Abstract: Method for treating particulate used oil-coated catalysts to provide a rejuvenated catalyst material in a rejuvention vessel assembly. The pressurizable vertically-oriented vessel assembly has inlet and outlet openings for the catalyst and washing fluids, and has a removable lower sub-assembly head portion which contains a conical shaped grid unit located therein. The vessel assembly is arranged to permit solvent washing, vacuum drying and acid treatment and gas drying of the used catalyst in a bed supported above the conical grid, by upward flow and recycle of the washing liquids and fluidization of the catalyst. Following rejuvenation of the catalyst, it is withdrawn from the vessel downwardly through the conical shaped grid and out through a central withdrawal conduit containing a slide valve unit for further processing or use as desired.

Abstract: A catalyst rejuvenation vessel assembly for treating particulate used oil-coated catalysts to provide a rejuvenated catalyst material is disclosed. A pressurizable vertically-oriented vessel assembly has inlet and outlet openings for the catalyst and washing fluids, and has a removable lower sub-assembly head portion which contains a conical shaped grid unit located therein. The vessel assembly is arranged to permit solvent washing, vacuum drying and acid treatment and gas drying of the used catalyst in a bed supported above the conical grid, by upward flow and recycle of the washing liquids and fluidization of the catalyst. Following rejuvenation of the catalyst, it is withdrawn form the vessel downwardly through the conical shaped grid and out through a central withdrawal conduit containing a slide valve unit for further processing or use as desired.

Abstract: An improved grid plate flow distributor assembly for use in a pressurized catalytic reactor in which gas and liquid materials flow uniformly upwardly through the grid into the reactor ebullated catalyst bed. The grid plate assembly contains multiple vertical flow tubes each covered at its upper end by a cap which is spaced outwardly from the tube upper end and preferably has tapered sides. The cap can have any horizontal cross-sectional shape, such as circular, polygonal, rectangular or triangular. If desired, a horizontal elongated cap can be used which covers at least two adjacent vertical flow tubes. Such elongated caps can be provided as concentric circular shapes above the grid plate. Also, if desired, a thermocouple can be provided extending upwardly above the cap, such as through selected caps to monitor the temperature distribution of the ebullated bed above the grid plate assembly.

Abstract: A staged distribution grid assembly and method for uniform fluid flow distribution upwardly into an ebullated catalyst bed of a reactor. In the staged grid assembly, the gas and liquid mixture flows first through a lower secondary flow distribution grid plate into an interim zone and then flows upwardly through an upper primary flow distribution grid plate into the reactor ebullated bed. The staged grid assembly contains an upper primary grid plate containing multiple flow tubes covered by bubble caps, and a lower secondary grid plate containing multiple flow tubes. The staged flow distribution grid assembly enables the primary grid to provide a more uniform distribution of gas and liquid flow upwardly into the ebullated bed across the entire cross-sectional area of the reactor, and thereby provides improved operation of the ebullated catalyst bed reactor.

Abstract: A method for adding and removing fine particles from a pressurized reactor is provided, which comprises connecting the reactor to a container, sealing the container from the reactor, filling the container with particles and a liquid material compatible with the reactants, pressurizing the container to substantially the reactor pressure, removing the seal between the reactor and the container, permitting particles to fall into or out of the reactor, and resealing the container from the reactor. An apparatus for adding and removing particles is also disclosed.

Abstract: A process and pressurized, gasification reactor apparatus for converting combustible carbon containing materials such as coal char and other carbonaceous solids or carbonaceous solids/heavy oil combinations to an intermediate heating value fuel gas. The gasification reactor includes an insulated fluidized bed reactor chamber, an upper reactor housing for a freely suspended bayonet bundle type heat exchanger for (a) superheating incoming saturated steam and (b) cooling outgoing high temperature product gas, and a lower reactor housing structure which includes a free-floating, conically-shaped perforated plenum chamber. The superheated steam and oxygen are premixed with the plenum chamber before being pressure directed into the fluidized bed reactor chamber for mixture and combustion with the incoming combustible carbon containing materials such as coal char. After reaction of the superheated steam, oxygen and coal char in the fluidized bed reactor at temperatures ranging from 900.degree. F. to 1750.degree. F.