System and method for regenerating particulate solids

Abstract

According to one or more embodiments, particulate solids can be regenerated in a particulate solids treatment vessel. The particulate solids treatment vessel can be connected to a riser. The riser can extend through a riser port of a housing of a particulate solids separation section, such that the riser can include an inner riser section and an outer riser section. The particulate solids separation section can include a gas outlet port, a riser port, and a particulate solids outlet port. The particulate solids separation section can house a gas / solids separation device and a particulate solids collection area. The riser port can be positioned on a sidewall of the housing, such that the riser port is not located on a central vertical axis of the particulate solids separation section. The particulate solids can be separated from a gas in the particulate solids separation section.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit and priority of U.S. Application Serial No. 63 / 126,089, filed on December 16, 2020, entitled "Systems and Methods for Regenerating Particulate Solids," the entire contents of which are incorporated herein by reference. Technical Field

[0003] The embodiments described herein generally involve chemical processing, and more specifically, methods and systems for catalytic chemical transformation. Background Technology

[0004] Many chemicals can be produced using processes employing particulate solids, such as solid particulate catalysts. In these processes, the particulate solids may become "used" and exhibit reduced activity in subsequent reactions. Furthermore, endothermic processes require heat, and the "used" catalyst must be reheated. Therefore, the used particulate solids can be transferred to a regeneration unit for reheating and regeneration, thereby increasing their activity for use in subsequent reactions. After regeneration in the regeneration unit, the regenerated particulate solids can be transferred back to the reactor for use in subsequent reactions. Summary of the Invention

[0005] There is a need for improved methods for regenerating, reactivating, or increasing the activity of particulate solids used in the production of various chemicals, such as, but not limited to, light olefins. Many regenerator systems for regenerating particulate solids include a particulate solids handling vessel positioned directly below a particulate solids separation section, such that a riser extends from the particulate solids handling vessel through the bottom of the particulate solids separation section. Such a design can adversely affect the flow of particulate solids through the particulate solids separation section by creating an annular space at the bottom of the section, in which the outlet cannot be positioned at the bottom of the section.

[0006] One or more currently disclosed methods for regenerating particulate solids utilize a system that addresses this problem. In one or more embodiments, the riser does not enter the particulate solids separation section through the bottom. Therefore, the particulate solids outlet can be positioned at the bottom of the particulate solids separation section, thereby improving the flow characteristics of the particulate solids leaving the particulate solids separation section.

[0007] According to one or more embodiments disclosed herein, particulate solids can be regenerated by a method comprising regenerating particulate solids in a particulate solids processing container. This regeneration of the particulate solids may include one or more of the following: oxidizing the particulate solids by contacting them with an oxygen-containing gas; burning coke present on the particulate solids; or burning supplemental fuel to heat the particulate solids. The method may further include conveying the particulate solids through a riser. The riser may extend through a riser port of a housing of a particulate solids separation section, such that the riser includes an inner riser segment located in an inner region of the particulate solids separation section and an outer riser segment located outside the housing of the particulate solids separation section. The particulate solids separation section may at least include a housing defining an inner region of the particulate solids separation section. The housing may include a gas outlet port, a riser port, and a particulate solids outlet port. The housing may house a gas / solid separation device and a particulate solids collection area in the inner region of the particulate solids separation section. The riser port may be located on a sidewall of the housing such that the riser port is not located on the central vertical axis of the particulate solids separation section. The method may further include separating the particulate solids from the gas in the gas / solid separation device and conveying the particulate solids separated from the gas to the particulate solids collection area located near the central vertical axis of the particulate solids separation section.

[0008] It should be understood that both the foregoing summary and the following detailed description present embodiments of the present technology and are intended to provide an overview or framework for understanding the nature and features of the claimed technology. Drawings are included to provide further understanding of the technology, and these drawings are incorporated in and form part of this specification. The drawings illustrate various embodiments and, together with the description, serve to explain the principles and operation of the technology. Furthermore, the drawings and description are intended to be illustrative only and are not intended to limit the scope of the claims in any way.

[0009] Further features and advantages of the invention disclosed herein will be set forth in the following detailed description, and will be apparent in part from the description or recognized by practice of the invention as described herein, including the following detailed description, claims and drawings. Attached Figure Description

[0010] The following detailed description of specific embodiments of this disclosure is best understood in conjunction with the following drawings, in which similar reference numerals indicate similar structures and in the drawings:

[0011] Figure 1A reactor system comprising a reactor section and a regenerator section according to one or more embodiments disclosed herein is schematically depicted;

[0012] Figure 2 A particulate solids handling container and an external riser segment are schematically depicted according to one or more embodiments disclosed herein;

[0013] Figure 3 A particulate solids separation section according to one or more embodiments disclosed herein is schematically depicted;

[0014] Figure 4 A particulate solids collection region according to one or more embodiments disclosed herein is depicted;

[0015] Figure 5 A particulate solids collection region according to one or more embodiments disclosed herein is depicted; and

[0016] Figure 6 The residence time distribution of the particulate solids collection area according to one or more embodiments disclosed herein is depicted graphically.

[0017] It should be understood that the accompanying drawings are schematic in nature and do not include some components commonly used in fluid catalytic reactor systems in the art, such as, but not limited to, temperature transmitters, pressure transmitters, flow meters, pumps, valves, etc. These components are well known to be within the spirit and scope of the disclosed embodiments. However, operating components (such as those described in this disclosure) may be added to the embodiments described in this disclosure.

[0018] Reference will now be made in more detail to various embodiments, some of which are shown in the accompanying drawings. Where possible, the same reference numerals will be used throughout the drawings to refer to the same or similar parts. Detailed Implementation

[0019] As described herein, the methods for regenerating particulate solids disclosed herein can be used to regenerate particulate solids from reactor systems used for processing chemical streams. Such methods utilize systems with specific characteristics, such as the specific orientation of system components. For example, in one or more embodiments described herein, the particulate solids processing vessel is not directly located below the particulate solids separation section. A specific embodiment disclosed in detail herein is depicted in… Figure 1 However, it should be understood that the principles disclosed and taught herein can be applied to other systems utilizing different system components oriented in different ways, or to different reaction schemes utilizing various catalyst compositions.

[0020] Now for reference Figure 1As will be understood with reference to the foregoing figures and description, the feed chemicals can react by contacting particulate solids, such as catalysts, in reactor section 200. The particulate solids can be separated from the reaction products in reactor section 200 and conveyed to regeneration section 300. In regeneration section 300, the particulate solids can be regenerated. These regenerated particulate solids can then be conveyed back to reactor section 200 for subsequent reaction cycles.

[0021] While some embodiments are described herein in the context of reactor system 100, it should be understood that the methods and systems described herein can be operated without reactor section 200, or using alternative means for reacting the feed stream. Therefore, reactor section 200 should not be construed as necessary or required in all embodiments of the currently disclosed methods and systems.

[0022] In a non-limiting example, the reactor system 100 described herein can be used to produce light olefins from a hydrocarbon feed stream. Light olefins can be produced using various hydrocarbon feed streams with different reaction mechanisms. For example, light olefins can be produced by at least dehydrogenation, cracking, dehydration, and methanol-to-olefins reactions. These reaction types can utilize different feed streams and different particulate solids to produce light olefins. It should be understood that when “catalyst” is mentioned herein, the catalyst can also refer to… Figure 1 The system refers to granular solids.

[0023] According to one or more embodiments, the reaction can be a dehydrogenation reaction. According to such embodiments, the hydrocarbon feed stream can include one or more of ethylbenzene, ethane, propane, n-butane, and isobutane. In one or more embodiments, the hydrocarbon feed stream can contain at least 50 wt.%, at least 60 wt.%, at least 70 wt.%, at least 80 wt.%, at least 90 wt.%, at least 95 wt.%, or even at least 99 wt.% of ethane. In another embodiment, the hydrocarbon feed stream can contain at least 50 wt.%, at least 60 wt.%, at least 70 wt.%, at least 80 wt.%, at least 90 wt.%, at least 95 wt.%, or even at least 99 wt.% of propane. In yet another embodiment, the hydrocarbon feed stream can contain at least 50 wt.%, at least 60 wt.%, at least 70 wt.%, at least 80 wt.%, at least 90 wt.%, at least 95 wt.%, or even at least 99 wt.% of n-butane. In another embodiment, the hydrocarbon feed stream may contain at least 50 wt.%, at least 60 wt.%, at least 70 wt.%, at least 80 wt.%, at least 90 wt.%, at least 95 wt.%, or even at least 99 wt.% of isobutane. In another embodiment, the hydrocarbon feed stream may contain at least 50 wt.%, at least 60 wt.%, at least 70 wt.%, at least 80 wt.%, at least 90 wt.%, at least 95 wt.%, or even at least 99 wt.% of the sum of ethane, propane, n-butane, and isobutane.

[0024] In one or more embodiments, the dehydrogenation reaction may utilize gallium and / or platinum particulate solids as catalysts. In such embodiments, the particulate solids may comprise gallium and / or platinum catalysts. As described herein, gallium and / or platinum catalysts comprise gallium, platinum, or both. Gallium and / or platinum catalysts may be supported on an alumina or alumina-silica support and may optionally include potassium. Such gallium and / or platinum catalysts are disclosed in U.S. Patent No. 8,669,406, which is incorporated herein by reference in its entirety. However, it should be understood that other suitable catalysts may be used for the dehydrogenation reaction.

[0025] In one or more embodiments, the reaction mechanism may be dehydrogenation followed by combustion (in the same chamber). In such embodiments, the dehydrogenation reaction can produce hydrogen as a byproduct, and the oxygen-carrying material can contact the hydrogen and facilitate its combustion, thereby forming water. Examples of such reaction mechanisms are disclosed in WO 2020 / 046978, which are considered possible reaction mechanisms for the systems and methods described herein, the teachings of which are incorporated herein by reference in their entirety.

[0026] According to one or more embodiments, the reaction can be a cracking reaction. According to such embodiments, the hydrocarbon feed stream can contain one or more of naphtha, n-butane, or isobutane. According to one or more embodiments, the hydrocarbon feed stream can contain at least 50 wt.%, at least 60 wt.%, at least 70 wt.%, at least 80 wt.%, at least 90 wt.%, at least 95 wt.%, or even at least 99 wt.% of naphtha. In another embodiment, the hydrocarbon feed stream can contain at least 50 wt.%, at least 60 wt.%, at least 70 wt.%, at least 80 wt.%, at least 90 wt.%, at least 95 wt.%, or even at least 99 wt.% of n-butane. In another embodiment, the hydrocarbon feed stream can contain at least 50 wt.%, at least 60 wt.%, at least 70 wt.%, at least 80 wt.%, at least 90 wt.%, at least 95 wt.%, or even at least 99 wt.% of isobutane. In another embodiment, the hydrocarbon feed stream may contain at least 50 wt.%, at least 60 wt.%, at least 70 wt.%, at least 80 wt.%, at least 90 wt.%, at least 95 wt.%, or even at least 99 wt.% of naphtha, n-butane, and isobutane.

[0027] In one or more embodiments, the cracking reaction may utilize one or more zeolites as catalysts. In such embodiments, the particulate solids may include one or more zeolites. In some embodiments, the one or more zeolites used in the cracking reaction may include ZSM-5 zeolite. However, it should be understood that other suitable catalysts may be used for the cracking reaction. For example, commercially available suitable catalysts may include Intercat Super Z Excel or Intercat Super Z Exceed. In another embodiment, in addition to the catalytically active material, the cracking catalyst may also include platinum. For example, the cracking catalyst may include 0.001 wt.% to 0.05 wt.% platinum. Platinum may be sprayed in the form of platinum nitrate and calcined at elevated temperatures (such as about 700°C). Without being bound by theory, it is believed that the addition of platinum to the catalyst may allow for easier combustion of supplemental fuels such as methane.

[0028] According to one or more embodiments, the reaction can be a dehydration reaction. According to such embodiments, the hydrocarbon feed stream can contain one or more of ethanol, propanol, or butanol. According to one or more embodiments, the hydrocarbon feed stream can contain at least 50 wt.%, at least 60 wt.%, at least 70 wt.%, at least 80 wt.%, at least 90 wt.%, at least 95 wt.%, or even at least 99 wt.% of ethanol. In another embodiment, the hydrocarbon feed stream can contain at least 50 wt.%, at least 60 wt.%, at least 70 wt.%, at least 80 wt.%, at least 90 wt.%, at least 95 wt.%, or even at least 99 wt.% of propanol. In another embodiment, the hydrocarbon feed stream can contain at least 50 wt.%, at least 60 wt.%, at least 70 wt.%, at least 80 wt.%, at least 90 wt.%, at least 95 wt.%, or even at least 99 wt.% of butanol. In another embodiment, the hydrocarbon feed stream may contain at least 50 wt.%, at least 60 wt.%, at least 70 wt.%, at least 80 wt.%, at least 90 wt.%, at least 95 wt.%, or even at least 99 wt.% of the total of ethanol, propanol, and butanol.

[0029] In one or more embodiments, the dehydration reaction may utilize one or more acid catalysts. In such embodiments, the particulate solid may comprise one or more acid catalysts. In some embodiments, the one or more acid catalysts used in the dehydration reaction may comprise zeolites (such as ZSM-5 zeolite), alumina, amorphous aluminosilicates, acidic clays, or combinations thereof. For example, according to one or more embodiments, potentially suitable commercially available alumina catalysts include SynDol (available from Scientific Design Company), V200 (available from UOP), or P200 (available from Sasol). Potentially suitable commercially available zeolite catalysts include CBV 8014 and CBV 28014 (each available from Zeolyst). Potentially suitable commercially available amorphous aluminosilicate catalysts include silica-alumina catalyst supports, grade 135 (available from Sigma-Aldrich). However, it should be understood that other suitable catalysts may be used for the dehydration reaction.

[0030] According to one or more embodiments, the reaction can be a methanol-to-olefins reaction. According to such embodiments, the hydrocarbon feed stream can contain methanol. According to one or more embodiments, the hydrocarbon feed stream can contain at least 50 wt.%, at least 60 wt.%, at least 70 wt.%, at least 80 wt.%, at least 90 wt.%, at least 95 wt.%, or even at least 99 wt.% of methanol.

[0031] In one or more embodiments, the methanol-to-olefins reaction can utilize one or more zeolites as catalysts. In such embodiments, the particulate solids may include one or more zeolites. In some embodiments, the one or more zeolites used in the methanol-to-olefins reaction may include one or more of ZSM-5 zeolite or SAPO-34 zeolite. However, it should be understood that other suitable catalysts can be used for the methanol-to-olefins reaction.

[0032] In one or more embodiments, the operation of the chemical process may include discharging a product stream from a reactor. The product stream may contain light olefins. As described herein, "light olefins" refers to one or more of ethylene, propylene, or butene. As described herein, butene may include any isomer of butene, such as α-butene, cis-β-butene, trans-β-butene, and isobutene. In one embodiment, the product stream may contain at least 50 wt.% light olefins. For example, the product stream may contain at least 60 wt.% light olefins, at least 70 wt.% light olefins, at least 80 wt.% light olefins, at least 90 wt.% light olefins, at least 95 wt.% light olefins, or even at least 99 wt.% light olefins.

[0033] Still referencing Figure 1 The reactor system 100 typically includes multiple system components, such as the reactor section 200 and the regeneration section 300. As described herein... Figure 1As used in the context, reactor section 200 generally refers to the portion of reactor system 100 where the main process reaction takes place and particulate solids are separated from the olefin-containing product stream of the reaction. In one or more embodiments, the particulate solids may be used, meaning they are at least partially deactivated. Furthermore, as used herein, regeneration section 300 generally refers to the portion of a fluid catalytic reactor system where particulate solids are regenerated, such as by combustion, and the regenerated particulate solids are separated from other process materials, such as gases released from previously burned materials on used particulate solids or from supplementary fuel. Reactor section 200 generally includes a reaction vessel 250, a riser 230 including an external riser section 232 and an internal riser section 234, and a particulate solids separation section 210. Regeneration section 300 generally includes a particulate solids handling vessel 350, a riser 330 including an external riser section 332 and an internal riser section 334, and a particulate solids separation section 310. Typically, the particulate solids separation section 210 can be in fluid communication with the particulate solids processing container 350, for example, via the riser 126, and the particulate solids separation section 310 can be in fluid communication with the reaction container 250, for example, via the riser 124 and the conveying riser 130.

[0034] Typically, reactor system 100 can be operated by feeding hydrocarbon feed and fluidized particulate solids into reaction vessel 250, and reacting the hydrocarbon feed with the fluidized particulate solids to produce an olefin-containing product in reaction vessel 250 of reactor section 200. The olefin-containing product and particulate solids can be discharged from reaction vessel 250 and reach gas / solid separator 220 in particulate solids separation section 210 via riser 230, where the particulate solids are separated from the olefin-containing product. The particulate solids can be discharged from particulate solids separation section 210 to particulate solids processing vessel 350. In particulate solids processing vessel 350, the particulate solids can be regenerated through various processes. For example, used particulate solids can be regenerated by one or more of the following methods: oxidizing the particulate solids by contacting with oxygen-containing gas, burning coke present on the particulate solids, and burning supplementary fuel to heat the particulate solids. The particulate solids are then discharged from the particulate solids processing container 350 and pass through a riser 330 to a riser termination device 378, where the gas and particulate solids from the riser 330 are partially separated. The gas from the riser 330 and the remaining particulate solids are conveyed to a secondary separation device 320 in the particulate solids separation section 310, where the remaining particulate solids are separated from the gas from the regeneration reaction. The particulate solids separated from the gas can be conveyed to the particulate solids collection area 380. The separated particulate solids are then conveyed from the particulate solids collection area 380 to the reaction vessel 250, where they are further utilized. Thus, the particulate solids can be circulated between the reactor section 200 and the regeneration section 300.

[0035] In one or more embodiments, reactor system 100 may include reactor section 200 or regeneration section 300, but not both. In another embodiment, reactor system 100 may include a single regeneration section 300 and multiple reactor sections 200.

[0036] Furthermore, as described herein, the structural features of reactor section 200 and regeneration section 300 may be similar or identical in some respects. For example, each of reactor section 200 and regeneration section 300 includes a reaction vessel (i.e., reaction vessel 250 of reactor section 200 and particulate solids handling vessel 350 of regeneration section 300), a riser (i.e., riser 230 of reactor section 200 and riser 330 of regeneration section 300), and a particulate solids separation section (i.e., particulate solids separation section 210 of reactor section 200 and particulate solids separation section 310 of regeneration section 300). It should be understood that, since many structural features in the reactor section 200 and the regeneration section 300 may be similar or identical in some respects, similar or identical portions of the reactor section 200 and the regeneration section 300 are provided throughout this disclosure with the same last two digits of reference numerals, and the disclosure relating to a portion of the reactor section 200 may be applied to similar or identical portions of the regeneration section 300, and vice versa.

[0037] like Figure 1 As depicted, reaction vessel 250 may include a reaction vessel particulate solids inlet port 252 defining the connection between the delivery riser 130 and the reaction vessel 250. Reaction vessel 250 may additionally include a reaction vessel outlet port 254 in fluid communication with or directly connected to an external riser segment 232 of the riser 230. As described herein, "reaction vessel" refers to a drum, barrel, vat, or other container suitable for a given chemical reaction. The shape of a reaction vessel may be generally cylindrical (i.e., having a substantially circular diameter), or alternatively, may be non-cylindrical, such as a prism shape having a triangular, rectangular, pentagonal, hexagonal, octagonal, elliptical, or other polygonal, or curved closed, or combined thereof cross-sectional shape. As used throughout this disclosure, reaction vessels typically include a metal frame and may additionally include a refractory lining or other materials for protecting the metal frame and / or controlling process conditions.

[0038] Generally, the terms "inlet port" and "outlet port" for any system unit of the fluid catalytic reactor system 100 described herein refer to an opening, hole, channel, pore, gap, or other similar mechanical feature within the system unit. For example, an inlet port allows material to enter a particular system unit, and an outlet port allows material to exit a particular system unit. Typically, an outlet port or inlet port defines an area of ​​the system unit of the fluid catalytic reactor system 100 to which a pipe, conduit, tube, hose, delivery line, or similar mechanical feature is attached, or defines a portion of the system unit to which another system unit is directly attached. While inlet and outlet ports may sometimes be described herein as functionally operable, they may have similar or identical physical properties, and their respective functions within an operable system should not be construed as limiting their physical structure. Other ports (such as riser port 218) may include openings in a given system unit to which other system units are directly attached, such as where riser 230 extends from riser port 218 into the particulate solids separation section 210.

[0039] The reaction vessel 250 can be connected to a conveyor riser 130, which, during operation, supplies the regenerated particulate solids and chemical feed to the reactor section 200. Particulate solids entering the reaction vessel 250 via the conveyor riser 130 can reach the conveyor riser 130 via a riser 124, thus reaching the regeneration section 300. In some embodiments, the particulate solids can directly originate from the particulate solids separation section 210 via a riser 122 and enter the conveyor riser 130, where they enter the reaction vessel 250. These particulate solids may be slightly deactivated, but in some embodiments, they may still be suitable for use in the reaction vessel 250.

[0040] like Figure 1 As depicted, the reaction vessel 250 can be directly connected to the external riser section 232. In one embodiment, the reaction vessel 250 may include a reaction vessel body section 256 and a reaction vessel transition section 258 positioned between the reaction vessel body section 256 and the external riser section 232. The reaction vessel body section 256 may typically include a larger diameter than the reaction vessel transition section 258, and the reaction vessel transition section 258 tapers from the diameter of the reaction vessel body section 256 to the diameter of the riser 230, such that the reaction vessel transition section 258 protrudes inward from the reaction vessel body section 256 to the external riser section 232. It should be understood that, as used herein, the diameter of a portion of a system unit refers to its overall width, such as... Figure 1 As shown in the horizontal direction.

[0041] In one or more embodiments, the reaction vessel 250 may have at least three times the maximum cross-sectional area of ​​the riser 230. For example, the reaction vessel 250 may have at least three, at least four, at least five, at least six, at least seven, at least eight, at least nine, or even at least ten times the maximum cross-sectional area of ​​the riser 230. As stated herein, unless otherwise expressly stated, “cross-sectional area” refers to the area of ​​a portion of a system component across a cross-section in a plane substantially orthogonal to the overall flow direction of the reactants and / or products.

[0042] Still referencing Figure 1 Reactor section 200 may include a riser 230 for conveying reactants, products, and / or particulate solids from reaction vessel 250 to particulate solids separation section 210. In one or more embodiments, the riser 230 may be generally cylindrical (i.e., having a substantially circular cross-sectional shape), or alternatively may be non-cylindrical, such as a prism shape having a triangular, rectangular, pentagonal, hexagonal, octagonal, elliptical, or other polygonal, or curved closed, or combinations thereof cross-sectional shape. As used throughout this disclosure, the riser 230 typically includes a metal frame and may additionally include a refractory lining or other materials for protecting the metal frame and / or controlling process conditions.

[0043] According to some implementation schemes, the riser 230 may include an outer riser segment 232 and an inner riser segment 234. As used herein, an "outer riser segment" refers to the portion of the riser outside the particulate solids separation section, and an "inner riser segment" refers to the portion of the riser inside the particulate solids separation section. For example, in Figure 1 In the described embodiment, the internal riser section 234 of the reactor section 200 can be located within the particulate solids separation section 210, while the external riser section 232 is located outside the particulate solids separation section 210.

[0044] In one or more embodiments, the particulate solids separation section 210 may include a housing 212, wherein the housing 212 may define an internal region 214 of the particulate solids separation section 210. The housing 212 may include a gas outlet port 216, a riser port 218, and a particulate solids outlet port 222. Furthermore, the housing 212 may accommodate the gas / solids separation device 220 and the particulate solids collection area 280 within the internal region 214 of the particulate solids separation section 210.

[0045] In one or more embodiments, the outer shell 212 of the particulate solids separation section 210 may define an upper section 276, an intermediate section 274, and a lower section 272 of the particulate solids separation section 210. Typically, the upper section 276 may have a substantially constant cross-sectional area, such that the cross-sectional area variation in the upper section 276 does not exceed 20%. Additionally, in one or more embodiments, the lower section 272 of the particulate solids separation section 210 may have a substantially constant cross-sectional area, such that the cross-sectional area variation in the lower section 272 does not exceed 20%. The cross-sectional area of ​​the lower section 272 may be greater than the maximum cross-sectional area of ​​the riser 230 and less than the maximum cross-sectional area of ​​the upper section 276. The intermediate section 274 may be shaped as a frustum, wherein the cross-sectional area of ​​the intermediate section 274 is not constant, and the cross-sectional area of ​​the intermediate section 274 transitions from the cross-sectional area of ​​the upper section 276 to the cross-sectional area of ​​the lower section 272 throughout the intermediate section 274.

[0046] like Figure 1 As depicted, the inner riser segment 234 of the riser 230 may extend through the riser port 218 of the particulate solids separation section 210. The riser port 218 may be any opening in the particulate solids separation section 210 through which at least the inner riser segment 234 of the riser 230 protrudes into the inner region 214 of the particulate solids separation section 210. In one or more embodiments, the inner riser segment 234 enters the particulate solids separation section 210 in an intermediate segment 274 or an upper segment 276 and does not pass through a lower segment 272.

[0047] At the upper section 276 of the particulate solids separation section 210, the internal riser section 234 may be in fluid communication with the gas / solids separation device 220. The gas / solids separation device 220 may be any mechanical or chemical separation device operable to separate particulate solids from the gas or liquid phase, such as a cyclone separator or multiple cyclone separators.

[0048] Particulate solids can move upwards from the reaction vessel 250 via riser 230 and into the gas / solid separator 220. The gas / solid separator 220 is operable to deposit the separated particulate solids into the bottom of the upper section 276 or into the middle section 274 or lower section 272. Separated vapors can be removed from the fluid catalytic reactor system 100 via pipe 120 at the gas outlet port 216 of the particulate solids separation section 210.

[0049] In one or more embodiments, the lower section 272 of the particulate solids separation section 210 may include a particulate solids collection region 280. In one or more embodiments, the particulate solids collection region 280 may allow particulate solids to accumulate within the particulate solids separation section 210. The particulate solids collection region 280 may include a stripping section. The stripping section may be used to remove product vapors from the particulate solids before they are fed to the regeneration section 300. Since the product vapors fed to the regeneration section 300 will be combusted, it is desirable to remove those product vapors using a stripping tower that utilizes a gas that is cheaper than the product gas for combustion.

[0050] The particulate solids collection area 280 in the lower section 272 may include a particulate solids outlet port 222. A riser 126 may be connected at the particulate solids outlet port 222 to a particulate solids separation section 210, through which particulate solids can be transferred out of reactor section 200 and into regeneration section 300. Optionally, the particulate solids may also be transferred directly back to reaction vessel 250 via riser 122. Alternatively, the particulate solids may be premixed with the regenerated particulate solids in the conveyor riser 130.

[0051] After separation in the particulate solids separation section 210, the used particulate solids are transferred to the regeneration section 300. As described herein, the regeneration section 300 may share many structural similarities with the reactor section 200. Therefore, the reference numerals assigned to these portions of the regeneration section 300 are similar to those used with reference to the reactor section 200, wherein given portions of the reactor section 200 and the regeneration section 300 may function similarly and have similar physical structures if the last two digits of the reference numerals are the same. Therefore, much of the disclosure relating to the regeneration section 300 can also be applied to the reactor section 200.

[0052] Now referencing the regeneration section 300, such as Figure 1 and Figure 2The depicted particulate solids handling container 350 of the regeneration section 300 may include one or more reactor vessel inlet ports 352 and reactor vessel outlet ports 354 that are in fluid communication with or even directly connected to an external riser section 332 of the riser 330. The particulate solids handling container 350 may be in fluid communication with the particulate solids separation section 210 via a riser 126 that supplies used particulate solids from the reactor section 200 to the regeneration section 300 for regeneration. The particulate solids handling container 350 may include additional reactor vessel inlet ports 352, wherein inlet 128 is connected to the particulate solids handling container 350. Inlet 128 may supply reaction fluids, such as supplemental fuel and oxygen-containing gases in liquid or gaseous form, including air, oxygen-enriched air, and even pure oxygen, which may be used to at least partially regenerate the particulate solids. In one or more embodiments, the particulate solids processing container 350 may include a plurality of additional reactor vessel inlet ports, and each additional reactor inlet port may supply a different reaction fluid to the particulate solids processing container 350. For example, the particulate solids may coke after reacting in the reaction vessel 250, and the coke may be removed from the particulate solids by a combustion reaction. In alternative examples, an oxygen-containing gas, such as air, may be fed into the particulate solids processing container 350 through inlet 128 to oxidize the particulate solids, or supplemental fuel may be fed into the particulate solids processing container 350 and burned to heat the particulate solids.

[0053] like Figure 1 and Figure 2 As depicted, the particulate solids handling container 350 can be directly connected to the outer riser section 332 of the riser 330. In one embodiment, the particulate solids handling container 350 may include a particulate solids handling container body section 356 and a particulate solids handling container transition section 358. The particulate solids handling container body section 356 typically includes a larger diameter than the particulate solids handling container transition section 358, and the particulate solids handling container transition section 358 tapers from the diameter of the particulate solids handling container body section 356 to the diameter of the outer riser section 332, such that the particulate solids handling container transition section 358 protrudes inward from the particulate solids handling container body section 356 to the outer riser section 332.

[0054] In one or more embodiments, the particulate solids handling container 350 may have at least three times the maximum cross-sectional area of ​​the riser 330. For example, the particulate solids handling container 350 may have at least three, at least four, at least five, at least six, at least seven, at least eight, at least nine, at least ten, at least eleven, at least twelve, at least thirteen, at least fourteen, or even at least fifteen times the maximum cross-sectional area of ​​the riser 330.

[0055] Additionally, the main body section 356 of the particulate solids treatment container typically includes a height, which is measured from the reactor vessel inlet port 352 to the particulate solids treatment container transition section 358. In one or more embodiments, the diameter of the main body section 356 may be greater than its height. In one or more embodiments, the ratio of the diameter to the height of the main body section 356 may be from 5:1 to 1:5. For example, the diameter-to-height ratio of the main body section 356 of the particulate solids handling container can be 5:1 to 1:5, 4:1 to 1:5, 3:1 to 1:5, 2:1 to 1:5, 1:1 to 1:5, 1:2 to 1:5, 1:3 to 1:5, 1:4 to 1:5, 5:1 to 1:4, 5:1 to 1:3, 5:1 to 1:2, 5:1 to 1:1, 5:1 to 2:1, 5:1 to 3:1, 5:1 to 4:1, or any combination or sub-combination of these ranges.

[0056] refer to Figure 1 and Figure 3 The particulate solids separation section 310 includes a housing 312 that defines an internal region 314 of the particulate solids separation section 310. The housing 312 may include a gas outlet port 316, a riser port 318, and a particulate solids outlet port 322. Furthermore, the housing 312 can accommodate the secondary separation device 320 and the particulate solids collection area 380 within the internal region 314 of the particulate solids separation section 310.

[0057] In one or more embodiments, the outer shell 312 of the particulate solids separation section 310 may define an upper section 376, an intermediate section 374, and a lower section 372 of the particulate solids separation section 310. Typically, the upper section 376 may have a substantially constant cross-sectional area, such that the cross-sectional area variation in the upper section 376 does not exceed 20%. In one or more embodiments, the cross-sectional area of ​​the upper section 376 may be at least three times the maximum cross-sectional area of ​​the riser tube 330. For example, the cross-sectional area of ​​the upper section 376 may be at least 3 times, at least 4 times, at least 5 times, at least 6 times, at least 7 times, at least 8 times, at least 9 times, at least 10 times, at least 12 times, at least 15 times, or even at least 20 times the maximum cross-sectional area of ​​the riser tube 330, such as 3 to 40 times. In another embodiment, the maximum cross-sectional area of ​​the upper section 376 may be 5 to 40 times the maximum cross-sectional area of ​​the riser tube 330. For example, the maximum cross-sectional area of ​​the upper segment 376 can be 5 to 40 times, 10 to 40 times, 15 to 40 times, 20 to 40 times, 25 to 40 times, 30 to 40 times, 35 to 40 times, 5 to 35 times, 5 to 30 times, 5 to 25 times, 5 to 20 times, 5 to 15 times, or even 5 to 10 times the maximum cross-sectional area of ​​the riser 330.

[0058] Additionally, in one or more embodiments, the lower segment 372 of the particulate solids separation section 310 may have a substantially constant cross-sectional area, such that the cross-sectional area variation in the lower segment 372 does not exceed 20%. The cross-sectional area of ​​the lower segment 372 may be greater than the maximum cross-sectional area of ​​the riser 330 and less than the maximum cross-sectional area of ​​the upper segment 376. The intermediate segment 374 may be shaped as a frustum, wherein the cross-sectional area of ​​the intermediate segment 374 is not constant, and the cross-sectional area of ​​the intermediate segment 374 transitions from the cross-sectional area of ​​the upper segment 376 to the cross-sectional area of ​​the lower segment 372 throughout the intermediate segment 374.

[0059] Refer again Figure 3 The particulate solids separation section 310 may include a central vertical axis 399. The central vertical axis may extend through the top and bottom of the particulate solids separation section 310, such that the central vertical axis 399 passes through the upper segment 376, the middle segment 374, and the lower segment 372 of the particulate solids separation section 310. In one or more embodiments, the upper segment 376, the middle segment 374, and the lower segment 372 of the particulate solids separation section 310 may be centered on the central vertical axis 399. For example, in an embodiment where the upper segment 376 and the lower segment 372 are substantially cylindrical, the central vertical axis 399 may pass through the midpoint of the diameter of the upper segment 376 and the midpoint of the diameter of the lower segment 372.

[0060] like Figure 1 and Figure 3 As depicted, the internal riser segment 334 of the riser 330 may extend through the riser port 318 of the particulate solids separation section 310. The riser port 318 may be any opening in the housing 312 of the particulate solids separation section 310 through which at least the internal riser segment 334 of the riser 330 protrudes into the internal region 314 of the particulate solids separation section 310. In one or more embodiments, the riser port 318 is not located on the central vertical axis 399 of the particulate solids separation section 310. In such embodiments, the riser port 318 may be located on the sidewall of the housing 312 such that the riser port 318 is neither located on the central vertical axis 399 nor oriented such that the riser 330 extends into the particulate solids separation section 310 in a direction substantially parallel to the central vertical axis 399.

[0061] In one or more embodiments, the internal riser segment 334 enters the particulate solids separation section 310 within an intermediate segment 374. In such embodiments, the internal riser segment 334 passes through at least a portion of the intermediate segment 374 and at least a portion of the upper segment 376. In such embodiments, the internal riser segment 334 does not pass through the lower segment 372 of the particulate solids separation section 310. In another embodiment, the internal riser segment 334 may enter the particulate solids separation section 310 within the upper segment 376, and the internal riser segment 334 may pass through at least a portion of the upper segment 376. In such embodiments, the internal riser segment 334 does not pass through the lower segment 372 or the intermediate segment 374.

[0062] Now for reference Figure 3 The internal riser segment 334 may include a vertical portion 396, a non-vertical portion 394, and a non-linear portion 395. As described herein, a "non-linear portion" may refer to a portion or riser segment including a curve or miter joint. The non-linear portion 395 may be positioned between the vertical portion 396 and the non-vertical portion 394, and may connect the vertical portion 396 and the non-vertical portion 394. Additionally, the non-vertical portion 394 of the internal riser segment 334 may be located near the riser port 318. In one or more embodiments, the non-vertical portion 394 of the internal riser segment 334 may be adjacent to or directly connected to the riser port 318. Therefore, the riser 330 may extend through the riser port 318 in a non-vertical direction.

[0063] Refer again Figure 2The external riser segment 332 may include a vertical portion 391, a non-vertical portion 393, and a non-linear portion 392. The non-linear portion 392 may be positioned between the vertical portion 391 and the non-vertical portion 393, and may connect the vertical portion 391 and the non-vertical portion 393. The non-vertical portion 393 of the external riser segment 332 may be located near the riser port 318. In one or more embodiments, the non-vertical portion 393 of the external riser segment 332 may be adjacent to or directly connected to the riser port 318. Furthermore, the vertical portion 391 of the external riser segment 332 may be located near the particulate solids handling container 350. In such embodiments, the expansion joint 382, ​​which is further described in detail herein, may be positioned between the vertical portion 391 of the external riser segment 332 and the particulate solids handling container 350.

[0064] In one or more embodiments, the riser 330 may extend diagonally through the riser port 318, wherein the diagonal direction is at an angle of 15 to 75 degrees to the vertical plane. For example, the diagonal direction may be at an angle of 15 to 75 degrees to the vertical plane, 20 to 75 degrees to the vertical plane, 25 to 75 degrees to the vertical plane, 30 to 75 degrees to the vertical plane, 35 to 75 degrees to the vertical plane, 40 to 75 degrees to the vertical plane, 45 to 75 degrees to the vertical plane, 50 to 75 degrees to the vertical plane, 55 to 75 degrees to the vertical plane, 60 to 75 degrees to the vertical plane, 65 to 75 degrees to the vertical plane, or 70 to 75 degrees to the vertical plane. 75 degrees, 15 to 70 degrees from the vertical plane, 15 to 65 degrees from the vertical plane, 15 to 60 degrees from the vertical plane, 15 to 55 degrees from the vertical plane, 15 to 50 degrees from the vertical plane, 15 to 45 degrees from the vertical plane, 15 to 40 degrees from the vertical plane, 15 to 35 degrees from the vertical plane, 15 to 30 degrees from the vertical plane, 15 to 25 degrees from the vertical plane, 15 to 20 degrees from the vertical plane, or any combination or sub-combination of these ranges. In one or more alternative embodiments, the riser 330 may extend through the riser port 318 in a substantially horizontal direction. As described herein, a “substantially horizontal” direction may be within 15 degrees, 10 degrees, or even 5 degrees of horizontal.

[0065] refer to Figure 1The housing 312 may also accommodate a riser termination device 378. The riser termination device 378 may be located near the internal riser section 334. In one or more embodiments, the riser termination device 378 may be directly connected to the vertical portion 396 of the internal riser section 334. Gas and particulate solids passing through the riser 330 may be at least partially separated by the riser termination device 378. The gas and remaining particulate solids may be conveyed to a secondary separation device 320 in the particulate solids separation section 310. The secondary separation device 320 may be any mechanical or chemical separation device operable to separate particulate solids from the gas or liquid phase, such as a cyclone separator or multiple cyclone separators.

[0066] According to one or more embodiments, the secondary separation unit 320 may be a cyclone separation system that may include two or more cyclone separation stages. In embodiments where the secondary separation unit 320 includes more than one cyclone separation stage, the first separation unit into which the fluidized stream enters is referred to as the primary cyclone separator. The fluidized effluent from the primary cyclone separator may enter the secondary cyclone separator for further separation. The primary cyclone separator may include, for example, a primary cyclone separator and systems commercially available under the names VSS (available from UOP), LD2 (available from Stone and Webster), and RS2 (available from Stone and Webster). Primary cyclone separators are described, for example, in U.S. Patent Nos. 4,579,716, 5,190,650, and 5,275,641, each of which is incorporated herein by reference in its entirety. In some separation systems that utilize a primary cyclone separator as the primary cyclone separation unit, one or more additional cyclone separators, such as secondary and tertiary cyclone separators, are used to further separate particulate solids from the product gas. It should be understood that any primary cyclone separation unit can be used in the embodiments disclosed herein.

[0067] The secondary separation unit 320 can deposit the separated particulate solids into the bottom of the upper section 376, the middle section 374, or the lower section 372 of the particulate solids separation section 310. Therefore, the particulate solids can flow from the bottom of the upper section 376 or the middle section 374 to the lower section 372 by gravity. The separated vapors can be removed from the fluid catalytic reactor system 100 through the pipe 129 at the gas outlet port 316 of the particulate solids separation section 310.

[0068] refer to Figure 1 and Figure 3The lower segment 372 of the particulate solids separation section 310 may include a particulate solids collection region 380, which may allow particulate solids to accumulate in the particulate solids separation section 310. In one or more embodiments, the particulate solids collection region 380 may include one or more of an oxygen soaking region, an oxygen stripping region, and a reduction region.

[0069] As described herein, an "oxygen immersion zone" can refer to the portion of the particulate solids collection area 380 where the particulate solids are exposed to the flow of oxygen-containing gas. In one or more embodiments, the particulate solids may generally flow downwards, while the oxygen-containing gas may generally flow upwards. The particulate solids may have an average residence time greater than 2 minutes in the oxygen immersion zone, and preferably a residence time of 2 to 14 minutes. The particulate solids can become oxygen-containing particulate solids within the oxygen immersion zone, and thus may have increased activity for one or more reactions (including but not limited to dehydrogenation reactions) occurring in reactor section 200.

[0070] The particulate solids collection region 380 may include an oxygen stripping zone. As described herein, an "oxygen stripping zone" refers to the region of the particulate solids collection region 380 where oxygen-containing gas molecules are removed from the particulate solids. Oxygen-containing gas molecules can be removed from the particulate solids by contacting them with a gas containing no more than 0.5 mol.% oxygen. Typically, the particulate solids move downwards, while the gas moves upwards through the oxygen stripping zone. Therefore, excess oxygen-containing gas may not be conveyed to reactor section 200 along with the particulate solids.

[0071] As described herein, the "reduction zone" can refer to the region where a reducing agent, such as hydrogen or methane, is fed into a catalyst stream that is not involved in gas fluidization, such as nitrogen or steam. The reducing agent removes oxygen from the particles; thereby increasing the efficiency of the particles in carrying out the reaction.

[0072] Refer again Figure 1 and Figure 3 The particulate solids collection area 380 may include a particulate solids outlet port 322. In one or more embodiments, the particulate solids outlet port 322 may be located near or even on the central vertical axis 399. According to one or more embodiments, the bottom of the particulate solids collection area 380 may be curved, such that the particulate solids outlet port 322 is located at the lowest part of the particulate solids collection area 380. A riser 124 may be connected to the particulate solids separation section 310 at the particulate solids outlet port 322, and particulate solids may be transferred through the riser 124 out of the regeneration section 300 and into the reactor section 200. Thus, particulate solids can be continuously recycled through the reactor system 100.

[0073] Without being bound by theory, it is believed that when the riser 330 does not pass through the particulate solids collection region 380 and when the particulate solids outlet port 322 is located on the central vertical axis 399, the flow of particulate solids through the particulate solids collection region 380 can be improved compared to a design where the riser 330 does pass through the particulate solids collection region 380. When the riser 330 does not pass through the particulate solids collection region 380, the particulate solids outlet port 322 can be located on the central vertical axis 399, and the particulate solids can move through the particulate solids collection region 380 in a manner more closely resembling a piston flow. This may result in an increase in the minimum residence time of the particulate solids within the particulate solids collection region 380, which may be beneficial when stripping, oxygen soaking, or other anticipated processes occur within the particulate solids collection region 380.

[0074] As described herein, the components of a system unit, such as the walls of a reaction vessel, separation section, or riser, may comprise metallic materials, such as carbon or stainless steel. Additionally, the walls of various system units may have portions that are attached to other parts of the same system unit or to another system unit. Sometimes, attachment points or connection points are referred to herein as “attachment points” and may incorporate any known bonding medium, such as, but not limited to, welding, adhesives, solder, etc. It should be understood that components of the system may be “directly connected” at attachment points such as welds.

[0075] To mitigate damage caused by hot particulate solids and gases, refractory materials can be used as linings for various system components. Refractory materials may be included in the riser 330 and the particulate solids separation section 310. It should be understood that while the embodiments provide specific arrangements and materials of refractory materials, these embodiments should not be considered as limitations on the physical structure of the disclosed system. For example, the refractory lining may extend along the inner surface of the riser 330 and along the inner surfaces of the intermediate sections 374 and the upper section 376 of the particulate solids separation section 310. The refractory lining may include hexagonal mesh or other suitable refractory materials.

[0076] The weight of the particulate solids, the thermal stress caused by the differential growth of individual components, and the mechanical loads exerted on the particulate solids processing container 350 by other components of the regeneration section 300 can be high. Therefore, without the use of expansion joints, springs can be used to allow movement of the particulate solids processing container 350 while controlling the nozzle force within limits at the 318 joint. For example, the particulate solids processing container 350 can be suspended on a spring, or the spring can be positioned below the particulate solids processing container 350 to support all or part of its weight and the expected catalyst weight. Figure 1A spring bracket 188 is depicted at the particulate solids processing container 350, which is mechanically attached to the regeneration section 300, wherein the regeneration section 300 is suspended from the support structure by the spring bracket 188.

[0077] Additionally, the granular solids processing container 350 and the riser 330 can undergo thermal expansion. Therefore, suspending the granular solids processing container 350 on the spring support 188 or supporting the granular solids processing container 350 with the spring support 188 can reduce the tension between the granular solids processing container 350 and the external riser section 332. Expansion joints are typically not used when using springs. Now refer to... Figure 2 Expansion joint 382 can be positioned between the particulate solids processing container 350 and the external riser section 332. As described herein, "expansion joint" can refer to a bellows made of metal or other suitable material that reduces stress between system components joined by the expansion joint. For example, expansion joints can be used to reduce stress between system components caused by thermal expansion and contraction. In the use of expansion joints, the particulate solids processing container 350 is typically supported by a rod hanger or skirt via a fixed bracket (without springs). In one or more embodiments, expansion joint 382 can be used in conjunction with a spring bracket to mitigate stress caused by thermal expansion between the particulate solids processing container 350 and the external riser section 332.

[0078] Example

[0079] The following examples illustrate the features of this disclosure, but are not intended to limit the scope of this disclosure. The following embodiments discuss the performance of particulate solids collection regions according to one or more embodiments disclosed herein.

[0080] The flow of particulate solids through two particulate solid collection regions is modeled. The first particulate solid collection region 410 is depicted in... Figure 4 The first particulate solids collection area 410 includes a ring-shaped outlet riser 420 located at the bottom of the particulate solids collection area 410. The outlet riser 420 is not positioned on the central axis 430 of the first particulate solids collection area 410. The first particulate solids collection area 410 also includes several cable beam supports covered by a subway grille 440.

[0081] The second particulate solid collection area 510 is depicted in Figure 5 The second particulate solids collection area 510 has a cylindrical shape and an outlet riser 520 located at the bottom of the particulate solids collection area 510. The outlet riser 520 is positioned on the central axis 530 of the second particulate solids collection area 510. The second particulate solids collection area 510 also includes several cable beam supports covered by a subway grille 540.

[0082] Computational fluid dynamics (CFD) simulations were performed to model the flow of particulate solids through a first and a second particulate solids collection region. The solids residence time distribution (RTD) was thus obtained in each container. For simulation purposes, the diameter of each particulate solids collection region in the first and second regions was set to 46 inches. The apparent gas velocity at the bottom of each container was 0.3 ft / sec, and the average particulate solids flux was 3.4 lb / ft. 2 -sec. Additionally, the average turnaround time for granular solids is 8 minutes.

[0083] CFD simulations of the first particulate solids collection area predict a minimum residence time of approximately 30 seconds for particulate solids due to short-circuiting on the outlet riser side of the container. The CFD simulations also predict that approximately 42% of the particulate solids will have a residence time of less than 4 minutes. CFD simulations of the second particulate solids collection area predict a minimum residence time of more than 1 minute for particulate solids, with only 30% of the particulate solids having a residence time of less than 4 minutes.

[0084] The RTDs of the first and second particulate solids collection regions are graphically depicted in... Figure 6 The RTD of the first particulate solids collection zone is depicted by line 610, and the RTD of the second particulate solids collection zone is depicted by line 620. Additionally, the RTDs of one continuous stirred tank reactor (CSTR) and three CSTRs in series are shown in the diagram. Figure 6 For reference only. The RTD of a single CSTR is depicted by line 630, and the RTD of three cascaded CSTRs is depicted by line 640. (See also...) Figure 6 As shown, the RTD of the first particulate solids collection region is comparable to that of a single CSTR, and the RTD of the second particulate solids collection region is comparable to that of three CSTRs in series. The second particulate solids collection region offers advantages over the first because the flow of particulate solids through the second particulate solids collection region more closely resembles a piston flow. Therefore, less particulate solids leave the particulate solids collection region rapidly, and less particulate solids remain in the particulate solids collection region for a longer period. This results in more consistent processing of particulate solids within the particulate solids collection region.

[0085] In a first aspect of this disclosure, particulate solids can be regenerated by a method comprising regenerating the particulate solids in a particulate solids processing container. This regeneration of the particulate solids may include one or more of the following: oxidizing the particulate solids by contacting them with an oxygen-containing gas; burning coke present on the particulate solids; or burning supplementary fuel to heat the particulate solids. The method may further include conveying the particulate solids through a riser. The riser may extend through a riser port of a housing of a particulate solids separation section, such that the riser includes an inner riser segment located in an inner region of the particulate solids separation section and an outer riser segment located outside the housing of the particulate solids separation section. The particulate solids separation section may include at least a housing defining an inner region of the particulate solids separation section. The housing may include a gas outlet port, a riser port, and a particulate solids outlet port. The housing may house a gas / solid separation device and a particulate solids collection area in the inner region of the particulate solids separation section. The riser port may be located on a sidewall of the housing such that the riser port is not located on the central vertical axis of the particulate solids separation section. The method may further include separating the particulate solids from the gas in the gas / solid separation device and conveying the particulate solids separated from the gas to the particulate solids collection area located near the central vertical axis of the particulate solids separation section.

[0086] The second aspect of this disclosure may include the first aspect, wherein the particulate solids processing container has a maximum cross-sectional area that is at least three times the maximum cross-sectional area of ​​the riser.

[0087] A third aspect of this disclosure may include either the first or the second aspect, wherein the riser extends through the riser port in a non-vertical direction.

[0088] The fourth aspect of this disclosure may include any one of the first to third aspects, wherein the lift tube extends through the lift tube port in a diagonal direction, wherein the diagonal direction is at an angle of 15 to 75 degrees to the vertical plane.

[0089] The fifth aspect of this disclosure may include any one of the first to fourth aspects, wherein the riser extends through the riser port in a substantially horizontal direction.

[0090] The sixth aspect of this disclosure may include any one of the first to fifth aspects, wherein the internal riser segment includes a vertical portion, a non-vertical portion located near the riser port, and a non-linear portion connecting the vertical portion and the non-vertical portion.

[0091] The seventh aspect of this disclosure may include any one of the first to sixth aspects, wherein the housing further accommodates a riser termination device, and wherein the riser termination device is located near the internal riser segment.

[0092] The eighth aspect of this disclosure may include any one of the first to seventh aspects, wherein the external riser segment includes a vertical portion located near the particulate solids processing container, a non-vertical portion located near the riser port, and a non-linear portion connecting the vertical portion and the non-vertical portion.

[0093] The ninth aspect of this disclosure may include any one of the first to eighth aspects, wherein the maximum cross-sectional area of ​​the housing is at least three times the maximum cross-sectional area of ​​the riser.

[0094] The tenth aspect of this disclosure may include any one of the first to ninth aspects, wherein the maximum cross-sectional area of ​​the housing is 5 to 40 times the maximum cross-sectional area of ​​the riser.

[0095] The eleventh aspect of this disclosure may include any one of the first to tenth aspects, wherein the gas / solid separation device includes one or more cyclone separators.

[0096] The twelfth aspect of this disclosure may include any one of the first to eleventh aspects, wherein the riser does not pass through the particulate solid collection area.

[0097] The thirteenth aspect of this disclosure may include any one of the first to twelfth aspects, wherein the particulate solid collection area includes an oxygen soaking zone, an oxygen stripping tower, a reduction zone, or a combination thereof.

[0098] The fourteenth aspect of this disclosure may include any one of the first to thirteenth aspects, wherein the particulate solids processing container is supported by a spring support.

[0099] The fifteenth aspect of this disclosure may include any one of the first to fourteenth aspects, wherein the particulate solid outlet port is located on the central vertical axis of the particulate solid separation section.

[0100] The subject matter of this disclosure has been described in detail and with 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 such component or feature is necessary for a particular embodiment or any other embodiment. Furthermore, it will be apparent to those skilled in the art that various modifications and changes can be made to the described embodiments without departing from the spirit and scope of the claimed subject matter.

[0101] For purposes of description and limitation of this disclosure, it should be noted that the terms “about” or “approximately” are used in this disclosure to indicate the degree of uncertainty attributable to any quantitative comparison, value, measurement or other representation. The terms “about” and / or “approximately” are also used in this disclosure to indicate the degree to which a quantitative representation may vary from a specified reference without causing a fundamental change in the subject matter of interest.

[0102] It should be noted that one or more of the appended claims use the term "wherein" as a transitional expression. For the purpose of defining this technology, it should be noted that this term is introduced in the claims as an open transitional phrase used to introduce a description of a series of features of the structure, and should be interpreted in a similar manner to the more commonly used open prepositional term "comprising".

[0103] It should be understood that when the first component is described as "containing" the second component, it is anticipated in some embodiments that the first component is "composed of" or "substantially composed of" the second component. It should also be understood that when the first component is described as "containing" the second component, it is anticipated in some embodiments that the first component may contain at least 10%, at least 20%, at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, at least 95%, or even at least 99% of the second component (wherein the percentage may be weight percentage or molar percentage).

[0104] Furthermore, the term "substantially composed of" is used in this disclosure to refer to a quantitative value that does not materially affect the essential and novel characteristics of this disclosure. For example, a chemical composition "substantially" composed of a particular chemical component or group of chemical components should be understood to mean that the composition contains at least about 99.5% of that particular chemical component or group of chemical components.

[0105] It should be understood that any two quantitative values ​​assigned to a certain characteristic can constitute a range for that characteristic, and all combinations of ranges formed by all said quantitative values ​​of a given characteristic are considered in this disclosure. It should be understood that in some embodiments, the compositional range of a chemical component in the composition should be understood as a mixture containing isomers of that component. In other embodiments, the chemical compound may be present in alternative forms, such as derivatives, salts, hydroxides, etc.

Claims

1. A method for regenerating particulate solids, the method comprising: Regenerating the particulate solids in a particulate solids processing container, wherein the regeneration of the particulate solids includes one or more of the following: The particulate solid is oxidized by contact with oxygen-containing gas. Combustion of coke present on the particulate solid, or Combustion of supplemental fuel is used to heat the particulate solids; The particulate solids are then conveyed through a riser tube extending through a riser tube port of the housing of the particulate solids separation section, such that the riser tube includes an inner riser tube segment located in the inner region of the particulate solids separation section and an outer riser tube segment located outside the housing of the particulate solids separation section, wherein the particulate solids separation section includes at least the housing defining the inner region of the particulate solids separation section, the housing including a gas outlet port, the riser tube port and a particulate solids outlet port, and wherein the housing houses a gas / solid separation device and a particulate solids collection area in the inner region of the particulate solids separation section, and wherein the riser tube port is positioned on a side wall of the housing such that the riser tube port is not located on the central vertical axis of the particulate solids separation section; The particulate solids are separated from the gas in the gas / solid separation device; The particulate solids separated from the gas are conveyed to the particulate solids collection area located on the central vertical axis of the particulate solids separation section; and The particulate solid outlet port is located on the central vertical axis of the particulate solid separation section.

2. The method according to claim 1, wherein the particulate solids processing container has a maximum cross-sectional area, the maximum cross-sectional area being at least three times the maximum cross-sectional area of ​​the riser.

3. The method of claim 1, wherein the riser extends through the riser port in a non-vertical direction.

4. The method according to any one of claims 1-3, wherein the lifting tube extends through the lifting tube port in a diagonal direction, wherein the diagonal direction is at an angle of 15 degrees to 75 degrees with the vertical plane.

5. The method according to any one of claims 1 to 3, wherein the riser extends through the riser port in a substantially horizontal direction, wherein the substantially horizontal direction is within 15 degrees of the horizontal.

6. The method according to any one of claims 1-3, wherein the internal riser segment comprises a vertical portion, a non-vertical portion directly connected to the riser port, and a non-linear portion connecting the vertical portion and the non-vertical portion.

7. The method according to any one of claims 1-3, wherein the housing further includes a riser termination device, and wherein the riser termination device is directly connected to the vertical portion of the internal riser segment.

8. The method according to any one of claims 1-3, wherein the external riser segment comprises a vertical portion connected to the particulate solids processing container, a non-vertical portion directly connected to the riser port, and a non-linear portion connecting the vertical portion and the non-vertical portion.

9. The method according to any one of claims 1-3, wherein the maximum cross-sectional area of ​​the outer casing is at least three times the maximum cross-sectional area of ​​the riser tube.

10. The method according to any one of claims 1-3, wherein the maximum cross-sectional area of ​​the housing is 5 to 40 times the maximum cross-sectional area of ​​the riser tube.

11. The method according to any one of claims 1-3, wherein the gas / solid separation device comprises one or more cyclone separators.

12. The method according to any one of claims 1-3, wherein the lifting tube does not pass through the particulate solids collection area.

13. The method according to any one of claims 1-3, wherein the particulate solid collection zone comprises an oxygen soaking zone, an oxygen stripping tower, a reduction zone, or a combination thereof.

14. The method according to any one of claims 1-3, wherein the particulate solids processing container is supported by a spring support.

Images