WO2026006262A1 - Chemical processing vessels that include support assemblies and methods of using the same - Google Patents

Abstract

A chemical processing vessel may include one or more side walls defining a main interior space, a beam positioned within the main interior space, and a support assembly coupled to one or more of the one or more side walls. The beam may include a body extending in a substantially horizontal dimension. The body may extend from a first end to a second end. Also disclosed herein are methods of using such chemical processing vessels.

Description

CHEMICAL PROCESSING VESSELS THAT INCLUDE SUPPORT ASSEMBLIES AND METHODS OF USING THE SAME

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to U.S. Provisional Application Serial No. 63/665,530 filed June 28, 2024, the entire disclosure of which is hereby incorporated by reference.

FIELD

[0002] The embodiments described herein generally relate to chemical processes and, more particularly, to equipment utilized in chemical processes.

BACKGROUND

[0003] Reactor vessels may include mechanical components that are housed within the vessels, commonly referred to as “internals” in industry. For example, in fluidized bed reactors, bubble breakers such as gratings may be utilized as internals, which aid in breaking bubbles that form in the solid particulate fluidized bed. Such internals must be adequately mechanically supported within the vessels, which can be challenging due to the fact that internals may be heavy and large, and that internals may significantly thermally expand during exposure to normal chemical processing temperatures.

SUMMARY

[0004] Some processing vessels, in which fluidized bed operation may take place, may utilize internal structures (e.g., gratings acting as bubble breakers) that need to be supported by beams that may run across the interior region of the processing vessel. Such beams may be supported by support assemblies that are coupled to sidewalls of the processing vessels. As is described herein, in some embodiments, there may be a propensity for coking on or around the support assemblies. In operating conditions that generate coke in the processing vessel, it has been observed that conventional support assemblies may be particularly susceptible to coking. Coke build-up is unwanted and may cause process irregularities and eventual need for process shutdown to clean out the coke, which will generally reduce efficiency for making chemical products. [0005] In some conventional embodiments, the support assemblies may be relatively non- aerodynamic and cause gas flow to stagnate at or around the support assemblies. It is believed that this gas stagnation promotes coke build-up over time. As is described herein, it has been discovered that coke buildup may be reduced by utilizing support assemblies that have a relatively large open areas through which gases may pass. Such support assembly configurations may, unexpectedly, reduce coke buildup in the processing vessel.

[0006] According to some additional conventional embodiments, the beams and support assemblies may contact one another along relatively large planar surfaces. It has been observed that such areas may promote coke build-up over time. As is also described herein, it has been discovered that coke buildup may be reduced by utilizing support assemblies and/or beams that are non-planar at their contact points. Such a non-planar configuration may, unexpectedly, reduce coke buildup in the processing vessel. According to one or more embodiments of the present disclosure, a chemical processing vessel may include one or more side walls defining a main interior space and a beam positioned within the main interior space. The beam may include a body extending in a substantially horizontal dimension, the body extending from a first end to a second end. The chemical processing vessel may further include a support assembly coupled to one or more of the one or more side walls. The support assembly may include a beam-supporting member that contacts and supports the beam at or near the first end of the beam. The support assembly may have an open area of at least 50% at all horizontal cross-sections along a height of the support assembly. The open area at each height of the support assembly may be a ratio of a cross-sectional open area of the support assembly to a cross-sectional area of the smallest rectangle drawn around the cross-sectional area of the support assembly.

[0007] According to one or more embodiments of the present disclosure, a chemical processing vessel may comprise one or more side walls defining a main interior space, a beam positioned within the main interior space, and a support assembly coupled to one or more of the one or more side walls. The beam may comprise a body extending in a substantially horizontal dimension. The body may extend from a first end to a second end. The support assembly may comprise a beam-supporting member that contacts and supports the beam at or near the first end of the beam. The support assembly may have an open area of at least 50% at all horizontal crosssections along a height of the support assembly. The open area at each height of the support assembly may be a ratio of a cross-sectional open area of the support assembly to a cross-sectional area of the smallest rectangle drawn around the cross-sectional area of the support assembly. [0008] According to one or more additional embodiments of the present disclosure, a method for chemical processing may comprise contacting a reactant with fluidized particles in a chemical processing vessel. The fluidized particles may comprise a fluidized bed flow regime, and coke may be generated in the chemical processing vessel. The chemical processing vessel may comprise one or more side walls defining a main interior space, a beam positioned within the main interior space, and a support assembly coupled to one or more of the one or more side walls. The beam may comprise a body extending in a substantially horizontal dimension. The body may extend from a first end to a second end. The support assembly may comprise a beam-supporting member that contacts and supports the beam at or near the first end of the beam. The support assembly may have an open area of at least 50% at all horizontal cross-sections along a height of the support assembly. The open area at each height of the support assembly may be a ratio of a cross-sectional open area of the support assembly to a cross-sectional area of the smallest rectangle drawn around the cross-sectional area of the support assembly.

[0009] According to one or more yet additional embodiments of the present disclosure, a chemical processing vessel may comprise one or more side walls defining a main interior space, a beam positioned within the main interior space, and a support assembly coupled to one or more of the one or more side walls. The beam may comprise a body extending in a substantially horizontal dimension. The body may extend from a first end to a second end. The support assembly may comprise a beam-supporting member that at least partially contacts and supports the beam at or near the first end of the beam. The beam-supporting member may comprise a beamcontacting surface that is in direct contact with the beam. The beam may comprise a support assembly-contacting surface that is in direct contact with the beam-supporting member. One or both of the support assembly-contacting surface of the beam may be non-planar, or the beamcontacting surface of the beam-supporting member is non planar.

[0010] According to one or more yet additional embodiments of the present disclosure, a method for chemical processing may comprise contacting a reactant with fluidized particles in a chemical processing vessel. The fluidized particles may comprise a fluidized bed flow regime, and coke may be generated in the chemical processing vessel. The chemical processing vessel may comprise one or more side walls defining a main interior space, a beam positioned within the main interior space, and a support assembly coupled to one or more of the one or more side walls. The beam may comprise a body extending in a substantially horizontal dimension. The body may extend from a first end to a second end. The support assembly may comprise a beam-supporting member that at least partially contacts and supports the beam at or near the first end of the beam. The beam-supporting member may comprise a beam-contacting surface that is in direct contact with the beam. The beam may comprise a support assembly-contacting surface that is in direct contact with the beam-supporting member. One or both of the support assembly-contacting surface of the beam may be non-planar, or the beam-contacting surface of the beam-supporting member is non planar.

[0011] These and other features, and characteristics of the present technology, as well as the methods of operation and functions of the related elements of structure and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following description and the appended claims with reference to the accompanying drawings, all of which form a part of this specification, wherein like reference numerals designate corresponding parts in the various figures. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the invention. As used in the specification and in the claims, the singular form of 'a', 'an', and 'the' include plural referents unless the context clearly dictates otherwise.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The following detailed description of specific embodiments of the present disclosure can be best understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which:

[0013] FIG. 1 A schematically depicts a front cross-sectional view of a chemical processing vessel, according to one or more embodiments illustrated and described herein;

[0014] FIG. IB schematically depicts a perspective view of the interior of the chemical processing vessel of FIG. 1 A, according to one or more embodiments illustrated and described herein;

[0015] FIG. 2A schematically depicts a top-view of a cross-sectional open area of a support, according to one or more embodiments illustrated and described herein;

[0016] FIG. 2B schematically depicts a cross-sectional area of the smallest rectangle drawn around the cross-sectional area of the support assembly of FIG. 2A, according to one or more embodiments illustrated and described herein; [0017] FIG. 3 A schematically depicts a perspective view of a grating that includes a plurality of rectangular openings, according to one or more embodiments illustrated and described herein;

[0018] FIG. 3B schematically depicts a perspective view of a grating that includes a plurality of parallelogram-shaped openings, according to one or more embodiments illustrated and described herein;

[0019] FIG. 4 schematically depicts a perspective view of a beam and a support assembly, according to one or more embodiments illustrated and described herein;

[0020] FIG. 5A schematically depicts a first perspective view of a beam and a support assembly, according to one or more embodiments illustrated and described herein;

[0021] FIG. 5B schematically depicts a second perspective view of the beam and support assembly of FIG. 4A, according to one or more embodiments illustrated and described herein

[0022] FIG. 6 schematically depicts an perspective view of a beam and a support assembly with a rod, according to one or more embodiments illustrated and described herein;

[0023] FIG. 7A schematically depicts a perspective view of a beam and a support assembly with a rod and pins, according to one or more embodiments illustrated and described herein;

[0024] FIG. 7B schematically depicts a perspective view of another beam and a support assembly with a rod and pins, according to one or more embodiments illustrated and described herein; and

[0025] FIG. 8 schematically depicts a perspective view of a chevron.

[0026] It should be understood that the drawings are schematic in nature, and do not include some components of a fluid catalytic reactor system commonly employed in the art, such as, without limitation, temperature transmitters, pressure transmitters, flow meters, pumps, valves, and the like. It would be known that these components are within the spirit and scope of the present embodiments disclosed. However, operational components, such as those described in the present disclosure, may be added to the embodiments described in this disclosure. [0027] Reference will now be made in greater detail to various embodiments, some embodiments of which are illustrated in the accompanying drawings. Whenever possible, the same reference numerals will be used throughout the drawings to refer to the same or similar parts.

DETAILED DESCRIPTION

[0028] Embodiments described herein are generally directed to chemical processing vessels and methods for their use. The chemical processing vessels described herein include beams and support assemblies that support the beams, where the beams may support reactor internals such as gratings or chevrons. The present embodiments, as described herein, may reduce coking, especially in conditions where coking is prominent and causes reduced process efficiencies, such as reactions operating at relatively high temperatures in the presence of hydrocarbons. Moreover, while the present embodiments may be useful in coking reactions, the presently disclosed embodiments of chemical processing vessels may be utilized in reactions that do not produce appreciable amounts of coke or where coking is not of major concern.

[0029] Now referring to FIG. 1A, one embodiment of a chemical processing vessel 100 is schematically depicted in a cross-sectional view. FIG. IB additionally depicts a portion of the embodiment of FIG. 1A but from a perspective view compared to that of FIG. 1A. This embodiment is not the only contemplated embodiment, and it should be understood that those skilled in the art may generalized the teachings with respect to FIG. 1 A and FIG. IB, and various modifications and variations can be made to the described embodiments of FIG. 1A and FIG. IB.

[0030] The chemical processing vessel 100 of FIG. 1A includes side walls 102, and the side walls 102 define amain interior space 104. The side walls 102 may form a cylindrical main interior space 104. According to embodiments, a feed stream of reactants and a fluidized particulate may each move upwardly through the chemical processing vessel 100 and each may exit upwardly through a frustum as depicted.

[0031] Referring now to both FIGS. 1A and IB, a beam 106 is placed within the main interior space 104 and includes a beam body 108 extending in a substantially horizontal direction. The beam body extends from a first end 110 to a second end 112 (as depicted in FIG. IB). The main interior space 104 also includes a support assembly 114 coupled to one or more of the side walls 102. The support assembly 114 includes a beam-supporting member 116 that contacts and supports the beam 106 at or near the first end 110 of the beam 106. As described herein, it should be understood that “substantially vertical” and “substantially horizontal” are intended to include directions or planes that are not completely vertical or horizontal, such as directions or planes 1 degree, 2 degrees, 3 degrees, 4 degrees, or even 5 degrees off of horizontal or vertical.

[0032] As is described in more detail herein, the support beam may include an open area 118 of at least 50% (or even at least 75%) at all horizontal cross-sections along a height of the support assembly 114. The open area 118 at each height of the support assembly is a ratio of a cross-sectional open area 105 (depicted in FIG. 2 A) of the support assembly 114 to a cross- sectional area of the smallest rectangle 107 (depicted in FIG. 2B) drawn around the cross-sectional area of the support assembly 114 (as explained further below). Without being bound by theory, it is believe that an open area 118 of at least 50% significantly reduces the propensity for coke buildup on or around the support assembly 114. It is believed that, and has been observed, that having an open area 118 of less than 50% (similar or identical to conventional embodiments) may promote undesirable coking. Embodiments with even larger open area 118, such as at least 75%, may even further promote fluid flow and reduce coking.

[0033] The chemical processing vessel 100 includes the side walls 102 that define the main interior space 104. The side walls 102 making up the chemical processing vessel 100 may be side walls of a vessel, drum, barrel, vat, or any other container suitable for a given chemical reaction, such that the chemical processing vessel 100 may be any of these geometric configurations. As described in greater detail herein, the chemical processing vessel 100 may operate as a fluidized bed reactor. The side walls 102 may be made up of metal or any other suitable material for withstanding temperatures of up to, from example, 925 °C within the main interior space 104, and optionally may be coated with refractory materials for heat management. Various components may be positioned within the main interior space 104, as is described herein.

[0034] The beam 106 is positioned within the main interior space 104. While FIG. IB depicts six beams 106 within the main interior space 104, it should be understood that any number of beams 106 may be placed within the main interior space 104, depending on the size and shape of the chemical processing vessel 100. The beam 106 may substantially lie in the horizontal plane. The substantially horizontal plane is defined by the x-y axes of FIG. 1. The beam 106 may be used to support various structures within the main interior space 104, such as an internal structure 120. [0035] The internal structure 120, such as a grating tray 122 (depicted in FIG. 3 and discussed further herein below), may also lie substantially in the horizontal plane. The internal structure 120 may function to break up a plurality of fluidized gas bubbles flowing in a vertical direction defined by the z-axis by allowing for restricted passage of fluids. The internal structure 120 may function to redistribute a flow of the plurality of fluidized gas bubbles to prevent maldistribution of solids of the fluidized bed. The internal structure 120 may also reduce back-mixing of a catalyst emulsion phase and gases entrained in the catalyst emulsion phase. The internal structure 120 may be made of metal or any other suitable material capable of withstanding reaction temperatures within the main interior space 104 of the chemical processing vessel 100. In some embodiments, a plurality of internal structures 120 are positioned along multiple vertical elevations along the z-axis; the plurality of the internal structures 120 may be spaced vertically with a distance of 2 feet to 6 feet apart. As such, there may be one, two, three four, or more layers of internal structures 120 positioned along multiple vertical elevations along the z-axis.

[0036] According to additional embodiments, the internal structure 120 supported by the beams 106 may be a wide variety of reactor internals such as, without limitation, sensors, structured packing, baffles, heat exchangers, sampling ports, agitators, and the like.

[0037] In one or more embodiments, the internal structure 120 may include a grating tray 122. Examples of grating trays 122 are depicted in FIGS. 3A and 3B. The grating tray 122 may include a plurality of openings 136, although other geometries for bubble breaking or solids distribution are contemplated herein. The plurality of openings 136 may be through a substantially horizontal surface portion of the grating tray 122 in the substantially horizontal plane, defined by the x-y axes of FIG. 3 A. The plurality of openings 136 may include from 30% to 95% of the horizontal surface portion of the grating tray 122. The plurality of openings 136 may make up a square, rectangular, hexagonal, honeycomb, or any other suitable pattern. As an exemplary embodiment, FIG. 3 A depicts a rectangular plurality of openings 136a and FIG. 3B depicts a diamond plurality of openings 136b. The plurality of openings 136 may be from 0.5 inches to 10 inches in width or diameter, or from 1 inch to 4 inches in width or diameter, such that the plurality of openings 136 are smaller in width or diameter than the plurality of fluidized gas bubbles; thus, the plurality of openings 136 may break up the plurality of fluidized gas bubbles flowing in the vertical direction defined by the z-axis in FIG. 3 A. The internal structure 120, such as the grating tray 122, are supported by the beam 106. [0038] Referring now to FIG. 8, the internal structure 120 may also include a chevron 150. The chevron 150 may include a first end 152 and a second end 154 opposite from the first end 152. The first end 152 and the second end 154 of the chevron 150 may be in contact with the beam 106, such that the chevron 150 is supported by the beam 106 on the first end 152 and the second end 154. The chevrons 150 may break up the plurality of fluidized gas bubbles flowing in the vertical direction defined by the z-axis in FIG. 3A.

[0039] Referring to FIG. 4, the beam 106 may be an I-beam 128. The I-beam 128 includes a top flange 127, a bottom flange 129, and a web 131, such that the top flange 127 and the bottom flange 129 provide resistance against bending or buckling. The I-beam 128 may be made of structural steel, aluminum, stainless steel (304H, 347H, 321H), alloy 800H or any other suitable material. The internal structure 120 may rest on the bottom flange 129.

[0040] The internal structure 120 may span from one side wall 102 to another side wall 102, and may be contoured in shape to the arrangement of the side walls 102. Without use of beams 106, the internal structure 120 may bend under a weight of the internal structure 120 when spanning the side walls 102, or may not be able to be supported at all with perimeter attachments directly to the side walls 102. Thus, to prevent deformation of the internal structure 120, the beam 106 supports the internal structure 120. The beam 106 may support the internal structure 120 in a variety of manners. In some embodiments, the internal structure 120 may rest on the bottom flange 129 between each web 131 of the beam 106. In other embodiments, the internal structure 120 may rest on the top flange 127. In some embodiments, there may be two or more internal structures 120 supported by the beam 106, such that the internal structures 120 are positioned along multiple vertical elevations along the z-axis of the beam 106. The beam 106 may also function to break up the plurality of fluidized gas bubbles flowing in the vertical direction defined by the z-axis.

[0041] Referring again to FIG. 1 B, the beam 106 is positioned within the main interior space 104 of the chemical processing vessel 100. The beam 106 includes the body 108 and opposite ends of the body 108. For example, the body 108 of the beam 106 extends from the first end 110 to the second end 112. Each of the first end 110 and the second end 112 may be coupled to the side walls 102 via the support assembly 114.

[0042] The support assembly 114 may be coupled to the side walls 102. The support assembly includes the beam-supporting member 116 that contacts/supports the beam 106 at or near the first end 110 and/or the second end 112 of the beam 106. The beam 106 may be coupled to the support assembly 114 in a variety of manners. As depicted in FIG. 4, the support assembly 114 may couple the beam 106 to the side wall 102 through welding, bolting, or any other suitable coupling means.

[0043] As depicted in FIG. 5 A and FIG. 5B, the first end 110 and the second end 112 of the beam 106 may rest on the support assembly 114 freely. As such, the beam 106 may sidingly engage the beam-supporting member 116. This may allow for thermal expansion of the beam 106 during chemical processes taking place within the interior space 104 of the chemical processing vessel 100, such as at elevated temperatures of greater than 500 °C. Thermal expansion of the beam 106 in the horizontal direction may be several inches or more. As such, the beam 106 may expand toward the side wall 102 when the beam 106 is heated, slidingly engaging the beamsupporting member 116. In embodiments, the first end 110 of the beam may be fixed to the beamsupporting member 116, while the second end 112 of the beam 106 slidingly engages the beamsupporting member 116. The beam 106 may slide within the open area 118 of the support assembly 114 in a variety of manners. While not depicted in FIG. IB, in some embodiments both ends of the beam 106 may utilize support members that slideably engage with the beam 106.

[0044] The beam 106 may slide within the open area 118 of the support assembly by direct contact of the beam 106 and the beam-supporting member 116. In embodiments, the bottom flange 129 and the top flange 127 of the I-beam may slide within the beam-supporting member 116. The beam may include beam sliding components 130 that are connected to the beam 106. The beam sliding components 130 may slidingly engage the beam-supporting member 116, such that the beam slides on the beam-supporting member 116 through the beam sliding components 130. The beam sliding components 130 may be on a top, bottom, or sides of the beam 106.

[0045] The beam-supporting member 116 may include beam-supporting member sliding components 132 that slidingly engage the beam 106. The beam-supporting member sliding components 132 may slidingly engage the beam 106 directly, or the beam-supporting member sliding components 132 may engage the beam sliding components 130 of the beam 106.

[0046] As depicted in FIG. 5 A and FIG. 5B, the beam-supporting member 116 may include a support rod 126 extending in the substantially horizontal direction, such that the support rod 126 contacts the beam 106 or the beam sliding components 130. As such, the support rod 126 of the beam-supporting member 116 may act as the beam sliding components 130. The support rod 126 may contact the top and bottom of the beam 106, or only the bottom or top of the beam 106. The support rod 126 allows for a lessened contact surface between the beam 106 and the beamsupporting member 116. Use of the support rod 126 reduces friction between the beam 106 and the beam-supporting member 116, allowing the beam 106 to slide more easily within the beamsupporting member 116 and reducing coke build up at the point where the beam 106 contacts the beam-supporting member 116. The support rod 126 may also reduce the open area 118 of the support assembly 114, which also reduces coke build up at the point where the beam 106 contacts the beam-supporting member 116, as explained further below.

[0047J Referring now to FIG 2, the open cross-sectional open area 105 of the support assembly 114 is depicted in FIG. 2 A, while the smallest rectangle 107 drawn around the cross- sectional area of the support assembly 114 is depicted in FIG. 2B. As noted hereinabove, the support assembly 114 may have the open area 118. The open area 118 may be at least 50% at all horizontal cross-sections along a height of the support assembly 114. The open area 118 at each height of the support assembly 114 is defined by the ratio of the open cross-sectional open area 105 of the support assembly 114 to a cross-sectional area of the smallest rectangle 107 drawn around the cross-sectional area of the support assembly 114. In embodiments, the support assembly 114 may have an open area 118 of at least 40%, at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, or at least 95%. It is noted that the smallest rectangle 107 drawn around the cross-sectional area of the support assembly 114 includes both structures of the support assembly 114 (such as the support rod 126) and the open cross-sectional area 105.

[0048] Referring now to FIG. 6, the beam 106 may also include a beam rod 124 extending in the substantially horizontal direction, such that the beam rod 124 contacts the beam-supporting member 116 or a beam-contacting surface 134. There may be a top beam rod 124 A and a bottom beam rod 124B, such that each of the top beam rod 124A and the bottom beam rod 124B contact or have a minimal clearance with the beam-supporting member 116 or the beam-contacting surface 134. The top beam rod 124A and the bottom beam rod 124B may secure the beam 106 within the support assembly 114, such that when the chemical processing vessel 100 is being utilized, the beam 106 stays within the support assembly 114. Use of the beam rod 124 reduces friction between the beam 106 and the beam-supporting member 116, allowing the beam 106 to slide more easily within the beam-supporting member 116 and reducing coke build up at the point where the beam 106 contacts the beam-supporting member 116. Without being bound by any theory, it is believed that planar surfaces of beam 106 to support assembly 114 may have a propensity for coking which may develop over continued reaction time. The curved surface and “point” contact between the beam 106 and the support assembly 114 may reduce contact area and lower propensity for coking.

[0049] Referring now to FIG. 7 A and FIG. 7B, either or both of the top beam rod 124A and the bottom beam rod 124B may include pins 140. The pins 140 may further secure the beam 106 within the support assembly 114. The pins 140 may prevent the beam 106 from moving in the substantially horizontal direction. The beam rod 124 may contact the beam-supporting member 116 in a variety of manners. The beam-supporting member 116 may contact the beam rods 124 at or near ends of the beam rods 124 or near a center of the beam rods 124, as depicted in FIG. 7 A and FIG. 7B, respectively.

[0050] Referring again to FIG. 6, the beam-supporting member 116 may include a beamcontacting surface 134 that is in direct contact with either the beam 106 or the beam sliding components 130. The beam 106 may further include a support assembly-contacting surface 137 that is in direct contact with either the beam-supporting member 116 or the beam-contacting surface 134. Either or both of the beam-contacting surface 134 of the beam-supporting member 116 or the support assembly-contacting surface 137 of the beam 106 may be non-planar. As such, the beam-contacting surface 134 of the beam-supporting member 116 or the support assemblycontacting surface 137 of the beam 106 may be rounded. This may allow for the beam 106 to slide easily within the beam-supporting member 116. This may also reduce the contact area between the beam and the beam-supporting member 116, reducing coke buildup where the beam 106 contacts/slidingly engages the beam-supporting member 116. Such arrangements may utilize only a “point” contact or “line contact” between the parts, reducing areas where coke may have a propensity for building up.

[0051] Additional embodiments disclosed herein are directed to methods for chemical processing which utilize the chemical processing vessels presently disclosed. The methods may include contacting a reactant with fluidized particles in the chemical processing vessel. As described herein, the fluidized particles may comprise a fluidized bed flow regime. In additional embodiments, the vessel 100 may be used as a regeneration unit for, for example, removing coke for a solid particulate and/or heating a solid particulate. [0052] In one or more embodiments, based on the shape, size, flows of gases, and other processing conditions (such as temperature and pressure) in chemical processing vessel 100, the chemical processing vessel 100 may operate as a fluidized bed, referred to herein as a fluidized bed flow regime. As is understood by those in the art, fluidized bed flow regime generally occurs when a solid particulate substance is under the right conditions so that it behaves like a fluid. The usual way to achieve a fluidized bed is to pump pressurized fluid into the particles. According to various embodiments, the fluidized bed regime may be classified as a fast fluidized, turbulent, or bubbling bed fluidization. As described herein, a “fast fluidized” reactor may refer to a reactor utilizing a fluidization regime wherein the superficial velocity of the gas phase is greater than the choking velocity and may be semi-dense in operation. As described herein, a “turbulent” reactor may refer to a fluidization regime where the superficial velocity of less than the choking velocity and is more dense than the fast fluidized regime. As described herein, a “bubbling bed” reactor may refer to a fluidization regime wherein well defined bubbles in a highly dense bed are present in two distinct phases. The “choking velocity” refers to the minimum velocity required to maintain solids in the dilute-phase mode in a vertical conveying line.

[0053] It is contemplated herein that the fluidized particulates may be solid catalysts or non- catalytic solids such as, for example, materials capable of carrying oxygen. In non-limiting examples, the chemical processing vessel 100 described herein may be utilized to produce light olefins from hydrocarbon feed streams, such as propylene from propane or ethylene from ethane. Light olefins may be produced from a variety of hydrocarbon feed streams by utilizing different reaction mechanisms. For example, light olefins may be produced by at least dehydrogenation reactions, cracking reactions, dehydration reactions, and methanol-to-olefin reactions. These reaction types may utilize different feed streams and different catalytic particulate solids to produce light olefins.

[0054] According to one or more embodiments, the contacting of the reactant with the fluidized particles may be at relatively high temperatures, which may promote coking. For example, reactor temperatures may be at least 500 °C, at least 550 °C, at least 600 °C, at least 650 °C, at least 700 °C, at least 750 °C, at least 800 °C, at least 850 °C, or even at least 900 °C.

[0055] According to some embodiments, the chemical processing may comprise a dehydrogenation reaction that utilizes circulating a catalyst between the chemical processing vessel 100 and a regeneration unit, where alkanes are converted to alkenes in the chemical processing vessel 100 and where the catalyst is heated by a supplemental fuel in the regeneration unit. Such a process may convert propane to propylene, such as is described in U.S. Pat. No. 10,227,271, the entirety of which is incorporated by reference in this disclosure.

[0056] In additional embodiments, chemical processing may comprise a dehydrogenation reaction that utilizes circulating a solid particulate oxygen carrier material between the chemical processing vessel 100 and a regeneration unit, where alkanes are converted to alkenes in the chemical processing vessel 100 by thermal dehydrogenation, and where the produced hydrogen gas is converted to water by contact with oxygen released from the oxygen carrier material. Such a process may convert ethane to ethylene, such as is described in WO 2024/059554 Al, the entirety of which is incorporated by reference in this disclosure.

[0057] In additional embodiments, chemical processing may comprise a dehydrogenation reaction that utilizes circulating both a catalyst and a solid particulate oxygen carrier material between the chemical processing vessel 100 and a regeneration unit, where alkanes are converted to alkenes in the chemical processing vessel 100 by catalytic dehydrogenation, and where the produced hydrogen gas is converted to water by contact with oxygen released from the oxygen carrier material. Such a process may convert ethane to ethylene, such as is described in U.S. Patent No. 11,724,974, the entirety of which is incorporated by reference in this disclosure.

[0058] In some embodiments, the fluidized particulates may exhibit properties known in the industry as “Geldart A” or “Geldart B” properties. Particles may be classified as “Group A” or “Group B” according to D. Geldart, Gas Fluidization Technology, John Wiley & Sons (New York, 1986), 34-37; and D. Geldart, “Types of Gas Fluidization,” Powder Technol. 7 (1973) 285-292, which are incorporated herein by reference in their entireties.

[0059] Group A is understood by those skilled in the art as representing an aeratable powder, having a bubble-free range of fluidization; a high bed expansion; a slow and linear deaeration rate; bubble properties that may include a predominance of splitting/recoalescing bubbles, with a maximum bubble size and large wake; high levels of solids mixing and gas backmixing, assuming equal U-Umf (U is the velocity of the carrier gas, and Umf is the minimum fluidization velocity, typically though not necessarily measured in meters per second, m/s, i.e., there is excess gas velocity); axisymmetric slug properties; and no spouting, except in very shallow beds. The properties listed tend to improve as the mean particle size decreases, assuming equal particle size (cfp); or as the <45 micrometers (pm) proportion is increased; or as pressure, temperature, viscosity, and density of the gas increase. In general, the particles may exhibit a small mean particle size and/or low particle density (<1.4 grams per cubic centimeter, g/cm³), fluidize easily, with smooth fluidization at low gas velocities, and may exhibit controlled bubbling with small bubbles at higher gas velocities.

[0060J Group B is understood by those skilled in the art as representing a “sand-like” powder that starts bubbling at Umf; that exhibits moderate bed expansion; a fast deaeration; no limits on bubble size; moderate levels of solids mixing and gas backmixing, assuming equal U-Umf; both axisymmetric and asymmetric slugs; and spouting in only shallow beds. These properties tend to improve as mean particle size decreases, but particle size distribution and, with some uncertainty, pressure, temperature, viscosity, or density of gas seem to do little to improve them. In general, most of the particles having a particle size (cfp) of 40 pm <cfp <500 pm when the density (pp) is 1.4 <pp <4 g/cm³, and 60 pm <cfp <500 pm when the density (pp) is 4 g/cm³ and 250 pm <cfp <100 pm when the density (pp) is 1 g/cm³.

[0061] According to one or more embodiments, a portion of the beam that slidingly engages the beam-supporting member, a portion of the beam-supporting member that slidingly engages the beam, or both, comprises an anti-coking coating. For example, the beam-contacting surface 134 and/or the beam rod 124 may include an anti-coking coating. The anti-coking coating refers to any coating that reduces coking of hydrocarbons at elevated temperatures, as compared with exposure of the hydrocarbons to the raw surface of the metal component upon which it is applied. A variety of compositions may be utilized as the anti-coking coating, some of which are described hereinbelow.

[0062] According to one or more embodiments, the anti-coking coating may comprise a ceramic material. Such coatings may include, without limitation, metal oxides and/or metal carbides, such as SiC and AI2O3. Contemplated commercially available coating compositions that may be suitable for use as the anti-coking coating include, without limitation, Cerakote V-Series, Cerablak HTP-100, and Emisshield M-l or M-6 sintered coatings. According to some embodiments, the coatings may be applied as ceramic particles suspended in an inorganic binder matrix, which may be painted onto the metal component. In some other embodiments, the coatings may be applied by spray gun application. Curing may be needed to remove solvents and/or chemically change the coating composition following application. [0063 J According to one or more embodiments, the anti-coking coating that is positioned over the metal component may comprise one or more of aluminum, silicon, chromium, or cerium. In some embodiments, the anti-coking coating may include aluminum, silicon, chromium, and cerium. In some embodiments, the anti-coking coating is a ceramic material that comprises aluminum, silicon, chromium, and cerium. The aluminum, silicon, chromium, and/or cerium may be present as oxides, nitrides, alloys of other metals (such as those in the composition of the metal component), or as elemental constituents. For example, the anti-coking coating may include one or more of AIN, Cr3Si, AlNi, AlFe, CeFeSi, and Ce.

[0064] According to one or more embodiments, the anti-coking coating that includes one or more of aluminum, silicon, chromium, or cerium may be fabricated over the metal component by a variety of techniques. For example, pack cementation coatings from intermetallic compounds may be applied. Two application methods for this technique include chemical vapor deposition (CVD) and thermal diffusion. Without being bound by any particular theory, it is believed that these methods may ensure the anti-coking coating completely covers the substrate surface and prevents any direct contact between hydrocarbons and the substrate. In utilizing this fabrication technique to apply the anti-coking coating to the metal component, the constituent elements of the anti-coking coating in the solid phase may be reacted in activators such as sodium chloride and ammonium chloride. This reaction may generate gaseous metal halides that are capable of diffusing to the substrate surface, where they undergo disproportionate reaction. As the resulting permeating source material accumulates on the substrate surface, it may further diffuse into the substrate, forming a diffusion coating. The diffusion coating may comprise of aluminum nitrides, chromium silicate, aluminum nickel, silicon dioxide, cerium, cerium iron silicide, and aluminum iron, which may create three regions. The three regions may include an outer layer, an interdiffusion layer, and a transitional layer. The outer layer may contain relatively large amounts of aluminum and chromium in the form of aluminum nitrides and chromium silicates, as well as relatively small amounts of silicon, cerium, nitrogen, oxygen, iron, and nickel.

[0065] According to one or more embodiments, without being bound by any particular theory, it is believed that, at high temperatures, the aluminum and chromium may oxidize on the substrate surface, which still may offer protection. The inter-diffusion layer may be composed of aluminum, iron, and nickel in the form of aluminum nickel and aluminum iron. Additionally, the transitional layer may be comprised of high amounts of chromium, iron, and nickel. [0066 J To produce one or more of the embodiments described herein, uncoated samples may be encapsulated in a retort with composite powder, which may include aluminum, chromium, silicon, and cerium (IV) oxide. Then an activator, such as ammonium chloride, and an inert filler, such as aluminum oxide, may be added. The retort may be sealed with refractory mud and placed in an oven for about 2 hours. Following this, the retort may be heat treated for eight hours at about 1000 °C in a preheated muffle furnace in the air atmosphere. After being heat treated, the sample may be cooled to room temperature, polished with sandpaper, and ultrasonically cleaned with ethanol for about three minutes.

[0067J According to other embodiments, the anti-coking coating may comprise a metalized surface, whereby a portion of the metal component is metalized. In some embodiments, the metallization is an aluminized surface, such that the anti-coking coating comprises aluminum. In one or more embodiments, morphology of the aluminized surface depends upon the conditions which are used to perform the coating, but may involve the alloying of aluminum with the underlying substrate across a thin band within the coating. Total thickness of this type of coating may be from 50 microns to 150 microns. Aluminization may be performed via pack cementation (PC), though may also be performed via vapor phases aluminizing (VP A), chemical vapor deposition (CVD), or other methods. In PC, the metal substrate will be surrounded by a “pack”, consisting of an inert filler (e.g. AI2O3 powder), the coating material (aluminum metal), and a halide salt “activator” (e.g. ammonium chloride). The substrate and surrounding packing will then be heated (commonly in either an inert or hydrogen atmosphere) to high temperature (e.g. 800- 1100 °C). At this point a gaseous metal halide (e.g. aluminum chloride) will form from the coating material and the activator. The metal halide deposits the aluminum onto the substrate surface forming a layer with thicknesses commonly ranging 50-150 um. The aluminum diffuses into the substrate with prolonged heat treatment. The ultimate morphology and thickness (commonly 50- 150 um) of this layer depends on the conditions and the packing. Upon exposure to atmosphere, and inert aluminum oxide layer is formed.

[0068] In one or more embodiments, and according to the composition of the anti-coking coating, the anti-coking coating may be applied in a variety of thicknesses. For example, in some embodiments, the anti-coking coating may have a thickness of from 25 microns to 500 microns, such as at least 25 microns and less than 400 microns, less than 300 microns, less than 200 microns, less than 100 microns, or less than 50 microns, or such as less than or equal to 500 microns and at least 50 microns, at least 100 microns, at least 200 microns, at least 300 microns, or at least 400 microns.

[0069] The present disclosure describes numerous technical aspects, including aspects 1-15 below.

[0070] Aspect 1. A chemical processing vessel comprising: one or more side walls defining a main interior space; a beam positioned within the main interior space, the beam comprising a body extending in a substantially horizontal dimension, the body extending from a first end to a second end; and a support assembly coupled to one or more of the one or more side walls, the support assembly comprising a beam-supporting member that contacts and supports the beam at or near the first end of the beam, wherein the support assembly has an open area of at least 50% at all horizontal cross-sections along a height of the support assembly, wherein the open area at each height of the support assembly is a ratio of a cross-sectional open area of the support assembly to a cross-sectional area of the smallest rectangle drawn around the cross-sectional area of the support assembly.

[0071] Aspect 2. The chemical processing vessel of aspect 1, further comprising an internal structure positioned within the main interior space, wherein the internal structure is supported by the beam.

[0072] Aspect 3. The chemical processing vessel of aspect 2, wherein the internal structure comprises a grating tray or a chevron.

[0073] Aspect 4. The chemical processing vessel of any preceding aspect, wherein the support assembly has an open area of at least 75% at all horizontal cross-sections along the height of the support assembly.

[0074] Aspect 5. The chemical processing vessel of any preceding aspect, wherein the beam slidingly engages the beam-supporting member, wherein a portion of the beam that slidingly engages the beam-supporting member, a portion of the beam-supporting member that slidingly engages the beam, or both, comprises an anti-coking coating.

[0075] Aspect 6. The chemical processing vessel of any preceding aspect, wherein the beam further comprises a beam rod extending in the substantially horizontal dimension, wherein the rod contacts the beam-supporting member. [0076J Aspect 7. The chemical processing vessel of any of aspects 1-7, wherein the beamsupporting member comprises a support rod extending in the substantially horizontal dimension, wherein the rod contacts the beam.

[0077J Aspect 8. The chemical processing vessel of any preceding aspect, wherein the beam further comprises beam sliding components that slidingly engage the beam-supporting member.

[0078J Aspect 9. The chemical processing vessel of any preceding aspect, wherein the beamsupporting member further comprises beam-supporting member sliding components that slidingly engage the beam.

[0079] Aspect 10. A method for chemical processing, the method comprising contacting a reactant with fluidized particles in the chemical processing vessel of any preceding aspect, wherein the fluidized particles comprise a fluidized bed flow regime, and wherein coke is generated in the chemical processing vessel.

[0080] Aspect 11. A chemical processing vessel comprising: one or more side walls defining a main interior space; a beam positioned within the main interior space, the beam comprising a body extending in a substantially horizontal dimension, the body extending from a first end to a second end; a support assembly coupled to one or more of the one or more side walls, the support assembly comprising a beam-supporting member that at least partially contacts and supports the beam at or near the first end of the beam, wherein: the beam-supporting member comprises a beam-contacting surface that is in direct contact with the beam; the beam comprises a support assembly-contacting surface that is in direct contact with the beam-supporting member; and one or both of: the support assembly-contacting surface of the beam is non planar; or the beamcontacting surface of the beam-supporting member is non planar.

[0081] Aspect 12. The chemical processing vessel of aspect 11, wherein the beam further comprises beam sliding components that slidingly engage the beam-supporting member, wherein a portion of the beam that slidingly engages the beam-supporting member, a portion of the beamsupporting member that slidingly engages the beam, or both, comprises an anti-coking coating.

[0082] Aspect 13. The chemical processing vessel of aspect 11 or aspect 12, wherein the beam-supporting member further comprises beam-supporting member sliding components that slidingly engage the beam. [0083] Aspect 14. The chemical processing vessel of any of aspects 11-13, wherein the support assembly-contacting surface of the beam or the beam-contacting surface of the support assembly comprises a rod extending in the substantially horizontal dimension.

[0084] Aspect 15. A method for chemical processing, the method comprising contacting a reactant with fluidized particles in the chemical processing vessel of any of aspects 11-14, wherein the fluidized particles comprise a fluidized bed flow regime, and wherein coke is generated in the chemical processing vessel.

[0085] The subject matter of the present disclosure has been described in detail and by reference to specific embodiments. It should be understood that any detailed description of a component or feature of an embodiment does not necessarily imply that the component or feature is essential to the particular embodiment or to any other embodiment. Further, it should be apparent to those skilled in the art that various modifications and variations can be made to the described embodiments without departing from the spirit and scope of the claimed subject matter.

[0086] It is noted that one or more of the following claims utilize the term "wherein" as a transitional phrase. For the purposes of defining the present invention, it is noted that this term is introduced in the claims as an open-ended transitional phrase that is used to introduce a recitation of a series of characteristics of the structure and should be interpreted in like manner as the more commonly used open-ended preamble term "comprising."

Claims

1. A chemical processing vessel comprising: one or more side walls defining a main interior space; a beam positioned within the main interior space, the beam comprising a body extending in a substantially horizontal dimension, the body extending from a first end to a second end; and a support assembly coupled to one or more of the one or more side walls, the support assembly comprising a beam-supporting member that contacts and supports the beam at or near the first end of the beam, wherein the support assembly has an open area of at least 50% at all horizontal cross-sections along a height of the support assembly, wherein the open area at each height of the support assembly is a ratio of a cross-sectional open area of the support assembly to a cross-sectional area of the smallest rectangle drawn around the cross-sectional area of the support assembly.

2. The chemical processing vessel of claim 1, further comprising an internal structure positioned within the main interior space, wherein the internal structure is supported by the beam.

3. The chemical processing vessel of claim 2, wherein the internal structure comprises a grating tray or a chevron.

4. The chemical processing vessel of any preceding claim, wherein the support assembly has an open area of at least 75% at all horizontal cross-sections along the height of the support assembly.

5. The chemical processing vessel of any preceding claim, wherein the beam slidingly engages the beam-supporting member, wherein a portion of the beam that slidingly engages the beam-supporting member, a portion of the beam-supporting member that slidingly engages the beam, or both, comprises an anti-coking coating.

6. The chemical processing vessel of any preceding claim, wherein the beam further comprises a beam rod extending in the substantially horizontal dimension, wherein the rod contacts the beam-supporting member.

7. The chemical processing vessel of any of claims 1-7, wherein the beam-supporting member comprises a support rod extending in the substantially horizontal dimension, wherein the rod contacts the beam.

8. The chemical processing vessel of any preceding claim, wherein the beam further comprises beam sliding components that slidingly engage the beam-supporting member.

9. The chemical processing vessel of any preceding claim, wherein the beam-supporting member further comprises beam-supporting member sliding components that slidingly engage the beam.

10. A method for chemical processing, the method comprising contacting a reactant with fluidized particles in the chemical processing vessel of any preceding claim, wherein the fluidized particles comprise a fluidized bed flow regime, and wherein coke is generated in the chemical processing vessel.

11. A chemical processing vessel comprising: one or more side walls defining a main interior space; a beam positioned within the main interior space, the beam comprising a body extending in a substantially horizontal dimension, the body extending from a first end to a second end; a support assembly coupled to one or more of the one or more side walls, the support assembly comprising a beam-supporting member that at least partially contacts and supports the beam at or near the first end of the beam, wherein: the beam-supporting member comprises a beam-contacting surface that is in direct contact with the beam; the beam comprises a support assembly-contacting surface that is in direct contact with the beam-supporting member; and one or both of: the support assembly-contacting surface of the beam is non planar; or the beam-contacting surface of the beam-supporting member is non planar.

12. The chemical processing vessel of claim 11, wherein the beam further comprises beam sliding components that slidingly engage the beam-supporting member, wherein a portion of the beam that slidingly engages the beam-supporting member, a portion of the beam-supporting member that slidingly engages the beam, or both, comprises an anti-coking coating.

13. The chemical processing vessel of claim 11 or claim 12, wherein the beam-supporting member further comprises beam-supporting member sliding components that slidingly engage the beam.

14. The chemical processing vessel of any of claims 11-13, wherein the support assemblycontacting surface of the beam or the beam-contacting surface of the support assembly comprises a rod extending in the substantially horizontal dimension.

15. A method for chemical processing, the method comprising contacting a reactant with fluidized particles in the chemical processing vessel of any of claims 11-14, wherein the fluidized particles comprise a fluidized bed flow regime, and wherein coke is generated in the chemical processing vessel.