Impact of Fluids Distribution and Separation Systems on the Fluid Dynamics of a Resid Hydroprocessor

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The LC-FinerSM, a heavy oil hydroprocessor, is used by Syncrude Canada Ltd to upgrade Canadian bitumen to**synthetic crude oil via catalytic hydrogenation. The LC-FinerSM geometry, in particular the entrance**(gas-liquid distributor) and exit (liquid recycle pan), affects the reactor performance. An even spatial**distribution of the fluids is essential for proper hydrogenation and to limit the formation of coke which, by**settling at bottom of the reactor and detrimentally affecting the fluids distribution, can become**self-propagating. The fluids distribution system also influences bubble formation, which in turn affects bed**hydrodynamics and transport phenomena. Moreover, since bubbles do not readily coalesce in the bed, the**original bubble size distribution likely impacts phase separation in the recycle pan, and gas entrained with the**recycled liquid increases the gas flow through the distribution system resulting in greater bed gas holdups at the**expense of the liquid holdup and ultimately product yield. Moreover, greater yields lead to better process**energy efficiencies and thus reduced impact on the environment (e.g., greenhouse gas emissions).**Optimization of economic return and environmental impact are central to the successful development of the**Canadian oil sands industry, which will lead the growth in crude oil supply from 4.0 million barrels/day in**2015 to an estimated 5.5 million barrels/day in 2030.**This research project will have both multiphase computational fluid dynamics and experimental campaigns,**leveraged by existing unique equipment and specialized instrumentation. Enhancements in reactor**performance, via changes in reactor internal geometry and operating conditions that increase the liquid holdup**and run time, will be proposed. Graduate and undergraduate students will partake in operation of high pressure**equipment at the pilot scale, mathematical modeling and communication/interaction with an industrial partner**for complete and comprehensive training.