Fixed bed radial flow reactor for light paraffin conversion

Abstract

Systems and methods are provided for conversion of light paraffinic gases to form liquid products in a process performed in a fixed bed radial-flow reactor. The light paraffins can correspond to C3+ paraffins. Examples of liquid products that can be formed include C6-C12 aromatics, such as benzene, toluene, and xylene. The fixed bed radial-flow reactor can allow for improved control over the reaction conditions for paraffin conversion in spite of the fixed bed nature of the reactor. This can allow the process to operate with improved efficiency while reducing or minimizing the complexity of operation relative to non-fixed bed reactor systems.

1 . A fixed bed radial flow reactor, comprising:
 an outer annular volume defined by an interior of a reactor wall and an exterior of a gas-permeable catalyst bed wall, the interior of the reactor wall defining an outer annular radius R1;   a central volume defined by the interior of a gas-permeable central column wall and a column cap, the interior of the central column wall defining a column radius R3;   an inner annular volume defined by an interior of the catalyst bed wall, an exterior of the central column wall, an inner annular top, and an inner annular bottom, the interior of the catalyst bed wall defining an inner annular radius R2, the inner annular volume comprising a catalyst bed, the inner annular volume being in direct fluid communication with the outer annular volume through the catalyst bed wall, the inner annular volume being in direct fluid communication with the central volume through the central column;   a plurality of catalyst particles in the catalyst bed, the catalyst particles comprising an equivalent particle diameter d P,e ; and   a first reactor opening and a second reactor opening, the first reactor opening being in fluid communication with the outer annular volume, the second reactor opening being in fluid communication with the central volume,   wherein the outer annular radius R1, inner annular radius R2, and the equivalent particle diameter d P,e  satisfy the relationship
     C*d   P,e   ≤R 1− R 2≤ D*d   P,e  
 
   where C is at least 30 and D is 300 or less, and   wherein the inner annular radius R2, the column radius R3, and the equivalent particle diameter d P,e  satisfy the relationship
     A*d   P,e   ≤R 2− R 3≤ B*d   P,e  
 
   where A is at least 100 and B is 600 or less.   
     
     
         2 . The reactor of  claim 1 , wherein A is at least 300, or wherein B is 400 or less, or a combination thereof. 
     
     
         3 . The reactor of  claim 1 , wherein C is at least 50, or wherein D is less than 150, or a combination thereof. 
     
     
         4 . The reactor of  claim 1 , wherein the equivalent particle diameter is about 0.2 cm to about 4.0 cm. 
     
     
         5 . The reactor of  claim 1 , wherein the first reactor opening comprises a reactor inlet, or wherein the second reactor opening comprises a reactor outlet, or a combination thereof. 
     
     
         6 . The reactor of  claim 1 , wherein the inner annular volume further comprises gas phase hydrocarbons, at least 5 vol % of the gas phase hydrocarbons comprising C 3+  paraffins relative to a weight of the gas phase hydrocarbons. 
     
     
         7 . The reactor of  claim 6 , wherein the at least 5 vol % of C 3+  paraffins comprises at least 5 vol % of C 3 -C 6  paraffins or C 3 -C 4  paraffins. 
     
     
         8 . The reactor of  claim 1 , wherein the catalyst particles comprise at least one medium pore molecular sieve having a Constraint Index of 2-12. 
     
     
         9 . The reactor of  claim 1 , wherein the catalyst particles comprise ZSM-5, ZSM-11, ZSM-12, ZSM-22, ZSM-23, ZSM-35, ZSM-48, MCM-22, MCM-49, or a combination thereof. 
     
     
         10 . The reactor of  claim 1 , wherein the catalyst particles comprise 0.1 wt % to 5.0 wt % of a metal from Groups 3-13 of the periodic table relative to a weight of the catalyst particles. 
     
     
         11 . The reactor of  claim 10 , wherein the metal comprises Ga, In, or a combination thereof. 
     
     
         12 . The reactor of  claim 1 , wherein the catalyst bed wall comprises a perforated wall, a catalyst bed screen, or a combination thereof. 
     
     
         13 . A method for processing a paraffin-containing feed, comprising:
 exposing a feed comprising about 30 vol % to about 70 vol % of C 3+  paraffins to one or more fixed beds of a conversion catalyst to form a conversion effluent comprising C 6 -C 12  aromatics, the one or more fixed beds of the conversion catalyst comprising fixed beds in one or more radial flow reactors, a combined pressure drop across the one or more fixed beds being less than about 100 kPag, the one or more radial flow reactors comprising:
 an outer annular volume defined by an interior of a reactor wall and an exterior of a gas-permeable wall, the interior of the reactor wall defining an outer annular radius R1; 
 a central volume defined by the interior of a central column and a column cap, the interior of the central column defining a column radius R3; and 
 an inner annular volume defined by an interior of the gas-permeable wall, an exterior of the central column, an inner annular top, and an inner annular bottom, the interior of the gas-permeable wall defining an inner annular radius R2, the inner annular volume comprising a catalyst bed, the inner annular volume being in direct fluid communication with the outer annular volume through the gas-permeable wall, the inner annular volume being in direct fluid communication with the central volume through the central column, 
 wherein the conversion catalyst comprises catalyst particles comprising an equivalent particle diameter d P,e , 
 wherein the outer annular radius R1, inner annular radius R2, and the equivalent particle diameter d P,e  satisfy the relationship
     C*d   P,e   ≤R 1− R 2≤ D*d   P,e  
 
 
 where C is at least 30 and D is 300 or less, and 
 wherein the inner annular radius R2, the column radius R3, and the equivalent particle diameter d P,e  satisfy the relationship
     A*d   P,e   ≤R 2− R 3≤ B*d   P,e  
 
 
 where A is at least 100 and B is 600 or less. 
   
     
     
         14 . The method of  claim 13 , wherein the feed is exposed to the conversion catalyst at a temperature of about 450° C. to about 650° C., a pressure in the one or more fixed catalyst beds comprising at least about 200 kPa-a, and a WHSV of about 0.1 hr −1  to about 4.0 hr −1 . 
     
     
         15 . The method of  claim 13 , the method further comprising heating at least a portion of the feed after exposure of the feed to a first catalyst bed of the one or more catalyst beds and prior to exposure of the feed to a second catalyst bed of the one or more catalyst beds. 
     
     
         16 . The method of  claim 13 , wherein a temperature drop across a first catalyst bed of the one or more catalyst beds is about 125° C. or less. 
     
     
         17 . The method of  claim 13 , further comprising:
 separating C 3+  paraffins from a natural gas feedstock to form at least a fraction comprising C 3+  paraffins;   mixing at least a portion of the fraction separated C 3+  paraffins with a gas comprising methane, ethane, or a combination thereof to form an enriched feedstock,   wherein exposing the feed comprising about 30 vol % to about 70 vol % of C 3+  paraffins to one or more fixed beds of conversion catalyst comprises exposing at least a portion of the enriched feedstock to the one or more fixed beds of conversion catalyst.   
     
     
         18 . The method of  claim 17 , wherein the gas comprising methane, ethane, or a combination thereof comprises a portion of the natural gas feedstock, a fraction separated from the natural gas feedstock, or a combination thereof. 
     
     
         19 . The reactor of  claim 17 , wherein the about 30 vol % to about 70 vol % C 3+  paraffins comprise about 30 vol % to about 70 vol % of C 3 -C 6  paraffins or C 3 -C 4  paraffins. 
     
     
         20 . The method of  claim 13 , further comprising separating the conversion effluent to form a fraction comprising C 6 -C 12  aromatics (or C 6 -C 9  aromatics), and combining at least a portion of the fraction comprising C 6 -C 12  aromatics with a hydrocarbon liquid. 
     
     
         21 . The method of  claim 13 , wherein A is at least 300, or wherein B is 400 or less, or a combination thereof, or wherein C is at least 50, or wherein D is less than 150, or a combination of any two or more thereof, or a combination of all thereof. 
     
     
         22 . The method of  claim 13 , wherein the equivalent particle diameter is about 0.2 cm to about 4.0 cm. 
     
     
         23 . The method of  claim 13 , wherein the catalyst particles comprise ZSM-5, ZSM-11, ZSM-12, ZSM-22, ZSM-23, ZSM-35, ZSM-48, MCM-22, MCM-49, or a combination thereof. 
     
     
         24 . The method of  claim 13 , wherein the catalyst particles comprise 0.1 wt % to 5.0 wt % of a metal from Groups 3-13 of the periodic table relative to a weight of the catalyst particles. 
     
     
         25 . The method of  claim 13 , wherein the metal comprises Ga, In, or a combination thereof.