Flow distribution for monolithic reactors

Abstract

Systems, apparatus, and methods for distributing a mixed phase fluid to a monolith catalyst bed within a reactor, wherein a mixed phase fluid may be generated by a nozzle tray comprising a plurality of nozzles, the mixed phase fluid may be distributed by the nozzles to a mixed phase distributor system, and the mixed phase fluid may be further distributed by the mixed phase distributor system to a plurality of monolith channels within the reactor.

What is claimed is: 
     
         1 . A method for distributing a fluid mixture within a reactor, the method comprising:
 a) contacting a liquid hydrocarbon feed with a gas within each of a plurality of fluid distribution nozzles;   b) via the plurality of nozzles, forming a mixed phase fluid comprising the liquid hydrocarbon feed and the gas;   c) via the plurality of nozzles, distributing the mixed phase fluid to a mixed phase distributor system; and   d) via the mixed phase distributor system, distributing the mixed phase fluid to each of a plurality of channels of at least one monolith block.   
     
     
         2 . The method according to  claim 1 , wherein:
 the mixed phase distributor system is configured for laterally dispersing the mixed phase fluid within the reactor, and   the mixed phase distributor system is disposed above the at least one monolith block.   
     
     
         3 . The method according to  claim 1 , wherein step a) comprises:
 accelerating the gas into each of the nozzles to provide a low pressure zone within a void within each of the nozzles; and   via the low pressure zone, drawing the liquid hydrocarbon feed into the void, wherein:   the mixed phase fluid comprises a homogeneous mixture comprising the liquid hydrocarbon feed and the gas, and   the gas comprises hydrogen gas.   
     
     
         4 . The method according to  claim 1 , wherein:
 the mixed phase distributor system is disposed beneath the plurality of nozzles;   the mixed phase distributor system comprises an upper screen, a particulate layer disposed above the upper screen, and a lower screen disposed beneath the upper screen; and   the particulate layer is inert to materials selected from the group consisting of: the liquid hydrocarbon feed, the gas, and combinations thereof.   
     
     
         5 . The method according to  claim 4 , wherein each of the upper screen and the lower screen is configured for causing a pressure drop in the range from about 0.05 to 0.5 psi. 
     
     
         6 . The method according to  claim 4 , wherein step d) comprises:
 contacting the mixed phase fluid with the particulate layer, wherein the particulate layer is configured for laterally dispersing the mixed phase fluid; and   contacting the mixed phase fluid with the upper screen, wherein the upper screen is configured for restricting vertical passage of the mixed phase fluid therethrough.   
     
     
         7 . The method according to  claim 6 , wherein the mixed phase fluid comprises a liquid foam, and step d) further comprises:
 contacting the foam with the lower screen, wherein the lower screen is configured for stabilizing the foam;   passing the foam through the lower screen in a direction towards the at least one monolith block; and   contacting the plurality of channels with the foam.