U.S. patent application number 17/146761 was filed with the patent office on 2022-07-14 for petrochemical processing systems and methods for reducing the deposition and accumulation of solid deposits during petrochemical processing.
This patent application is currently assigned to Saudi Arabian Oil Company. The applicant listed for this patent is Saudi Arabian Oil Company. Invention is credited to Ki-Hyouk Choi, Mazin M. Fathi.
Application Number | 20220220392 17/146761 |
Document ID | / |
Family ID | |
Filed Date | 2022-07-14 |
United States Patent
Application |
20220220392 |
Kind Code |
A1 |
Fathi; Mazin M. ; et
al. |
July 14, 2022 |
PETROCHEMICAL PROCESSING SYSTEMS AND METHODS FOR REDUCING THE
DEPOSITION AND ACCUMULATION OF SOLID DEPOSITS DURING PETROCHEMICAL
PROCESSING
Abstract
The present disclosure is directed to petrochemical processing
systems that may include a component including a first surface
oriented to contact a process fluid, which may define a plurality
of channels. The petrochemical processing systems may further
include a plurality of metal spheres disposed at least partially in
the plurality of channels. Each one of the plurality of metal
spheres may be fixed in place within one of the plurality of
channels such that each of the plurality of metal spheres is freely
rotatable. Methods for reducing accumulation and formation of solid
deposits during petrochemical processing using the petrochemical
processing systems are also disclosed.
Inventors: |
Fathi; Mazin M.; (Damman,
SA) ; Choi; Ki-Hyouk; (Dhahran, SA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Saudi Arabian Oil Company |
Dhahran |
|
SA |
|
|
Assignee: |
Saudi Arabian Oil Company
Dhahran
SA
|
Appl. No.: |
17/146761 |
Filed: |
January 12, 2021 |
International
Class: |
C10G 9/16 20060101
C10G009/16; C10G 75/04 20060101 C10G075/04; C10G 9/20 20060101
C10G009/20 |
Claims
1. A petrochemical processing system comprising: a component
comprising a first surface oriented to contact a process fluid,
where the first surface defines a plurality of channels aligned
with a flow direction of the process fluid, wherein the plurality
of channels are grooves recessed within the first surface; and a
plurality of metal spheres disposed at least partially in the
plurality of channels, where each of the plurality of metal spheres
is fixed in place within one of the plurality of channels such that
each of the plurality of metal spheres is freely rotatable at least
about an axis perpendicular to the flow direction.
2. The petrochemical processing system of claim 1, where the
component further comprises a wall having the first surface.
3. The petrochemical processing system of claim 1, where the
component further comprises a wall and an insert fixedly coupled to
the wall, where the insert has the first surface.
4. The petrochemical processing system of claim 1, where the
component comprises a second surface opposite the first surface,
the second surface comprising a heat transfer element.
5. The petrochemical processing system of claim 1, where the
component comprises a second surface opposite the first surface,
the second surface comprising a conducting element operable to
receive an electric current, where the application of the electric
current through the conducting element generates a magnetic field
causing rotation of the plurality of metal spheres.
6. The petrochemical processing system of claim 1, where each of
the plurality of metal spheres is coupled to the first surface by a
coupling member that extends through a bore oriented along a
diameter of the metal sphere.
7. The petrochemical processing system of claim 6, where the
coupling member comprises a metal ring or metal rod having a
diameter of from 0.5 centimeters to 10 centimeters.
8. The petrochemical processing system of claim 1, where each metal
sphere has a diameter of from 1 centimeter to 20 centimeters.
9. The petrochemical processing system of claim 1, where each metal
sphere has a density of from 5 grams per cubic centimeter to 30
grams per cubic centimeter.
10. The petrochemical processing system of claim 1, where each
metal sphere has a hardness greater than or equal to 40 on the
Rockwell "C" Scale.
11. The petrochemical processing system of claim 1, where each
metal sphere has been heat treated at a temperature of from 750
degrees Celsius to 1,500 degrees Celsius.
12. The petrochemical processing system of claim 1, where the
plurality of metal spheres comprise an alloy comprising nickel,
chromium, copper, molybdenum, or combinations of these.
13. The petrochemical processing system of claim 1, where each of
the plurality of metal spheres comprises one or more metal wedges
that extend through a bore oriented along a diameter of the metal
sphere that is normal to the first surface.
14. The petrochemical processing system of claim 1, where the
component has a contact surface comprising exposed portions of the
metal spheres and the first surface, and a surface area of the
contact surface is at least 45 percent greater than a surface area
of the first surface.
15. The petrochemical processing system of claim 1, where the
component comprises a reactor, a furnace, a heat exchanger, a
process line, or combinations of these.
16. The petrochemical processing system of claim 1, where the
petrochemical processing system comprises a visbreaker system, a
supercritical water system, a steam pyrolysis system, an
aqua-conversion system, or combinations of these.
17. The petrochemical processing system of claim 1, where each of
the metal spheres rotate about an axis that is perpendicular to a
line normal to the first surface.
18. A method for reducing accumulation and formation of solid
deposits during petrochemical processing, the method comprising:
passing a hydrocarbon feed through a petrochemical processing
system operable to heat the hydrocarbon feed to a temperature
suitable to thermally crack hydrocarbons in the hydrocarbon feed
and produce an effluent, where the petrochemical processing system
comprises: a component comprising a first surface oriented to
contact the hydrocarbon feed, where the first surface defines a
plurality of channels aligned with a flow direction of the process
fluid, wherein the plurality of channels are grooves recessed
within the first surface; and a plurality of metal spheres disposed
at least partially within the plurality of channels, where each of
the plurality of metal spheres is fixed in place within one of the
plurality of channels such that each of the plurality of metal
spheres is freely rotatable at least about an axis perpendicular to
the flow direction.
19. The method of claim 18, further comprising heating the
hydrocarbon feed to a temperature of from 250 degrees Celsius to
1,000 degrees Celsius within the petrochemical processing
system.
20. The method of claim 18, where the component comprises a second
surface opposite the first surface, the second surface comprising a
conducting element operable to receive an electric current, and the
method further comprising applying an electric current to the
conducting element, where applying the electric current generates a
magnetic field sufficient to rotate the plurality of metal spheres.
Description
BACKGROUND
Field
[0001] The present disclosure relates to systems and methods for
processing petroleum-based materials and, in particular, systems
and methods for reducing the deposition and accumulation of solid
deposits during petrochemical processing.
Technical Background
[0002] Petroleum-based materials, such as crude oil, can be
converted to petrochemical products, such as fuel blending
components, olefins, and aromatic compounds, which are basic
intermediates for a significant portion of the petrochemical
industry. Many petroleum-based materials are converted to
petrochemical products at elevated temperatures sufficient to
facilitate the catalytic or thermal reaction of hydrocarbons in the
petroleum-based materials. However, heating petroleum-based
materials to such elevated temperatures may result in the formation
of solid materials, which may accumulate as solid deposits in the
petrochemical processing systems used to convert the
petroleum-based materials into petrochemical products. For example,
when a crude oil is heated to temperatures sufficient to thermally
crack hydrocarbons in the crude oil, such as during a visbreaker
process, solid deposits of petroleum coke, asphaltenes, and salts
may form on the surfaces of the petrochemical processing system
that are in contact with the heated crude oil.
[0003] The excessive accumulation of solid deposits in
petrochemical processing systems may hinder heat transfer, restrict
flow of petroleum-based materials, and damage the petrochemical
processing systems. As a result, the operation of petrochemical
processing systems is often halted for hours, days, or even months
at a time in order to remove the solid deposits, which may also
result in further damage of the petrochemical processing systems.
Typically, the accumulation of solid deposits in petrochemical
processing systems may be reduced by limiting the petroleum-based
materials converted in the petrochemical processing systems or
reducing the severity of the operating conditions of the
petrochemical processing systems, such as by reducing the maximum
operating temperatures. However, such constraints may reduce the
efficiency and yield of petrochemical processing systems.
Alternatively, the accumulation of solid deposits in petrochemical
processing systems may be reduced by using unreactive or inert
materials that are resistant to corrosion by the heated
petroleum-based materials to construct the petrochemical processing
systems. However, the cost of such materials is often prohibitive
and prevents their practical incorporation.
SUMMARY
[0004] Accordingly, there is an ongoing need for systems and
methods for reducing the deposition and accumulation of solid
deposits, such as petroleum coke, during petrochemical processing.
The systems and methods of the present disclosure include
petrochemical processing systems including at least one component
that may include a first surface, which may define a plurality of
channels. The component may further include a plurality of metal
spheres disposed within the channels. The metal spheres may be
fixed in place within the channels such that the metal spheres may
be freely rotatable. The free rotation of the metal spheres may
provide a dynamic heated surface that contacts the petroleum-based
materials within the petrochemical processing system. The free
rotation of the spheres during operation of the petrochemical
processing system may reduce the deposition and accumulation of
solid deposits on the first surface of the component.
[0005] As a result, downtime of the petrochemical processing system
for the removal of solid deposits may be reduced and the efficiency
of the petrochemical processing system may be increased. Moreover,
the reduction in the deposition and accumulation of solid deposits
may be accomplished by the components of the present disclosure
without limiting the petroleum-based materials that may be
processed in the petrochemical processing system, limiting the
operating conditions of the petrochemical processing system,
incorporating costly and prohibitive materials, or combinations of
these. Furthermore, the enablement of a broad spectrum of
petroleum-based materials as feedstocks and more severe operating
conditions by the component of the present disclosure may also
result in a greater yield of products from the petrochemical
processing system, among other features.
[0006] According to at least one aspect of the present disclosure,
a petrochemical processing system may include a component including
a first surface oriented to contact a process fluid, which may
define a plurality of channels. The petrochemical processing system
may further include a plurality of metal spheres disposed at least
partially in the plurality of channels. Each one of the plurality
of metal spheres may be fixed in place within one of the plurality
of channels such that each of the plurality of metal spheres is
freely rotatable.
[0007] According to another aspect of the present disclosure, a
method for reducing accumulation and formation of solid deposits
during petrochemical processing may include passing a hydrocarbon
feed through a petrochemical processing system operable to heat the
hydrocarbon feed to a temperature suitable to thermally crack
hydrocarbons in the hydrocarbon feed and produce an effluent. The
petrochemical processing system may include a component including a
first surface oriented to contact a process fluid, which may define
a plurality of channels. The petrochemical processing system may
further include a plurality of metal spheres disposed at least
partially in the plurality of channels. Each one of the plurality
of metal spheres may be fixed in place within one of the plurality
of channels such that each of the plurality of metal spheres is
freely rotatable.
[0008] Additional features and advantages of the aspects of the
present disclosure will be set forth in the detailed description
that follows and, in part, will be readily apparent to a person of
ordinary skill in the art from the detailed description or
recognized by practicing the aspects of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The following detailed description of the present disclosure
may be better understood when read in conjunction with the
following drawings in which:
[0010] FIG. 1 schematically depicts a perspective view in partial
cross-section of a component of a petrochemical processing system,
according to one or more aspects of the present disclosure;
[0011] FIG. 2A schematically depicts a cross-sectional view of a
plurality of channels defined by the first surface of the component
depicted in FIG. 1, according to one or more aspects of the present
disclosure;
[0012] FIG. 2B schematically depicts a perspective view of a
portion of the plurality of channels defined by the first surface
of the component depicted in FIG. 1, according to one or more
aspects of the present disclosure;
[0013] FIG. 3 schematically depicts a sub-assembly of metal
spheres, according to one or more aspects of the present
disclosure;
[0014] FIG. 4A schematically depicts a cross-sectional view of the
component depicted in FIG. 1, according to one or more aspects of
the present disclosure;
[0015] FIG. 4B schematically depicts a portion of the component
depicted in FIG. 4A, according to one or more aspects of the
present disclosure;
[0016] FIG. 4C schematically depicts a perspective view of a
portion of the component depicted in FIG. 4A, according to one or
more aspects of the present disclosure; and
[0017] FIG. 5 schematically depicts a cross-section view of another
component of a petrochemical processing system, according to one or
more aspects of the present disclosure.
[0018] Reference will now be made in greater detail to various
aspects, some of which are illustrated in the accompanying
drawings.
DETAILED DESCRIPTION
[0019] The present disclosure is directed to systems and methods
for reducing the deposition and accumulation of solid deposits,
such as, but not limited to, petroleum coke, on surfaces of
components of the petrochemical processing system during
petrochemical processing. Referring to FIG. 1, a component 100 of a
petrochemical processing system is schematically depicted. The
component 100 may include a first surface 102, which may define a
plurality of channels 104. The component 100 may further include a
plurality of metal spheres 106 disposed within the channels 104.
The metal spheres 106 may be fixed in place within the channels
104. The free rotation of the metal spheres 106 may reduce the
deposition and accumulation of solid deposits on the first surface
102. Without being bound by any particular theory, it is believed
that this reduction of the deposition and accumulation of solid
deposits on the first surface 102 may be due to the free rotation
of the metal spheres 106 providing a dynamic heated surface that
contacts the petroleum-based materials. This heated dynamic surface
may reduce or prevent solid deposits from depositing on to the
surface and accumulating over time.
[0020] As a result, downtime of the petrochemical processing system
for the removal of solid deposits may be reduced and the efficiency
of the petrochemical processing system may be increased. Moreover,
this reduction in the deposition and accumulation of solid deposits
may be accomplished by the component 100 without limiting the
operating conditions of the petrochemical processing system,
incorporating costly and prohibitive materials, or both.
Furthermore, the enablement of more severe operating conditions by
the component 100 may also result in a greater yield of products
from the petrochemical processing system, among other features.
[0021] As used in the present disclosure, the indefinite articles
"a" and "an," when referring to elements of the present disclosure,
mean that least one of these elements are present. Although these
indefinite articles are conventionally employed to signify that the
modified noun is a singular noun, the indefinite articles "a" and
"an" also include the plural in the present disclosure, unless
stated otherwise. Similarly, the definite article "the" also
signifies that the modified noun may be singular or plural in the
present disclosure, unless stated otherwise.
[0022] As used in the present disclosure, the term "or" is
inclusive and, in particular, the term "A or B" refers to "A, B, or
both A and B." Alternatively, the term "or" may be used in the
exclusive sense only when explicitly designated in the present
disclosure, such as by the terms "either A or B" or "one of A or
B."
[0023] As used in the present disclosure, the term "cracking"
refers to any chemical reaction where a molecule having
carbon-carbon bonds is broken into more than one molecule by the
breaking of one or more of the carbon-carbon bonds; where a
compound including a cyclic moiety, such as an aromatic, is
converted to a compound that does not include a cyclic moiety; or
where a molecule having carbon-carbon double bonds are reduced to
carbon-carbon single bonds. As used in the present disclosure, the
term "thermal cracking" refers to cracking induced by elevated
temperatures.
[0024] As used in the present disclosure, the term "crude oil"
refers to a mixture of petroleum liquids and gases, including
impurities, such as sulfur-containing compounds,
nitrogen-containing compounds, and metal compounds, extracted
directly from a subterranean formation or received from a desalting
unit without having any fractions, such as naphtha, separated by
distillation.
[0025] As used in the present disclosure, the term "naphtha" refers
to an intermediate mixture of hydrocarbon-containing materials
derived from crude oil refining and having atmospheric boiling
points from 36.degree. C. to 220.degree. C. Naphtha may comprise
light naphtha comprising hydrocarbon-containing materials having
atmospheric boiling points from 36.degree. C. to 80.degree. C.,
intermediate naphtha comprising hydrocarbon-containing materials
having atmospheric boiling points from 80.degree. C. to 140.degree.
C., and heavy naphtha comprising hydrocarbon-containing materials
having atmospheric boiling points from 140.degree. C. to
200.degree. C. Naphtha may comprise paraffinic, naphthenic, and
aromatic hydrocarbons having from 4 carbon atoms to 11 carbon
atoms.
[0026] As used in the present disclosure, the terms "downstream"
and "upstream" refer to the positioning of components of a system
relative to a direction of flow of materials through the system.
For example, a second component may be considered "downstream" of a
first component if materials flowing through the system encounter
the first component before encountering the second component.
Likewise, the first component may be considered "upstream" of the
second component if the materials flowing through the system
encounter the first component before encountering the second
component.
[0027] As used in the present disclosure, the term "effluent"
refers to a stream that is passed out of a reactor, a reaction
zone, or a separator following a particular reaction or separation.
Generally, an effluent has a different composition than the stream
that entered the reactor, reaction zone, or separator. It should be
understood that when an effluent is passed to another component or
system, only a portion of that effluent may be passed. For example,
a slipstream may carry some of the effluent away, meaning that only
a portion of the effluent may enter the downstream component or
system. The terms "reaction effluent" and "reactor effluent" may be
used to particularly refer to a stream that is passed out of a
reactor or reaction zone.
[0028] As used in the present disclosure, the term "reactor" refers
to any vessel, container, or the like, in which one or more
chemical reactions may occur between one or more reactants,
optionally, in the presence of one or more catalysts. For example,
a reactor may include a tank or tubular reactor configured to
operate as a batch reactor, a continuous stirred-tank reactor
(CSTR), or a plug flow reactor. Example reactors include packed bed
reactors, such as fixed bed reactors, and fluidized bed
reactors.
[0029] As used in the present disclosure, the term "solid deposits"
refers to any solid state material that is formed during the
processing of a petroleum-based material or otherwise precipitates
from the petroleum-based material during processing. For example,
solid deposits can refer to petroleum coke that is formed during
the thermal cracking of hydrocarbons in petroleum-based materials,
as well as salts that remained in solution prior to processing, but
precipitated out of the petroleum-based materials during processing
due to, for example, the evaporation of the water in which they
were in solution.
[0030] It should further be understood that streams may be named
for the components of the stream, and the component for which the
stream is named may be the major component of the stream (such as
comprising from 50 wt. %, from 70 wt. %, from 90 wt. %, from 95 wt.
%, from 99 wt. %, from 99.5 wt. %, or from 99.9 wt. % of the
contents of the stream to 100 wt. % of the contents of the stream).
For example, a disclosed "hydrocarbon feed" should be understood to
comprise 50 wt. %, from 70 wt. %, from 90 wt. %, from 95 wt. %,
from 99 wt. %, from 99.5 wt. %, or from 99.9 wt. % of one or more
hydrocarbons.
[0031] Referring again to FIG. 1, a perspective view in partial
cross-section of a component 100 of a petrochemical processing
system of the present disclosure is schematically depicted. As
noted previously, the deposition and formation of solid deposits
may occur when petroleum-based materials are heated to elevated
temperatures, such as temperatures greater than or equal to
250.degree. C. Therefore, the systems and methods of the present
disclosure, which may reduce such deposition and accumulation of
solid deposits, may be applied to a variety of petrochemical
processing systems. Accordingly, the components 100 of the present
disclosure may be a component of any petrochemical processing
system where petroleum-based materials are heated to a temperature
sufficient to cause the deposition and accumulation of solid
deposits. For example, the component 100 may be a component of a
petrochemical processing system where hydrocarbons of
petroleum-based materials are thermally cracked, such as a
visbreaker system, a supercritical water system, a steam pyrolysis
system, an aqua-conversion system, or combinations of these.
Moreover, the component 100 may be any component of the
petrochemical processing system where petroleum-based materials are
heated to a temperature sufficient to cause the deposition and
accumulation of solid deposits, such as petroleum coke. For
example, the component 100 may be a reactor, a furnace, a heat
exchanger, a process line, or combinations of these.
[0032] As depicted in FIG. 1, the component 100 may include a wall
101 having a first surface 102, which may define a plurality of
channels 104. The component 100 may further include a plurality of
metal spheres 106 disposed within the channels 104. The metal
spheres 106 may be fixed in place within the channels 104 such that
the positions of the metal spheres 106 are fixed, but the metal
spheres 106 are freely rotatable. While the component 100 depicted
in FIG. 1 is cylindrical in shape, it should be understood that the
component 100 may be various shapes and sizes, such as flat, so
long as the component 100 is operable within the particular
petrochemical processing system in which it is used. The
cylindrical shaped component 100 depicted in FIG. 1 may be suitable
for use as a tubular reactor, a process line, or both, but a flat
or plate-shaped component 100 may be more suitable for use in a
plate reactor or plate and frame heat exchanger.
[0033] The wall 101 having the first surface 102 may be made from
one or more materials suitable for use within the petrochemical
processing system. For example, the wall 101 having the first
surface 102 may be made from one or more metals, such as iron,
nickel, chromium, copper, molybdenum, or combinations of these. The
wall 101 having the first surface 102 may also be made from alloys
of these metals, such as a carbon steel, a stainless steel, a
nickel-chromium alloy, a nickel-copper alloy, a
nickel-chromium-molybdenum alloy, or combinations of these. The
particular composition of the wall 101 having the first surface 102
should be selected based on the process conditions of the
petrochemical processing system in which the component 100 is used.
For example, when processing relatively light petroleum-based
materials, such as naphtha, carbon steel or stainless steel may be
used despite having inferior resistance to corrosion when compared
to a nickel-chromium alloy. However, when processing relatively
corrosive petroleum-based materials, such as petroleum residua,
materials with superior resistance to corrosion, such as a
nickel-chromium-molybdenum alloy may be used.
[0034] As noted previously, the first surface 102 of the wall 101
may define a plurality of channels 104. Referring now to FIGS. 2A
and 2B, cross-sectional and perspective views of the channels 104
defined by the first surface 102 of the component 100 are
schematically depicted. As depicted in FIGS. 2A and 2B, the
channels 104 may be recessed within the first surface 102. That is,
the channels 104 may be integral to the wall 101 defining the first
surface 102. In embodiments, the wall 101 may include a primary
wall and secondary insert wall coupled to a surface of the primary
wall. The secondary insert wall may comprise the first surface 102
that defines the plurality of channels 104. In embodiments, the
channels 104 may extend in a direction that generally corresponds
with the flow of the petroleum-based materials through the
component 100. For example, if the petroleum-based materials
generally flow through the component 100 in the +/-Y-direction, the
channels 104 may also extend along the first surface 102 in the
+/-Y-direction. The channels 104 may be any shape suitable for the
metal spheres 104 to be fixed in place within the channels 104
while also remaining freely rotatable. The channels 104 may be
semicircular (that is, the cross-sectional shapes of the channels
104 are semicircular), squared, angular, or combinations
thereof.
[0035] While the dimensions of the channels 104 (that is, a width
and depth of the channels 104) are not particularly limited, the
dimensions of the channels 104 may be selected based on the
dimensions of the metal spheres 106 disposed within the channels
104. The width of the channels 104 may be greater than the
diameters of the metal spheres 106 in order to enable the free
rotation of the metal spheres 106. Similarly, the depth of the
channels 104 may be less than or equal to half the diameter of the
metal spheres 106 such that half or more of each metal sphere
extends outward from the channels 104. When determining the
dimensions of the channels 104, the thermal expansion of the metal
spheres 106, as well as any other components that may be disposed
within the channels 104, may be considered to accommodate the
natural expansion of the metal spheres 106 at operating conditions
of the petrochemical processing system and to avoid any hindrance
of the free rotation of the metal spheres 106. For example, if the
composition of the metal spheres 106 has a lesser coefficient of
thermal expansion, the channels 104 may only be marginally larger
than the metal spheres 106 as the metal spheres 106 are not likely
to expand in size enough hinder their free rotation. In contrast,
if the composition of the metal spheres 106 has a greater
coefficient of thermal expansion, the width and depth of the
channels 104 may be increased in order to prevent the metal spheres
16 from becoming jammed or stuck in the channels 104, which may
prevent free rotation of the metal spheres 16.
[0036] In embodiments, each of the channels 104 may be separated
from the other channels 104 by one or more raised surfaces or
ridges 108, one or more latch grooves 110, or combinations of
these. The separation of the channels 104 by the ridges 108 and the
latch grooves 110 may provide an appropriate distance between the
channels 104 such that the metal spheres 106 are evenly spaced
across the first surface 102. An appropriate distance between the
channels 104 may be determined, at least in part, by the operating
conditions of the petrochemical processing system, such as the
petroleum-based material passed through the petrochemical
processing system, the operating temperatures of the petrochemical
processing system, or both. For example, when the operating
conditions of the petrochemical processing system are known to
result in the formation of significant amounts of solid deposits,
the distance between the channels 104 may be reduced, which may
reduce the potential for the formation and accumulation of solid
deposits on the ridges between the channels 104 (a phenomena
commonly referred to as channeling). Moreover, the latch grooves
110 may enable sub-assemblies of the metal spheres 106, as
discussed subsequently, to be coupled to the first surface 102 to
position the metal spheres 106 securely within the channels
104.
[0037] Referring again to FIG. 1, as noted previously, the metal
spheres 106 may be disposed within the channels 104 defined by the
first surface 102 of the component 100. The metal spheres 106 may
be fixed in place within the channels 104 such that the metal
spheres 106 are freely rotatable. The metal spheres 106 may reduce
the deposition and accumulation of solid deposits on the first
surface 102. Without being bound by any particular theory, it is
believed that this reduction or prevention of the formation and
accumulation of solid deposits on the first surface 102 may be due
to the free rotation of the metal spheres 106, which provides a
dynamic heated surface that contacts the petroleum-based materials.
Each of the metal spheres 106 may be fixed in place within the
channels 104 by, for example, a metal rod that extends through the
metal sphere 106, such as through a bore that extends through the
metal sphere 106. In embodiments, each of the metal spheres 106 may
be fixed in place within the channels 104 by one or more metal rods
that are fixed, such as by welding, to antipodal points of the
metal sphere. The metals rods may then be coupled to the channels
104, such as by slotting into grooves located within the channels
104.
[0038] As noted previously, the metal spheres 106 may be fixed in
place within the channels 104 such that the positions of the metal
spheres 106 are fixed, but the metal spheres 106 are freely
rotatable. In embodiments, the metal spheres 106 may be fixed in
place such that they rotate in the same direction as the flow of
petroleum-based materials through the component 100. For example,
if the petroleum-based materials generally flow through the
component 100 in the +/-Y-direction, each of the metal spheres 106
may be freely rotatable about an axis that is perpendicular to the
+/-Y-direction, such as, for example, perpendicular to a line
normal to the first surface 102. Without being bound by any
particular theory, it is believed that fixing the metal spheres 106
in such a manner may enable the metal spheres 106 to be rotated at
sufficient speeds by the petroleum-based materials passed through
the component 100.
[0039] The metal spheres 106 may be selected based on a variety of
factors. The composition, density, coefficient of thermal
expansion, melting point, compressive and tensile strengths, bulk
modulus, and hardness of the metal spheres 106 may all be
considered in view of the petrochemical processing system. For
example, the repeated heating and cooling of the metal spheres 106
that may occur during operation of the petrochemical processing
system may result in repeated thermal expansion and contraction,
which may induce mechanical fatigue crevices in the metal spheres
106. As such, the metal spheres 106 may be selected to have a
lesser coefficient of thermal expansion in order to reduce the
thermal expansion and contraction that occurs.
[0040] The metal spheres 106 may be made from materials suitable
for use within the petrochemical processing system. For example,
the metal spheres 106 may be made from one or more metals, such as
iron, nickel, chromium, copper, molybdenum, or combinations of
these. The metal spheres 106 may also be made from alloys of these
metals, such as a carbon steel, a stainless steel, a
nickel-chromium alloy, a nickel-copper alloy, a
nickel-chromium-molybdenum alloy, or combinations of these. The
particular composition of the metal spheres 106 should be selected
based on the process conditions of the petrochemical processing
system in which the component 100 is used and, in embodiments, may
be the same materials as the first surface 102. For example, when
processing relatively light petroleum-based materials, such as
naphtha, carbon steel or stainless steel may be used despite having
inferior resistance to corrosion when compared to a nickel-chromium
alloy. However, when processing corrosive petroleum-based
materials, such as petroleum residua, materials with superior
resistance to corrosion, such as a nickel-chromium-molybdenum alloy
may be used.
[0041] The metal spheres 106 may have diameters suitable to reduce
or prevent the formation and accumulation of solid deposits on the
first surface 102 of the component 100. Diameters suitable to
reduce the formation of solid deposits on the first surface 102 of
the component 100 may be from 1 centimeter (cm) to 100 cm. For
example, the metal spheres 106 may have a diameter of from 1 cm to
20 cm, from 1 cm to 10 cm, from 1 cm to 8 cm, from 1 cm to 6 cm,
from 1 cm to 4 cm, from 1 cm to 2 cm, from 2 cm to 20 cm, from 2 cm
to 10 cm, from 2 cm to 8 cm, from 2 cm to 6 cm, from 2 cm to 4 cm,
from 4 cm to 20 cm, from 4 cm to 10 cm, from 4 cm to 8 cm, from 4
cm to 6 cm, from 6 cm to 20 cm, from 6 cm to 10 cm, from 6 cm to 8
cm, from 8 cm to 20 cm, from 8 cm to 10 cm, or from 10 cm to 20 cm.
When the metal spheres 106 are too small, such as when the metal
spheres 106 have diameters less than 1 cm, even minor buildup of
solid deposits on the first surface 102 of the component 100 may
cover portions of the metal spheres 106, prevent the free rotation
of the metal spheres 106, or both. This may effectively create
stagnant portions of the first surface 102, which may facilitate
the further formation and accumulation of solid deposits.
[0042] The metal spheres 106 may have densities suitable for
operation within the component 100. Densities suitable for
operation within the component 100 may be from 5 grams per cubic
centimeter (g/cm.sup.3) to 30 g/cm.sup.3. For example, each of the
metal spheres 106 may have a density of from 5 g/cm.sup.3 to 30
g/cm.sup.3, from 5 g/cm.sup.3 to 25 g/cm.sup.3, from 5 g/cm.sup.3
to 20 g/cm.sup.3, from 5 g/cm.sup.3 to 15 g/cm.sup.3, from 5
g/cm.sup.3 to 10 g/cm.sup.3, from 10 g/cm.sup.3 to 30 g/cm.sup.3,
from 10 g/cm.sup.3 to 25 g/cm.sup.3, from 10 g/cm.sup.3 to 20
g/cm.sup.3, from 10 g/cm.sup.3 to 15 g/cm.sup.3, from 15 g/cm.sup.3
to 30 g/cm.sup.3, from 15 g/cm.sup.3 to 25 g/cm.sup.3, from 15
g/cm.sup.3 to 20 g/cm.sup.3, from 20 g/cm.sup.3 to 30 g/cm.sup.3,
from 20 g/cm.sup.3 to 25 g/cm.sup.3, or from 25 g/cm.sup.3 to 30
g/cm.sup.3. When the metal spheres 106 are not dense enough, such
as when the metal spheres 106 have a density less than 5
g/cm.sup.3, the metal spheres 106 may be more susceptible to
erosion and corrosion caused by contact with heated petroleum-based
materials. In contrast, when the metal spheres 106 are too dense,
such as when the metal spheres 106 have a density greater than 30
g/cm.sup.3, the weight of the metal spheres 106 may exceed the
operation limits of the component 100 and cause mechanical
deterioration or failure of the component 100. Moreover, the
density of the metal spheres 106 may be an indicator of the bulk
modulus of the metal spheres 106, which is a measure of the metal
spheres 106 ability to resist deformation when under compression,
such as during operation of the petrochemical processing
system.
[0043] The metal spheres 106 may be suitably hard for operation
within the component 100. A suitable hardness for operation within
the component 100 may be greater than or equal to 40 on the
Rockwell "C" Scale when measured according to ASTM E18-20. For
example, each of the metal spheres 106 may have a hardness of from
40 to 68, from 40 to 64, from 40 to 60, from 40 to 56, from 40 to
52, from 40 to 48, from 40 to 44, from 44 to 68, from 44 to 64,
from 44 to 60, from 44 to 56, from 44 to 52, from 44 to 48, from 48
to 68, from 48 to 64, from 48 to 60, from 48 to 56, from 48 to 52,
from 52 to 68, from 52 to 64, from 52 to 60, from 52 to 56, from 56
to 68, from 56 to 64, from 56 to 60, from 60 to 68, from 60 to 64,
or from 64 to 68 on the Rockwell "C" Scale when measured according
to ASTM E18-20. The hardness of the metal spheres 106 is directly
proportional to the compressive and tensile strengths of the metal
spheres 106. Moreover, the hardness of the metal spheres 106 is
directly proportional to the ability of the metal spheres 106
resist deformation by stretching, compression, penetration,
indentation, and scratching. When the metal spheres 106 are not
hard enough, such as when the metal spheres 106 have a hardness
less than 40 on the Rockwell "C" Scale when measured according to
ASTM E18-20, the metal spheres 106 may be more susceptible to
erosion and corrosion during the operation of the petrochemical
processing system, either due to contact with heated
petroleum-based materials, repeated rotation, or both.
[0044] The metal spheres 106 may be subjected to a heat treatment
prior to use in the component 100. Suitable heat treatments may be
conducted at temperatures from 750 degrees Celsius (.degree. C.) to
1,500.degree. C. For example, the metal spheres 106 may be heat
treated at a temperature of from 750.degree. C. to 1,500.degree.
C., from 750.degree. C. to 1,350.degree. C., from 750.degree. C. to
1,200.degree. C., from 750.degree. C. to 1,050.degree. C., from
750.degree. C. to 900.degree. C., from 900.degree. C. to
1,500.degree. C., from 900.degree. C. to 1,350.degree. C., from
900.degree. C. to 1,200.degree. C., from 900.degree. C. to
1,050.degree. C., from 1,050.degree. C. to 1,350.degree. C., from
1,050.degree. C. to 1,200.degree. C., or from 1,200.degree. C. to
1,350.degree. C. prior to use in the component 100. Without being
bound by any particular theory, it is believed the heat treatment
may harden the metal spheres 106, such that each of the metal
spheres 106 has a hardness as discussed previously in the present
disclosure. When the metal spheres 106 are not heat treated or are
heat treated at an unsuitable temperature, such as less than
750.degree. C. or greater than 1,500.degree. C., prior to use in
the component 100, the metal spheres 106 may not be suitably hard
for operation within the component 100.
[0045] In embodiments, the metal spheres 106 may be coupled
together in a plurality of sub-assemblies, which may each be
disposed within the channels 104. Referring now to FIG. 3, a
plurality of metal spheres 106 coupled together in such a
sub-assembly 111 is schematically depicted. As depicted in FIG. 3,
the metal spheres 106 may be coupled together in a sub-assembly 111
by a coupling member 112 that may extend through each of the metal
spheres 106, such as through a bore oriented along an axis of each
of the metal spheres 106. While the sub-assembly 111 depicted in
FIG. 3 is circular, it should be understood that the sub-assembly
111 may be linear or have other various shapes and sizes, so long
as the sub-assembly 111 may be coupled to the first surface 102 of
the component 100 in which it is used to position the metal spheres
106 within the channels 104. The circular sub-assembly 111 depicted
in FIG. 3 may be suitable for use with a cylindrical shaped
component 100, such as the component depicted in FIG. 1, but a
linear sub-assembly 111 may be more suitable for use with a
component 100 having a plate shape.
[0046] The coupling member 112, which may be, for example, a ring
or a rod, may be made from materials suitable for use within the
petrochemical processing system. For example, the coupling member
112 may be made from one or more metals, such as iron, nickel,
chromium, copper, molybdenum, or combinations of these. The
coupling member 112 may also be made from alloys of these metals,
such as a carbon steel, a stainless steel, a nickel-chromium alloy,
a nickel-copper alloy, a nickel-chromium-molybdenum alloy, or
combinations of these. The particular composition of the coupling
member 112 should be selected based on the process conditions of
the petrochemical processing system in which the component 100 is
used and, in embodiments, may be the same material as the wall 101
having the first surface 102, the metal spheres 106, or both. For
example, when processing relatively light petroleum-based
materials, such as naphtha, carbon steel or stainless steel may be
used despite having inferior resistance to corrosion when compared
to a nickel-chromium alloy. However, when processing corrosive
petroleum-based materials, such as petroleum residua, materials
with superior resistance to corrosion, such as a
nickel-chromium-molybdenum alloy may be used.
[0047] The coupling member 112 may have a size suitable to
facilitate the extension of the coupling member 112 through the
metal spheres 106. Sizes suitable to facilitate the extension of
the coupling member 112 through the metal spheres 106 may include
cross-sectional diameters of from 0.5 cm to 10 cm. For example, the
coupling member 112 may have a cross-sectional diameter of from 0.5
cm to 5 cm, from 0.5 cm to 4 cm, from 0.5 cm to 3 cm, from 0.5 cm
to 2 cm, from 0.5 cm to 1 cm, from 1 cm to 10 cm, from 1 cm to 5
cm, from 1 cm to 4 cm, from 1 cm to 3 cm, from 1 cm to 2 cm, from 2
cm to 10 cm, from 2 cm to 5 cm, from 2 cm to 4 cm, from 2 cm to 3
cm, from 3 cm to 10 cm, from 3 cm to 5 cm, from 3 cm to 4 cm, from
4 cm to 10 cm, from 4 cm to 5 cm, or from 5 cm to 10 cm. When the
coupling member 112 is too small, such as when the coupling member
112 has a cross-sectional diameter less than 0.5 cm, the coupling
member 112 may be more susceptible to mechanical failure during the
operation of the petrochemical processing system. Conversely, when
the coupling member 112 is too large, such as when the coupling
member 112 has a cross-sectional diameter greater than 10 cm,
excess amounts of material may be required to be removed from the
metal spheres 106 in order to form a bore suitable for the coupling
member 112 to extend through. When excess amounts of material are
removed from the metal spheres 106, the mechanical strength of the
metal spheres 106 may be negatively affected. It should be
understood that the size of the coupling member 112 should be
selected based on the size of the metal spheres 106. For example,
when the dimeter of the metal spheres 106 is 1 cm, a coupling
member 112 having a cross-sectional diameter greater than 0.5 cm
may not be suitable for use with the metal spheres 106. In
particular, a borehole large enough to accommodate the coupling
member 112 may require the removal of excess material from the
metal spheres 106 or may be larger than the diameter of the metal
spheres 106 and, as a result, unable to be drilled.
[0048] The number and size of the metal spheres 106 included in
each sub-assembly 111 may be determined, at least in part, by the
number and size of the channels 104 defined by the first surface
102 of the component 100. For example, when six channels having
diameters of 50 cm are defined by the first surface 102, each
sub-assembly may comprise six metal spheres 106 having diameters
less than 50 cm. The number and size of the metal spheres 106
included in each sub-assembly 111 may also be determined, at least
in part, by the operating conditions of the petrochemical
processing system, such as the petroleum-based material passed
through the petrochemical processing system, the operating
temperatures of the petrochemical processing system, or both. For
example, when the operating conditions of the petrochemical
processing system is known to result in the formation of
significant amounts of solid deposits, the size and number of the
metal spheres 106 may be selected such that the space between the
metal spheres 106 is reduced as much as possible without hindering
the free rotation of the metal spheres 106. Without being bound by
any particular theory, it is believed that when the spaces between
the metal spheres 106 is reduced, the potential for the formation
of solid deposits within the spaces between the metal spheres 106
(a phenomena commonly referred to as channeling) may be
reduced.
[0049] In embodiments, the sub-assembly 111 may further comprise
one or more latches 114, which may be disposed between two or more
of the metal spheres 106 on the coupling member 112. The latches
114 may secure the sub-assembly 111 within the component 100 by
being disposed within the latch grooves 110 defined by the first
surface 102 of the component 100. By securing the sub-assembly 111
at select points within the component 100, the metal spheres 106
may be fixed in place within the channels 104 without hindering the
free rotation of the metal spheres 106. Each of the latches 114 may
be a metal wedge having dimensions sufficient to enable each of the
latches 114 to be slotted or inserted into each of the latch
grooves 110. Once slotted into each of the latch grooves 110, each
of the latches 114 may be secured within their respective latch
grooves 110 in order to prevent their dislodgment during operation
of the petrochemical processing system. The latches 114 may be
secured within the latch grooves 110 by clamps, screws, clips,
pins, interlocking surfaces, or combinations of these. Other known
methods of attaching the latches 114 to the first surface 102 are
contemplated.
[0050] The latches 114 may be made from materials suitable for use
within the petrochemical processing system. For example, the
latches 114 may be made from one or more metals, such as iron,
nickel, chromium, copper, molybdenum, or combinations of these. The
latches 114 may also be made from alloys of these metals, such as a
carbon steel, a stainless steel, a nickel-chromium alloy, a
nickel-copper alloy, a nickel-chromium-molybdenum alloy, or
combinations of these. The particular composition of the latches
114 should be selected based on the process conditions of the
petrochemical processing system in which the component 100 is used
and, in embodiments, may be made from the same materials as the
first surface 102, the metal spheres 106, the coupling member 112,
or combinations of these. For example, when processing relatively
light petroleum-based materials, such as naphtha, carbon steel or
stainless steel may be used despite having inferior resistance to
corrosion when compared to a nickel-chromium alloy. However, when
processing corrosive petroleum-based materials, such as petroleum
residua, materials with superior resistance to corrosion, such as a
nickel-chromium-molybdenum alloy may be used.
[0051] Referring now to FIGS. 4A-4C, a plurality of sub-assemblies
111 may be disposed within the component 100. As depicted in FIGS.
4A-4C, each sub-assembly 111 may be secured within the component
100 by disposing the metal spheres 106 within the channels 104,
while also inserting the latches 114 within the latch grooves 110.
Each sub-assembly 111 may be secured within the component 100
transverse relative to the channels 104 such that each of the metal
spheres 106 of the individual sub-assemblies 111 are disposed in a
different channel 104. As noted previously, the sub-assemblies 111
may be secured within the component 100 by slotting one or more
latches 114 of the sub-assemblies 111 into the latch grooves 110
defined by the first surface 102. Once slotted into the latch
grooves 110, each of the latches 114 may be secured within their
respective latch grooves 110 by, for example, clamps, screws,
clips, pins, interlocking surfaces, or combinations of these. When
the sub-assembly 111 is disposed within the component 100, the
coupling member 112 may be positioned along and contact the first
surface 102. Depending on the depth of the channels 104, this
placement of the coupling member 112 may enable about half of the
volume of the metal spheres 106 to be disposed within the channels
104, which may result in uniform rotation and load balance of the
metal spheres 106.
[0052] Referring again to FIG. 1, once fully assembled, the surface
of the component 100 that contacts petroleum-based materials (also
referred to as a contact surface) may include any portion of the
first surface that has not been covered by the metal spheres 106,
such as the ridges 108 or any unfilled channels 104, and any
exposed portion of the surface of the metal spheres 106. The
surface area of the contact surface of the fully assembled
component 100 may be significantly greater than the surface area of
the first surface 102 alone. That is, the installation of the metal
spheres 106 within the channels 104 defined by the first surface
102 may significantly increase the surface area that contacts any
petroleum-based materials passed through the component 100. For
example, in embodiments, the contact surface of the fully assembled
first component 100 may be at least 45 percent (%), at least 50%,
at least 55%, at least 60%, at least 65%, at least 70%, or at least
75% greater than the surface area of the first surface 102
alone.
[0053] Without being bound by any particular theory, it is believed
that such an increased surface area may reduce the time required
for a petroleum-based material to be processed within the component
100, increase the yield of effluent from the component 100, or
both. The time required for a petroleum-based material to be
processed within the component 100 (that is, the residence time)
may be determined by dividing the volume of the component 100 by
the volumetric flow rate of the petroleum-based materials though
the component 100. The inclusion of the metal spheres 106 within
the component 100 may increase the contact surface of the component
100 while also reducing the volume of the component 100. As a
result, the residence time of the petroleum-based material within
the component 100 may be reduced without reducing the yield of the
petrochemical processing system. That is, not only may the metal
spheres reduce the formation and accumulation of solid deposits on
the first surface 102, the metal spheres may also increase the
yield and efficiency of the petrochemical processing system by
increasing the surface area available for heat transfer to or from
the petroleum-based materials.
[0054] Referring now to FIG. 5, one or more of the first surface
102, the channels 104, and the metal spheres 106 may be further
modified depending on the operating conditions of the petrochemical
processing system. For example, as depicted in FIG. 5, the metal
spheres 106 may further comprise metal wedges 116 that extend
through the metal spheres 106. In embodiments, the metal wedge 116
may extend through a bore that extends all the way through the
metal spheres 106 such that the metal wedges 116 protrudes from the
metal sphere 106 at both ends of the bore. In embodiments, the
metal wedge 116 may include one or more individual metal wedges
that are coupled, such as be welding, at antipodal points of the
metal sphere 106. The bore or the antipodal points may be oriented
along a diameter of the metal sphere 106 that is normal to the
first surface 102. When the bore is oriented along such a diameter,
the rotation speed of the metal sphere 106 about an axes that is
perpendicular to a line normal to the first surface 102 may be
increased by the metal wedge 116. The rotational speed may be
increased by the force of the flowing fluids contacting the wedges.
As a result, the dynamics of the first surface 102 may be further
increased and the deposition and accumulation of solid deposits may
be reduced. In such embodiments, the shape and dimensions of the
channels 104 may also be further modified to accommodate the metal
wedges 116 so as to not inhibit the free rotation of the metal
spheres 106.
[0055] Referring again to FIG. 1, the component 100 may further
comprise a second surface 118, which is opposite the first surface
102. In embodiments, the second surface 118 may comprise one or
more additional elements that may facilitate the function of the
component 100 within the petrochemical processing system. For
example, in embodiments the second surface 118 may comprise one or
more heat transfer elements 120, such as a heating coil, heat
transfer fluid conduit, heating or cooling jacket, or other heat
transfer element, or combinations of elements. The heat transfer
elements 120 may facilitate the heating or cooling of the component
100 and, in particular, maintaining the contact surface of the
component 100 at a temperature suitable for the processing of a
petroleum-based material.
[0056] Additionally or alternatively, the second surface 118 may
comprise a conducting element 122 electrically coupled to a power
source and operable to conduct an electric current. Without being
bound by any particular theory, it is believed that the passing of
an electric current through the conducting element may generate a
magnetic field within the component 100. The magnetic field may
cause the metal spheres to rotate even when no petroleum-based
materials are being passed through the component 100. Such induced
rotation may be particularly useful in petrochemical processing
systems, such as batch reactors, where the movement or flow rate of
the petroleum-based materials through the component 100 is too slow
to rotate the metal spheres 106.
[0057] Still referring to FIG. 1, methods for reducing deposition
and accumulation of solid deposits, such as petroleum coke, during
petrochemical processing may be conducted using the component 100
of the petrochemical processing system. As noted previously, the
petrochemical processing system may include a component 100
including a first surface 102, which may define a plurality of
channels 104. The component 100 may further include a plurality of
metal spheres 106 disposed within the channels 104. The metal
spheres 106 may be fixed in place within the channels 104 such that
the positions of the metal spheres 106 are fixed, but the metal
spheres 106 are freely rotatable. The component may also have
include any of the features, characteristics, or properties
previously described in the present disclosure for the component
100. The method may comprise passing a hydrocarbon feed through a
petrochemical processing system operable to heat the hydrocarbon
feed to a temperature suitable to thermally crack hydrocarbons in
the hydrocarbon feed and produce an effluent. As noted previously,
the systems and methods of the present disclosure, which reduce the
deposition and accumulation of solid deposits, may be applied to a
variety of petrochemical processing systems, such as a visbreaker
system, a supercritical water system, a steam pyrolysis system, an
aqua-conversion system, or combinations of these. Accordingly, the
effluent produced by the methods of the present disclosure may be a
visbreaker effluent, a supercritical water effluent, a steam
pyrolysis effluent, an aqua-conversion effluent, or combinations of
these.
[0058] The hydrocarbon feed may comprise a mixture of
petroleum-based materials. The petroleum-based materials of the
hydrocarbon feed may comprise hydrocarbons derived from crude oil.
The hydrocarbon feed may comprise crude oil, distillates, residues,
tar sands, bitumen, atmospheric residue, vacuum gas oils,
demetalized oils, naphtha streams, gas condensate streams, or
combinations of these. The hydrocarbon feed may further comprise
one or more non-hydrocarbon constituents, such as metal compounds,
sulfur compounds, nitrogen compounds, inorganic compounds, or
combinations of these. One or more supplemental feeds (not
depicted) may be mixed with the hydrocarbon feed prior to
introducing the hydrocarbon feed to the petrochemical processing
system or introduced independently to the petrochemical processing
system in addition to the hydrocarbon feed. For example, the
hydrocarbon feed may comprise a naphtha stream and one or more
supplemental streams, such as vacuum residue, atmospheric residue,
vacuum gas oils, demetalized oils, gas condensate, or other
hydrocarbon streams, or combinations of these.
[0059] In embodiments, the petrochemical processing system may be
operable to heat the hydrocarbon feed to a temperature suitable to
thermally crack hydrocarbons in the hydrocarbon feed and produce an
effluent. The hydrocarbon feed may be heated by the petrochemical
processing system and, in particular, the component 100 of the
petrochemical processing system by one or more heating elements on
the second surface 118 of the component 100. In embodiments, the
hydrocarbon feed may be heated to a temperature of from 250.degree.
C. to 1,000.degree. C. For example, the hydrocarbon feed may be
heated to a temperature of from 250.degree. C. to 875.degree. C.,
from 250.degree. C. to 750.degree. C., from 250.degree. C. to
625.degree. C., from 250.degree. C. to 500.degree. C., from
250.degree. C. to 375.degree. C., from 375.degree. C. to
1,000.degree. C., from 375.degree. C. to 875.degree. C., from
375.degree. C. to 750.degree. C., from 375.degree. C. to
625.degree. C., from 375.degree. C. to 500.degree. C., from
500.degree. C. to 1,000.degree. C., from 500.degree. C. to
875.degree. C., from 500.degree. C. to 750.degree. C., from
500.degree. C. to 625.degree. C., from 625.degree. C. to
1,000.degree. C., from 625.degree. C. to 875.degree. C., from
625.degree. C. to 750.degree. C., from 750.degree. C. to
1,000.degree. C., from 750.degree. C. to 875.degree. C., or from
875.degree. C. to 1,000.degree. C.
[0060] The passing of the hydrocarbon feed through the
petrochemical processing system and, in particular, the component
100 of the petrochemical processing system, may cause the metal
spheres 106 of the component 100 to rotate. As noted previously,
the rotation of the metal spheres 106 may reduce the deposition and
accumulation of solid deposits on the first surface 102 of the
component 100. Without being bound by any particular theory, it is
believed that this reduction or prevention of the formation and
accumulation of solid deposits on the first surface 102 may be due
to the free rotation of the metal spheres 106 providing a dynamic
heated surface that contacts the hydrocarbon feed. That is, as a
result of the free rotation of the metal spheres 106, no single
portion of the contact surface of the component 100 remains static
for a time sufficient for solid deposits to be deposited or further
accumulate.
[0061] In embodiments, the hydrocarbon feed may be passed through
the component 100 at a relatively slow flow rate, or even remains
static within the component 100, such as when the component 100 is
a batch reactor. Such slow flow rates may be insufficient to rotate
the metal spheres 106 or may result in the metal spheres 106
rotating at a speed slow enough for at least some deposition and
accumulation of solid deposits to occur. In such embodiments, the
rotation of the metal spheres 106 may be induced, the rotation
speed of the metal spheres 106 may be increased, or both. The
forced rotation of the metal spheres may be induced by, for
example, the generation of a magnetic field within the component
100. As described previously, the outer surface 118 of the
component 100 may include a conducting element 122, which may
generate a magnetic field when an electric current is passed
through it. As such, the method may further include applying an
electric current to the conducting element 122. The application of
the electric current may generate a magnetic field sufficient to
rotate the metal spheres 106.
[0062] In embodiments, the metal spheres 106 may be rotated, either
due to the flow of the hydrocarbon feed through the component 100,
the forced rotation of the metal spheres 106 by the generation of a
magnetic field, or both, at a rate sufficient to reduce the
deposition and accumulation of solid deposits. The speed of the
rotation may depend on the composition of the hydrocarbon feed and
the propensity of the hydrocarbon feed to produce solid deposits,
and may be determined during the initial operation of the
petrochemical processing system. For example, a greater speed of
rotation may be used when processing hydrocarbon feeds that produce
greater amounts of solid deposits during processing. In contrast,
lower speeds may be used when processing hydrocarbon feeds that
produce less amounts of solid deposits during processing, which may
reduce the wear of the metal spheres 106, the energy requirements
to induce the forced rotation of the metal spheres 106, or
both.
[0063] A first aspect of the present disclosure may include a
petrochemical processing system including a component including a
first surface oriented to contact a process fluid, where the first
surface defines a plurality of channels; and a plurality of metal
spheres disposed at least partially in the plurality of channels,
where each of the plurality of metal spheres is fixed in place
within one of the plurality of channels such that each of the
plurality of metal spheres is freely rotatable.
[0064] A second aspect of the present disclosure may include a
method for reducing accumulation and formation of solid deposits
during petrochemical processing including passing a hydrocarbon
feed through a petrochemical processing system operable to heat the
hydrocarbon feed to a temperature suitable to thermally crack
hydrocarbons in the hydrocarbon feed and produce a effluent, where
the petrochemical processing system comprises: a component
comprising a first surface oriented to contact the hydrocarbon
feed, where the first surface defines a plurality of channels; and
a plurality of metal spheres disposed at least partially within the
plurality of channels, where each of the plurality of metal spheres
is fixed in place within one of the plurality of channels such that
each of the plurality of metal spheres is freely rotatable.
[0065] A third aspect of the present disclosure may include the
second aspect, further including heating the hydrocarbon feed to a
temperature of from 250.degree. C. to 1,000.degree. C. within the
petrochemical processing system.
[0066] A fourth aspect of the present disclosure may include any
one of the first through third aspects, where the component may
further include a wall having the first surface.
[0067] A fifth aspect of the present disclosure may include any one
of the first through fourth aspects, where the wall may include an
alloy including nickel, chromium, copper, molybdenum, or
combinations of these.
[0068] A sixth aspect of the present disclosure may include any one
of the first through fifth aspects, where the component may further
include a wall and an insert fixedly coupled to the wall, where the
insert has the first surface.
[0069] A seventh aspect of the present disclosure may include any
one of the first through sixth aspects, where the component may
include a second surface opposite the first surface, the second
surface including a heat transfer element.
[0070] An eighth aspect of the present disclosure may include any
one of the first through sixth aspects, where the component may
include a second surface opposite the first surface, the second
surface including a conducting element that may be operable to
receive an electric current, where the application of the electric
current through the conducting element may generate a magnetic
field that may cause rotation of the plurality of metal
spheres.
[0071] A ninth aspect of the present disclosure may include any one
of the first through eighth aspects, where each of the plurality of
metal spheres may be coupled to the first surface by a coupling
member that may extend through a bore oriented along a diameter of
the metal sphere.
[0072] A tenth aspect of the present disclosure may include the
ninth aspect, where the coupling member may include a metal ring or
metal rod having a diameter of from 0.5 cm to 10 cm.
[0073] An eleventh aspect of the present disclosure may include
either the ninth or tenth aspect, where the coupling member may
include an alloy including nickel, chromium, copper, molybdenum, or
combinations of these.
[0074] A twelfth aspect of the present disclosure may include any
one of the first through eleventh aspects, where each metal sphere
may have a diameter of from 1 cm to 20 cm.
[0075] A thirteenth aspect of the present disclosure may include
any one of the first through twelfth aspects, where each metal
sphere may have a density of from 5 g/cm.sup.3 to 30
g/cm.sup.3.
[0076] A fourteenth aspect of the present disclosure may include
any one of the first through thirteenth aspects, where each metal
sphere may have a hardness greater than or equal to 40 on the
Rockwell "C" Scale.
[0077] A fifteenth aspect of the present disclosure may include any
one of the first through fourteenth aspects, where each metal
sphere may be heat treated at a temperature of from 750.degree. C.
to 1,500.degree. C.
[0078] A sixteenth aspect of the present disclosure may include any
one of the first through fifteenth aspects, where the plurality of
metal spheres may include an alloy including nickel, chromium,
copper, molybdenum, or combinations of these.
[0079] A seventeenth aspect of the present disclosure may include
any one of the first through sixteenth aspects, where each of the
plurality of metal spheres may include one or more metal wedges
that extend through a bore oriented along a diameter of the metal
sphere that is normal to the first surface.
[0080] An eighteenth aspect of the present disclosure may include
any one of the first through seventeenth aspects, where the
component may have a contact surface including exposed portions of
the metal spheres and the first surface, and a surface area of the
contact surface may be at least 45% greater than a surface area of
the first surface.
[0081] A nineteenth aspect of the present disclosure may include
any one of the first through eighteenth aspects, where the
component may include a reactor, a furnace, a heat exchanger, a
process line, or combinations of these.
[0082] A twentieth aspect of the present disclosure may include any
one of the first through nineteenth aspects, where the
petrochemical processing system may include a visbreaker system, a
supercritical water system, a steam pyrolysis system, an
aqua-conversion system, or combinations of these.
[0083] A twenty-first aspect of the present disclosure may include
any one of the first through twentieth aspects, where each of the
metal spheres may rotate about an axis that is perpendicular to a
line normal to the first surface.
[0084] A twenty-second aspect of the present disclosure may include
any one of the first through twenty-first aspects, where the
channels may be semicircular shaped.
[0085] It is noted that any two quantitative values assigned to a
property may constitute a range of that property, and all
combinations of ranges formed from all stated quantitative values
of a given property are contemplated in this disclosure.
[0086] It is noted that one or more of the following claims utilize
the term "where" as a transitional phrase. For the purposes of
defining the present technology, 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."
[0087] Having described the subject matter of the present
disclosure in detail and by reference to specific aspects, it is
noted that the various details of such aspects should not be taken
to imply that these details are essential components of the
aspects. Rather, the claims appended hereto should be taken as the
sole representation of the breadth of the present disclosure and
the corresponding scope of the various aspects described in this
disclosure. Further, it will be apparent that modifications and
variations are possible without departing from the scope of the
appended claims.
* * * * *