Ebullated Bed Reactor Modeling For Residue Conversion PDF
Ebullated Bed Reactor Modeling For Residue Conversion PDF
Ebullated Bed Reactor Modeling For Residue Conversion PDF
www.elsevier.com/locate/ces
Abstract
Ebullated bed reactors are suitable for deeply converting heavy feedstocks such as residues. In this study, a dynamic reactor model is
developed taking into account hydrodynamics, catalytic and thermal kinetics. First, a validation of the hydrodynamic model is performed
on a bench scale reactor using a radioactive tracer test for residence time distribution measurements under industrial conditions. In a second
step, the complete dynamic model including kinetics is validated on the same reactor for various operating conditions. The model gives
good predictions of conversions and yields. An improvement is required to assess this model for a larger range of operating conditions.
䉷 2004 Elsevier Ltd. All rights reserved.
D8
two phases D7
zone
D6
three phases
zone
D5
Fig. 1. Ebullated bed reactor.
120 Table 2
Operating conditions for RTD measurements
100 Test LHSV H2 flow-rate Temp Recycle ratio
number (h-1) (NL/L) (◦ C) (L/L)
%vol of Ar in liquid
80
1 0,74 733 T 8.9
2 0,74 533 T 8.9
60 Soave
3 0,74 533 T 8.9
Peng-Robinson 4 0,74 1151 T 8.9
40 5 0,74 1151 T + 16 8.9
6 0,74 783 T + 16 8.9
20 7 0,74 783 T + 16 8.9
8 0,74 783 T + 16 23.6
9 0,74 783 T + 16 23.6
0
10 0,74 783 T + 16 23.6
0 5 10 15 20 25 30 11 0,74 480 T + 16 23.6
bench unit typical ratio recycle ratio 12 0,74 1151 T + 16 23.6
13 0,74 1151 T + 16 23.6
Fig. 3. Argon solubility. 14 0,74 360 T + 16 23.6
15 0,74 480 T + 16 19.7
16 0,74 480 T + 16 19.7
Detector D5
is absorbed because of the liquid flow-rate increase. Fig. 3 Detector D6
3000
shows the evolution of Argon solubility as a function of the Detector D7
liquid recycle ratio. These gas–liquid equilibrium calcula- 2000 Detector D8
tions were performed using two thermodynamic models for
Ki estimations: Soave–Redlich–Kwong, Peng–Robinson. It 1000
clearly appears that for a typical recycle ratio in the bench
unit (10.5), 55% of Argon is dissolved in the liquid phase. 0
This means that both phases (gas and liquid) were traced 0 200 400 600 800 1000 1200 1400
simultaneously. This partial dissolving of Argon leads to a Time (s)
more complicated interpretation of RTD experiments. In- Fig. 4. Typical responses collected at different levels after 1 injection.
deed, the hydrodynamic model should take into account
gas and liquid flow patterns and also the gas–liquid mass
transfer of Argon. Unfortunately, no other tracers, which are
completely liquid and stable under industrial conditions, are
available. 3.4. Hydrodynamic model
3.3. RTD experiments The reactor is divided into two zones: the catalytic zone
and the bubble column. Liquid flow in both zones is modeled
Table 2 summarizes operating conditions of 16 tracer in- with a dispersed-plug flow model (Froment and Bischoff,
jections. The tracer test was carried out at two temperatures 1990). The dispersion is closed between the bubble column
(where T is in the range of 350–450 ◦ C), 3 recycle ratios and the ebullated bed. The gas flow is assumed to be plug-
and 6 conditions of hydrogen flow-rate. The liquid hourly flow. The gas–liquid mass transfer of Argon is taken into
space velocity (LHSV) was maintained constant. account (tracer in liquid and gas phases is not in equilibrium)
Fig. 4 shows responses of detectors after one tracer injec- (Froment and Bischoff, 1990). The liquid recycle flow is
tion. It can be observed from this figure that there is a dis- assumed to be plug-flow. Model bases are summarized in
persion of the tracer along the column. Moreover, since no Fig. 5.
gas is present in the recycle line, the second peak confirms Material balances of Argon in the liquid phase, in both
the partial absorption of Argon in the liquid phase. This is ebullated bed and bubble column, are given by Eqs. (1) and
in agreement with gas–liquid equilibrium calculations. (2), respectively.
5640 J.-M. Schweitzer, S. Kressmann / Chemical Engineering Science 59 (2004) 5637 – 5645
kl.a liquid
εs = 0
PAr *
C Ar ε1 = 1 εg2
gas
εg2 CAr
PAr
*
C Ar
CAr
Qr gas
liquid + catalyst
εg1
εs
ε1 = 1 εg1 εs
Detector 4 Detector 5
1.2 1.2
1 1
C norm
C norm
exp simul
0.6 simul 0.6
0.4 0.4
0.2 0.2
0 0
0 500 1000 1500 2000 2500 0 500 1000 1500 2000 2500
time s time s
Detector 6 Detector 7
1 1
0.9 0.9
0.8 0.8
0.7 0.7
C norm
C norm
0.6 exp
0.6 exp
0.5 0.5 simul
simul
0.4 0.4
0.3 0.3
0.2 0.2
0.1 0.1
0 0
0 500 1000 1500 2000 2500 0 500 1000 1500 2000 2500
time s time s
Dax
1
= aεl + bεg + cv sl + dv sg + eεs . (6)
3.5. Experimental results and model validation
Fig. 7shows the good agreement in the three-phase zone be-
Fig. 6 shows a comparison between the model and ex- tween this correlation and experimental data. Nevertheless,
periments for 1 tracer injection (test number 5). A good the agreement in the two-phase zone is less good due to the
agreement was obtained between the model and experimen- poor significance of hydrodynamic parameters in this zone.
tal results. Table 3 gives optimized values of parameters for A model for gas holdup was developed based on approach
one condition. A statistical analysis of parameters was done of Krishna et al. (1997). The three-phase zone works in
in order to evaluate the significance of each of them. It is the churn-turbulent regime for gas holdup point of view. In
clearly shown that parameters relative to the bubble column this region the gas holdup is determined by the following
are less significant than those in the three-phase zone. This equation:
is due to the lack of experimental information. Indeed, only
1 detector was located in the bubble column region that is εg = εgtrans (1 − εb ) + εb with
not enough for a good hydrodynamic characterization of this 2
1
zone. The same procedure was used for the other injections εb = 1 (vsg − Vsmall εgtrans )2 . (7)
and hydrodynamic and mass transfer parameters (axial dis- D
5642 J.-M. Schweitzer, S. Kressmann / Chemical Engineering Science 59 (2004) 5637 – 5645
2.5E-03 2.0E-03
1.8E-03
Catalytic zone
Bubble column
2.0E-03 1.6E-03
1.4E-03
Dax correlation (m2/s)
1.0E-03
1.0E-03 8.0E-04
6.0E-04
5.0E-04 4.0E-04
2.0E-04
0.0E+00 0.0E+00
0.0E+00 5.0E-04 1.0E-03 1.5E-03 2.0E-03 2.5E-03 0.0E+00 5.0E-04 1.0E-03 1.5E-03 2.0E-03 2.5E-03
2
Dax model (m /s) Dax model (m2/s)
The feedstock which enters the reactor is character- Reaction Catalytic kinetic expression Thermal kinetic expression
ized by a True Boiling Point curve called TBP. From this c = k c C C 0.5 t = kt C
i→j rij ij i H2 rij ij i
curve, 4 pseudo-components were defined using a break-
down method. Each pseudo-component is characterized
by a temperature range, an average molecular weight, an
average specific gravity and a weight fraction in the feed-
stock. The feedstock we used in our test is a Canadian lumped kinetic schemes were used to describe the hydro-
heavy crude oil. The decomposition of the TBP curve into cracking and thermal cracking (Jacob et al., 1976). Fig. 8
pseudo-components is given in Table 4. shows these two schemes.
Each pseudo-component could react with or without hy-
4.2. Kinetics drogen to form lighter pseudo-components. The reaction
takes place at the solid–liquid interface (catalytic process)
Due to high process temperature (350–450 ◦ C), catalytic and in the liquid interface (thermal process). Kinetic ex-
and thermal cracking occurs simultaneously. Then, two pressions used for each reaction are given in Table 5 where
J.-M. Schweitzer, S. Kressmann / Chemical Engineering Science 59 (2004) 5637 – 5645 5643
Kinetics is included into the hydrodynamic model. The ma- Kinetic parameters were estimated using experimental
terial balance of each pseudo-component i and hydrogen data coming from the bench scale unit. Table 6 shows operat-
(with i = A, B, C, D, H2 ) in both zones may be written as ing conditions used for the model validation. The same total
follows: pressure was used for these three tests. In a first approach,
Three-phase zone: kinetic parameters of thermal cracking were not taken into
account. These parameters will be estimated in a further
εg1 Hi *Cil work, with more experimental data. Table 7 shows catalytic
1+ kinetic parameters at reference temperature T . A statisti-
(1 − εg1 − εs )RT *t
cal analysis will be done in a further work when more ex-
* Cil *Cil
2
s ε s
= Dax
1
− u l ± ric perimental data will be available. However, from these first
*z 2 1
*z 1 − εg1 − εs results, it may be noticed that kinetic constants are higher
εg1 *(ug1 Hi Cil ) when a heavy pseudo-component cracks instead of a lighter
± rit − . (12) one. This is in agreement with the literature data (Weitkamp,
(1 − εg1 − εs )RT *z
1975; Luzarraga and Voorhies, 1973; Haynes et al., 1983).
5644 J.-M. Schweitzer, S. Kressmann / Chemical Engineering Science 59 (2004) 5637 – 5645
60
% wt simulations
0.4 B
0.3 C
D Notation
0.2
0.1 Cil , CAr liquid concentrations of component i and Argon,
mol/m3
0
D reactor diameter, m
0 5000 10000 15000 20000 25000
time (s)
Dax
1 , D2
ax liquid axial dispersion coefficient in three- and
two-phase zones, m2 /s
Fig. 10. Outlet time profiles of yields. E activation energy, J/mol
εg1 , εg2 gas holdups in three- and two-phase zones, di-
mensionless
Fig. 9 shows a comparison in conversion and yields of all εs solid holdup, dimensionless
species between experimental data and calculations at 3 op- εgtrans transition gas holdup between homogenous and
erating conditions. A good agreement is obtained between churn turbulent regime, dimensionless
model and experiments. Fig. 10 shows the time evolution Hi , HAr Henry coefficients of component i and Argon,
of yields at the reactor outlet. Steady-state conditions are bar m3 /mol
reached after 5 h. Fig. 11 shows steady-state partial pres- kijc ,kijt kinetic constants in catalytic and thermal pro-
sures profiles along the reactor. It can be noticed that after cesses, dimensionless
J.-M. Schweitzer, S. Kressmann / Chemical Engineering Science 59 (2004) 5637 – 5645 5645
kla Mass transfer coefficient, s−1 Colyar, J.J., Wisdom, L.I., 1997. The H-oil process: a worldwide leader
in vacuum residue processing. 1997 National Petroleum Refiners
Ki gas–liquid partition coefficient of component i,
Association Annual Meeting, San Antonio, TX.
dimensionless Froment, G.F., Bischoff, K.B., 1990. Chemical Reactor Analysis and
Pi , PAr partial pressures of component i and Argon, bar Design, second ed., Wiley Series in Chemical Engineering. Wiley, New
or Pa York, pp. 259, 446.
Pt total pressure, bar or Pa Haynes, H.W., Parcher, J.F., Helmer, N.E., 1983. Hydrocracking of
ric , rit kinetic formation rate of component i in cat- polycyclic hydrocarbons over a dual-functional zeolite (faujasite)-based
catalyst. Industrial Engineering Chemical Process and Development 22
alytic and thermal processes (3), 401–409.
rijc , rijt kinetic reaction rate in catalytic and thermal pro- Jacob, S.M., Gross, B., Voltz, S.E., Weekman, V.W., 1976. A lumping
cesses, mol/kg/s mol/m3 /s and reaction scheme for catalytic cracking. A.I.Ch.E. Journal 22 (4),
R ideal gas constant, J/mol/K 701–713.
Kressmann, S., Boyer, C., Colyar, J.J., Schweitzer, J.M., Viguié,
T temperature, K
J.C., 2000. Improvements of ebullated-bed technology for upgrading
ug1 , ug2 gas velocities in three- and two-phase zones, m/s Heavy oils. Oil & Gas Science and Technology-Revue IFP 55 (4),
ul1 , ul2 liquid velocities in three- and two-phase zones, 397–406.
m/s Krishna, R., De Swart, J.W.A., Martina, G.B., Maretto, C., 1997. Gas
ur recycle velocity, m/s holdup in slurry bubble columns: effect of column diameter and slurry
concentrations. A.I.Ch.E. Journal 43 (2), 311.
vsg , vsl superficial gas and liquid velocities, m/s
Luzarraga, M.G., Voorhies, A., 1973. Hydroisomerization and hydro-
Vsmall velocity of small bubbles, m/s cracking of cyclohexane in the presence of a palladium–hydrogen–
faujasite-catalyst. Industrial Engineering Chemical Product Research
and Development 12 (3), 194–198.
References Morel, F., Kressmann, S., Harlé, V., Kasztelan, S., 1997. Processes and
catalysts for hydrocracking of heavy oil and residues. Studies in Surface
Colyar, J.J., Wisdom, L.I., 1992. Upgrading vacuum residue from Mexican Science and Catalysis 106, 1.
crudes for petroleos mexicanos hydrodesulfurization residue complex Weitkamp, J., 1975. The influence of chain length in hydrocracking
miguel hidalgo refinery. Japan Petroleum Institute, Tokyo, Japan. and hydroisomerization of n-alkanes. In: Ward, J., Qader, S.A. (Eds.)
Colyar, J.J., Wisdom, L.I., 1994. Second generation ebullated-bed Hydrocracking and Hydrotreating A.C.S. Symposium Series, vol. 20.
technology. JPI Petroleum Refining Conference, Tokyo, Japan. pp. 1–27.