hopper through a plurality of conduits; e. passing a relatively light liquid hydrocarbon stream, as compared to said hydrocarbon charge stream, into said lower portion of the reaction vessel to effect the removal of hydroprocessed charge stream material from said hydroprocessing catalyst, said light liquid hydrocarbon stream being passed into said catalyst collection hopper and then into said reaction vessel; f. passing quantities of used hydroprocessing catalyst from the catalyst collection hopper into a liquid filled lock hopper; g. isolating said liquid filled lock hopper from the catalyst collection hopper by a positive sealing valve means and reducing the pressure of said lock hopper to effect a depressurizing of the used hydroprocessing catalyst; h. withdrawing depressurized catalyst from the lock hopper and transferring depressurized catalyst to a washing zone where the catalyst is contacted with a volatile solvent to effect a removal of heavy hydrocarbon material; and, i. transferring the catalyst to a drying zone for removal of solvent.

Claim 16

A process for hydroprocessing a hydrocarbon charge stream which comprises the steps of: a. passing said hydrocarbon charge stream into an upper portion of a reaction vessel in admixture with hydrogen; b. withdrawing an effluent stream from a lower portion of said reaction vessel; c. passing quantities of solid hydroprocessing catalyst downward into said upper portion of said reaction vessel; d. passing quantities of used hydroprocessing catalyst downWard from the lower portion of said reaction vessel into a vertically segmented catalyst collection hopper through a plurality of conduits; e. passing a relatively light liquid hydrocarbon stream, as compared to said hydrocarbon charge stream, into said lower portion of the reaction vessel to effect the removal of hydroprocessed charge stream material from said hydroprocessing catalyst, said light liquid hydrocarbon stream being passed into said catalyst collection hopper and then into said reaction vessel; f. passing quantities of used hydroprocessing catalyst from the catalyst collection hopper into a liquid filled lock hopper; g. isolating said liquid filled lock hopper from the catalyst collection hopper by a positive sealing valve means and reducing the pressure of said lock hopper to effect a depressurizing of the used hydroprocessing catalyst; h. withdrawing depressurized catalyst from the lock hopper and transferring depressurized catalyst to a washing zone where the catalyst is contacted with a volatile solvent to effect a removal of heavy hydrocarbon material; and, i. transferring the catalyst to a drying zone for removal of solvent.

Claim 17

The process of claim 12 further characterized in that said hydrocarbon charge stream comprises crude column bottoms.

Claim 18

The process of claim 12 further characterized in that said hydrocarbon charge stream comprises material derived by the further fractionation of crude column bottoms material.