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.