REACTOR LIQUID COOLDOWN METHOD

Abstract

A reactor liquid cool down method is provided. The method includes obtaining a warm recycle stream (102) from a reactor (101) and compressing the warm recycle stream (102), thereby producing a compressed warm recycle stream (104); mixing a compressed warm recycle stream (104) with a controlled liquid cryogen stream (110) in a stainless steel mixing zone (107), thereby producing a cool recycle stream (112), wherein the cool recycle stream has a mean fluid temperature, monitoring the mean fluid temperature and comparing the mean fluid temperature to a predetermined control valve set point, thereby defining a temperature deviation; modulating a temperature control valve (109) to vary the controlled liquid cryogen stream (110) in order to produce a temperature deviation that is less than a predetermined value, and returning the cool recycle stream (112) to the reactor (101).

Description

RELATED APPLICATION

This patent application claims priority to U.S. Provisional Patent Application Ser. No. 61/755,117 filed on Jan. 22, 2013, which is hereby incorporated by reference in its entirety.

BACKGROUND

In order to shorten downtime for turnarounds, refineries use cold nitrogen injected into reactor recycle loops to cool down reactors quicker than with simply using the hydrocarbons in the system. This system will reduce the amount of nitrogen required for most cooldown cycles by almost ⅔—increasing the value to the customer drastically.

Systems outfitted with piping of incompatible metallurgy are not able to use liquid nitrogen and the nitrogen must be vaporized and brought to a acceptable temperature before injecting into the customer's system (using mobile nitrogen vaporization units). Systems outfitted with stainless steel piping are able to inject liquid nitrogen directly, which requires far less nitrogen—usually around ⅓, but the majority of cool downs are with cold gas. Both technologies are mature, although direct injection generally requires a higher level of safety consciousness. Some customers with stainless piping are further reluctant to pursue liquid cooldowns because of the risk of recycle compressor failure, or other failures that could result in liquid nitrogen reaching the reactor itself. The major drawback of cold gas systems is that the time it takes to perform the cool down to the customer's satisfaction, and the nitrogen usage—both of which offer an opportunity to create value for the customer through novel solutions.

SUMMARY

One embodiment of a reactor liquid cool down method includes obtaining a warm recycle stream (102) from a reactor (101) and compressing the warm recycle stream (102), thereby producing a compressed warm recycle stream (104); mixing a compressed warm recycle stream (104) with a controlled liquid cryogen stream (110) in a stainless steel mixing zone (107), thereby producing a cool recycle stream (112), wherein the cool recycle stream has a mean fluid temperature, monitoring the mean fluid temperature and comparing the mean fluid temperature to a predetermined control valve set point, thereby defining a temperature deviation; modulating a temperature control valve (109) to vary the controlled liquid cryogen stream (110) in order to produce a temperature deviation that is less than a predetermined value, and returning the cool recycle stream (112) to the reactor (101).

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a schematic representation of one embodiment of the present invention.

DESCRIPTION OF PREFERRED EMBODIMENTS

Illustrative embodiments of the invention are described below. While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the invention to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.

It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developer's specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.

The proposed solution may include a stainless piping skid that may be mounted on a non-DOT trailer (capable of being pulled by non-DOT pickup trucks). The customer's entire recycle stream is redirected through temporary piping into the skid, where liquid nitrogen could be injected without risk to the customer's piping.

The skid would include automatic bypass and isolation valves as well as a temperature control valve and multiple thermocouples (for voting purposes). The customer's stream would enter the skid through the first isolation valve. After a sufficient length of pipe to ensure adequate mixing, the combined stream would pass over three thermocouples before exiting the skid through the second isolation valve back Into the customer's piping.

The thermocouples would be used to isolate and bypass the skid in the event a predetermined low temperature limit was reached (to be agreed upon with the customer—2 out of 3 voting). The liquid nitrogen would enter the piping via a temperature control valve—the thermocouples would also be used as the control point (also to be agreed upon with the customer). Liquid nitrogen pressure would be provided by a small mobile nitrogen pumping and vaporization unit or simply the centrifugal pump on the liquid nitrogen transport. The skid would be controlled by a simple PLC. Power and air would be provided by the transport or pumper. In this manner, customers with incompatible piping in their existing system would be able to enjoy the benefits of liquid cooldown.

Turning to FIG. 1, reactor 101 is to be cooled down. In one embodiment of the present invention, warm recycle stream 102 is removed from reactor 101 and introduced into compressor 103. Compressed warm recycle stream 104 may pass through first isolation valve 106, after which it enters stainless steel mixing zone 107. Liquid cryogen stream 108 enters temperature control valve 109, thus generating controlled liquid nitrogen stream 110, which then enters stainless steel mixing zone 107. Liquid cryogen stream 108 may be any compatible cryogen known in the art. Liquid cryogen stream 108 may be liquid nitrogen.

Compressed warm recycle stream 104 and controlled liquid nitrogen stream 110 are mixed within stainless steel mixing zone 107, thereby producing cool recycle stream 112, which exhibits a mean fluid temperature. If the temperature of warm recycle stream 102 deviates from a predetermined temperature, compressed warm recycle stream 104 may be bypassed through line 115 and normally closed valve 105.

Temperature sensor 111 senses the mean fluid temperature, and transfers this temperature information to temperature control valve 109. In one embodiment of the present invention, three temperature sensors (111A, 111B, 111C) are used, thereby allowing the voting of two out of three, in order to improve reliability and accuracy. The mean temperature is compared to a predetermined temperature control valve set point. Temperature control valve 109 then adjusts controlled liquid nitrogen stream 110 in order to bring the mean temperature closer to the predetermined temperature control valve set point.

Stainless steel mixing zone is of sufficient length to obtain the proper mixing of controlled liquid nitrogen stream 110 and compressed warm recycle stream 104. For example, if natural turbulence is the sole mixing mechanism, as many as 100 diameters of mixing length may be necessary. If one or more static mixer is used, then less than 10 diameters will be necessary, preferably between 4 and 6 diameters, more preferably 5 diameters. Once the mixing is complete, cool recycle stream 112 passes through second isolation valve 113 and is returned to reactor 101.

A reactor liquid cool down method, comprising;

• • obtaining a warm recycle stream (102) from a reactor (101) and compressing the warm recycle stream (102), thereby producing a compressed warm recycle stream (104),
  • mixing the compressed warm recycle stream (104) with a controlled liquid cryogen stream (110) in a mixing zone (107), thereby producing a cool recycle stream (112), wherein the cool recycle stream has a mean fluid temperature,
  • monitoring the mean fluid temperature and comparing the mean fluid temperature to a predetermined control valve set point, thereby defining a temperature deviation,
  • modulating a temperature control valve (109) to vary the controlled liquid cryogen stream (110) in order to produce a temperature deviation that is less than a predetermined value, and
  • returning the cool recycle stream (112) to the reactor (101).

The reactor liquid cool down method as described above, further comprising;

• • monitoring a first mean fluid temperature of the warm recycle stream (102),
  • closing the temperature control valve (109), closing a first valve (106), a closing second valve (113), and opening a bypass valve (105) if the first mean fluid temperature is less than a predetermined minimum temperature,
    wherein the first valve (106) and the second valve (113) isolate the stainless steel mixing zone, and
    wherein the bypass valve (105) allows the warm recycle stream (102) to return to the reactor (101).

The reactor liquid cool down method as described above, wherein the mixing zone (107) is stainless steel.

The reactor liquid cool down method as described above, wherein the mean fluid temperature is monitored by temperature indicators.

The reactor liquid cool down method as described above, further comprising at least three temperature indicators, wherein a two out of three voting protocol is utilized.

The reactor liquid cool down method of as described above, wherein the liquid cryogen is liquid nitrogen.

Claims

1. A reactor liquid cool down method, comprising;

obtaining a warm recycle stream from a reactor and compressing the warm recycle stream, thereby producing a compressed warm recycle stream,

mixing the compressed warm recycle stream with a controlled liquid cryogen stream in a mixing zone, thereby producing a cool recycle stream, wherein the cool recycle stream has a mean fluid temperature,

monitoring the mean fluid temperature and comparing the mean fluid temperature to a predetermined control valve set point, thereby defining a temperature deviation,

modulating a temperature control valve to vary the controlled liquid cryogen stream in order to produce a temperature deviation that is less than a predetermined value, and

returning the cool recycle stream to the reactor.

2. The reactor liquid cool down method of claim 1, further comprising; wherein the first valve and the second valve isolate the stainless steel mixing zone, and wherein the bypass valve allows the warm recycle stream to return to the reactor.

monitoring a first mean fluid temperature of the warm recycle stream,

closing the temperature control valve, closing a first valve, a closing second valve, and opening a bypass valve if the first mean fluid temperature is less than a predetermined minimum temperature,

3. The reactor liquid cool down method of claim 1, wherein the mixing zone is stainless steel.

4. The reactor liquid cool down method of claim 1, wherein the mean fluid temperature is monitored by temperature indicators.

5. The reactor liquid cool down method of claim 4, further comprising at least three temperature indicators, wherein a two out of three voting protocol is utilized.

6. The reactor liquid cool down method of claim 1, wherein the liquid cryogen is liquid nitrogen.