Electrification of heat supply of fluidized regeneration system

Abstract

A system for reactivating a catalyst having a predetermined enthalpy includes a reactor, a regenerator, and a heater using electrical energy. The reactor is configured to produce a spent catalyst. The regenerator is configured to receive the spent catalyst from the reactor. The heater using electrical energy has a plurality of energy emitting components that are at least partially immersed in the spent catalyst. The heater is configured to provide a supplemental enthalpy to obtain a predetermined enthalpy.

Description

Technical Field

[0001] The present disclosure relates to catalyst regenerators with reduced carbon emissions.

[0002] background

[0003] Regenerated and heated catalysts are used in numerous chemical processing systems. Conventional techniques for regenerating or "reactivating" catalysts use fossil fuels to generate the heat necessary to reactivate the catalyst.

[0004] The present disclosure addresses the need for a regenerator that reduces the use of fossil fuels to reactivate catalysts, as well as other needs of the prior art.

[0005] Overview

[0006] In various aspects, the present disclosure provides a system for regenerating spent catalyst into a reactivated catalyst having a predetermined enthalpy. The system may include: a reactor configured to generate spent catalyst; a regenerator configured to regenerate the spent catalyst from the reactor; and a heater using electrical energy configured to selectively increase the enthalpy of the spent catalyst to a predetermined enthalpy, the heater having a plurality of energy-emitting components at least partially immersed in the spent catalyst.

[0007] In various aspects, the present disclosure provides a method for regenerating spent catalyst into a reactivated catalyst having a predetermined enthalpy. The method may include the steps of generating spent catalyst in a reactor; receiving the spent catalyst in a regenerator; at least partially immersing a plurality of energy-emitting components of a heater in the spent catalyst; and selectively operating the heater to increase the enthalpy of the spent catalyst to the predetermined enthalpy.

[0008] It will be appreciated that some features of the present disclosure have been summarized rather broadly so that the detailed description thereof below may be better understood and so that the contribution to the art may be appreciated. Of course, there are additional features of the disclosure that will be described below and, in some cases, will form the subject matter of the claims appended hereto. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] For a detailed understanding of the present disclosure, reference should be made to the following detailed description taken in conjunction with the accompanying drawings, wherein like elements are designated with like reference numerals, and wherein:

[0011] Figure 1 schematically illustrates a non-limiting embodiment of a regenerator according to one embodiment of the present disclosure that utilizes an external heater; and

[0012] Figure 2 schematically illustrates a non-limiting embodiment of a regenerator according to one embodiment of the present disclosure that utilizes an internal heater;

[0013] Figure 3 schematically illustrates another non-limiting embodiment of a regenerator according to one embodiment of the present disclosure, which utilizes an external heater; and

[0014] Figure 4A and Figure 4B An energy emitting component of a heater according to one embodiment of the present disclosure is schematically illustrated.

[0015] Details

[0016] In many aspects, the present disclosure provides systems and related methods for reactivating catalysts circulating in a treatment system. In certain embodiments, the present disclosure provides a regenerator having reduced carbon emissions compared to a regenerator that uses only fossil fuels to generate heat. Specific embodiments of the present disclosure are shown in the accompanying drawings and will be described in detail herein, it being understood that the present disclosure should be considered as an example of the principles of the disclosure and is not intended to limit the disclosure to what is illustrated and described herein.

[0017] First reference Figure 1 , which schematically illustrates a non-limiting embodiment of a regenerator 100 according to the present disclosure, which may be incorporated into a treatment system. The regenerator 100 may receive spent catalyst 10 from a reactor (not shown) via a riser 104 and output reactivated catalyst 106 via an outlet 108. "Reactivated" means that the catalyst has been heated to a predetermined value or "predetermined enthalpy" for use in a reactor (not shown). The predetermined enthalpy may be based on the heat required in the reactor (not shown) to cause one or more desired chemical reactions to occur. The predetermined enthalpy may be defined in terms of a 'value', which is a single value, a range of values, and an upper or lower limit. "Reactivated" also refers to coke, if any, having been burned off the catalyst particles. The energy required to reactivate the spent catalyst will be referred to as the reactivation energy.

[0018] The regenerator 100 includes a vessel 110 that houses a separation system 112 in an interior 114. The separation system 112 can be a cyclonic separation device configured to separate gases from solids. The gases within the interior 114 can exit via a flue gas plenum 116. In some embodiments, the outlet 108 can be fluidly connected to a catalyst stripper 118 that circulates the reactivated catalyst to a reactor (not shown). Air can be blown into the interior 114 via an inlet 119 to maintain fluidization and circulation of the catalyst and, if possible, to burn off coke on the catalyst particles, if any. The term "spent catalyst" as used throughout this document refers to catalyst at any stage of the reactivation process. In some embodiments, the reactivation process is not completed until the catalyst enters the reactor. In other embodiments, the reactivation process is completed after the catalyst exits via the outlet 108.

[0019] According to current teachings, the regenerator 100 can use electrical energy, if necessary, to selectively increase the enthalpy of the catalyst body formed from the spent catalyst. The regenerator 100 can operate in multiple operating modes. In one mode, the regenerator 100 uses only electrical energy to increase the enthalpy of the catalyst body to a predetermined enthalpy. In another mode, the regenerator 100 increases the enthalpy to a predetermined enthalpy by combining electrical energy with one or more non-electrical energy sources, such as combustion of coke deposits on the catalyst and / or a supplemental fuel source. In yet another mode, the regenerator 100 can use only one or more non-electrical energy sources. For example, in some cases, combustion of coke deposits can provide all the enthalpy required to achieve the predetermined enthalpy. Therefore, "selectively increase" means that the regenerator can have several operating modes, which can be selected as needed to achieve the predetermined enthalpy. In one non-limiting embodiment, a worker can monitor operating parameters such as temperature, flow rate, and / or pressure and manually activate a switch or other device to select the method for increasing the enthalpy through the regenerator 100. In another non-limiting embodiment, a suitably programmed processor can receive a signal from a sensor, such as a thermometer, and autonomously select or deselect the addition of heat by the regenerator 100 .

[0020] In some embodiments, the electrical energy may be generated using renewable energy sources (e.g., wind, solar, hydroelectric, tidal, geothermal, etc.). In other embodiments, the electrical energy may be generated using low-carbon / carbon-free energy sources (e.g., hydrogen, nuclear, etc.). In still other embodiments, the electrical energy may be generated using hydrocarbon-based fuels.

[0021] In one arrangement, one or more electrically powered heaters 130 may be located external to the vessel 110. The heaters 130 may utilize a "shell and tube" configuration. As shown, the heater 130 may include a shell 132 in which an array of energy-emitting elements 134 is disposed. The energy-emitting elements 134 may be powered using a suitable control system 136 and a power source 137. The power source 137 may be a renewable power source or a conventional power source as previously described. Catalyst from the vessel 110 enters the shell 132 via a suitable inlet 138 and flows downwardly along the energy-emitting elements 134. A fluidizing agent, such as steam or air, is injected into the shell 132 at or near the bottom of the shell 132 via a header or other inlet 140. As the catalyst flows downwardly to an outlet 144, the fluidizing agent flows upwardly to the gas outlet 142. In some embodiments, the catalyst density may be in the range of 35 to 40 pounds per cubic foot, and the vapor superficial velocity may be in the range of 0.2 to 0.4 feet per second. In other embodiments, the catalyst density may range from 25 to 50 pounds per cubic foot and the vapor superficial velocity may range from 0.1 to 0.8 feet per second. In other embodiments, the catalyst density may range from 15 to 60 pounds per cubic foot and the vapor superficial velocity may range from 0.01 to 1.5 feet per second. Although one shell 132 is shown, it should be understood that multiple shells may also be used.

[0022] In some embodiments, the energy emitting component 134 can be, or include, an electrical heating component. That is, the energy emitting component 134 can heat the catalyst directly or indirectly. It should be noted that during operation, the energy emitting component 134 is immersed in the body of the catalyst. Immersed means at least partially surrounded by the catalyst. Thus, the energy emitting component 134 can emit energy, in this case heat energy, in multiple directions and at multiple locations within the body of the catalyst. In other embodiments, the energy emitting component 134 can utilize other energy transmission media, such as infrared or induction.

[0023] See also Figure 2 , which schematically illustrates another non-limiting regenerator 100 according to the present disclosure. The regenerator 100 can receive spent catalyst 10 from the reactor 12 and output reactivated catalyst 106 via an outlet 108. As in the previously discussed embodiments, the regenerator 100 includes a vessel 110 that houses a separation system 112 in an interior 114. The separation system 112 can be a cyclonic separation device configured to separate gases from solids. The gases within the interior 114 can exit via a flue gas chamber 116. The outlet 108 can be in fluid communication with a catalyst stripper 118 that circulates the reactivated catalyst to the reactor 12. As previously discussed, the term "spent catalyst" refers to catalyst at any stage of the reactivation process.

[0024] The regenerator 100 can be configured to use electrical energy to reactivate the spent catalyst. In this embodiment, a heater 130 that uses electrical energy can be provided inside the vessel 110. The heater 130 can use an array of energy emitting components 134 as described above. The energy emitting components 134 can be powered using a suitable control system 136 / power supply 137 as described above. A fluidizing agent, such as steam or air, is injected at or near the bottom of the vessel 110 via a manifold or other inlet 140. As in Figure 1 As in the embodiment of FIG. 1 , the energy emitting member 134 is immersed in the catalyst body, which may be a bubbling bed / fast fluidized bed.

[0025] refer to Figure 3 , which schematically illustrates another non-limiting regenerator 100 according to the present disclosure. The regenerator 100 can receive spent catalyst 10 from the reactor 12 via line 14 and output reactivated catalyst 106 to a catalyst stripper (not shown), if present. For purposes of this disclosure, the reactor 12 is any structure that forms spent catalyst by reacting the catalyst with one or more feeds. The reactivated catalyst 106 is returned to the reactor 12 via line 16. The regenerator 100 can be configured as previously described. Specifically, a heater 130 using electrical energy can be located external to the vessel 110 of the regenerator 100 and, as in conjunction with Figure 1 The configuration is as described in the embodiment.

[0026] In yet another variation, not shown, the regenerator can be arranged with an external heater using back-mix flow and electrical energy. In such an arrangement, the regenerator does not have separate catalyst inlets and outlets. Instead, the catalyst exits the regenerator through the same channel in which it enters.

[0027] refer to Figures 4A-4B , which illustrates various non-limiting arrays of energy emitting components 134 according to the present disclosure.

[0028] Figure 4A 1 is a schematic elevation view of the housing 150. The energy emitting component 134 may be located in the housing 150 or other suitable locations. The housing 150 may be a shell 132 ( Figure 1 )、Container 112( Figure 2 ), fluid pipelines, such as pipeline 16 ( Figure 3 Optionally, the energy emitting member 134 may be suspended from a suitable structure, such as a plate 152. If desired, catalyst may be fed below the plate 152 using an inlet 154. A suitable control system 136 and power supply 137 ( Figure 1) energizes the energy emitting member 134. It will be appreciated that energy is emitted outwardly from the member into the catalyst body 10, and that energy is applied along the defined axial length. Thus, energy is applied along the axial length of the catalyst body 10, and also radially along the catalyst body 10.

[0029] Figure 4B 1 is a schematic end view of housing 150. In this embodiment, energy emitting member 134 is positioned parallel to the flow of catalyst (not shown). That is, energy emitting member 134 extends longitudinally in a generally collinear relationship with the flow of catalyst (not shown) in housing 150.

[0030] Therefore, it should be noted that the energy emitting components 134 are not limited to any particular geometry, shape, or arrangement. Furthermore, the array of energy emitting components 134 can be distributed throughout the regenerator 100 ( Figure 1 and Figure 3 ) or other locations downstream of the regenerator 100 ( Figure 1 and Figure 3 ).

[0031] As used throughout the claims, the words “comprising” and “comprises” should be interpreted to mean “including but not limited to” and “includes but not limited to,” respectively.

[0032] As used herein, the word "substantially" shall mean "mostly but not entirely as specified."

[0033] As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.

[0034] To the extent used herein, the term "about" with respect to a given parameter is inclusive of the stated value and has the meaning dictated by the context (eg, it includes the degree of error associated with measurement of the given parameter).

[0035] As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0036] For the purpose of illustration and explanation, the foregoing description is directed to a specific embodiment of the present disclosure. However, it will be apparent to those skilled in the art that many modifications and changes may be made to the embodiments set forth above without departing from the scope of the disclosure. The following claims are intended to be interpreted as encompassing all such modifications and changes.

Claims

1. A system for regenerating a spent catalyst into a reactivated catalyst having a predetermined enthalpy, the system comprising: a reactor configured to produce spent catalyst; a regenerator configured to regenerate spent catalyst from the reactor; and A heater using electrical energy is configured to selectively increase the enthalpy of the spent catalyst to a predetermined enthalpy, the heater having a plurality of energy emitting members at least partially immersed in the spent catalyst.

2. The system of claim 1, wherein the heater is located outside the regenerator.

3. The system of claim 1, wherein the heater is located inside the regenerator.

4. The system of claim 1 , wherein the heater comprises: - one or more shells located outside the regenerator, wherein the plurality of energy emitting components are located inside the shells, - a first inlet, which delivers the catalyst from the regenerator into the shell, and - A second inlet, which delivers the fluidizing agent into the shell.

5. The system of claim 4, wherein the heater further comprises: A catalyst outlet from which the catalyst in the shell exits.

6. The system of claim 5, further comprising a gas outlet from which the fluidizing agent in the shell exits.

7. The system of claim 1, further comprising a passage connecting the reactor and the regenerator, wherein at least the catalyst enters and exits the regenerator via the passage.

8. The system of claim 1, further comprising a power source configured to supply power to the heater.

9. The system of claim 8, wherein the power source is a renewable power source.

10. The system of claim 1, wherein the heater is further configured to have a first selectable mode of operation wherein the heater does not increase enthalpy if one or more non-electrical energy sources increases enthalpy to the predetermined enthalpy.

11. The system of claim 1 , wherein the heater is further configured to have a second selectable mode of operation, wherein the heater and one or more non-electrical energy sources increase enthalpy to the predetermined enthalpy.

12. The system of claim 1, wherein the heater is further configured to have a third selectable mode of operation wherein only the heater increases enthalpy to the predetermined enthalpy.

13. The system of claim 1, wherein the heater and one or more non-electrical energy sources increase enthalpy to the predetermined enthalpy.

14. A method for regenerating a spent catalyst into a reactivated catalyst having a predetermined enthalpy, the method comprising: generating spent catalyst in the reactor; receiving the spent catalyst in a regenerator; at least partially immersing a plurality of energy emitting components of a heater in the spent catalyst; and The enthalpy of the spent catalyst is selectively increased to the predetermined enthalpy by using the heater.

15. The method of claim 14, wherein the heater comprises at least one shell located outside the regenerator, wherein the plurality of energy emitting components are located inside the shell, and the method further comprises: - delivering the catalyst from the regenerator into the shell using a first inlet, and - A second inlet is used to deliver fluidising agent into the shell.

16. The method of claim 14, further comprising connecting the reactor and the regenerator with a channel, wherein at least the catalyst enters and exits the regenerator via the channel.

17. The method of claim 14, wherein If the one or more non-electrical energy sources increases the enthalpy to the predetermined enthalpy, selectively increasing includes not increasing the enthalpy.

18. The method of claim 14, wherein Selectively increasing includes increasing the enthalpy to the predetermined enthalpy using the heater and one or more non-electrical energy sources.

19. The method of claim 14, wherein Selectively increasing includes increasing the enthalpy to the predetermined enthalpy using only the heater.

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