A catalyst regeneration apparatus

Abstract

The present application belongs to the field of catalyst regeneration, and particularly relates to a catalyst regeneration device, which comprises a bucket elevator, a screw feeder and a reaction kiln body, the inside of the reaction kiln body is provided with a reaction kiln drum, the rear end of the reaction kiln drum is provided with the screw feeder, the top of the screw feeder is provided with a weighing hopper, the rear end of the screw feeder is provided with the bucket elevator, the rear end of the bottom of the reaction kiln drum is provided with a discharge hopper, the front end of the reaction kiln drum is provided with a pipeline rotary joint, and the front end of the bottom of the reaction kiln drum is provided with a driving device. The present application introduces carbon dioxide and oxygen to form a regeneration reaction gas, controls the reaction temperature in the reaction kiln, avoids the local high-temperature problem prone to occurring in the pure oxygen regeneration process, solves the irreversible damage problem of the catalyst carrier caused by high-temperature sintering in the prior art, guarantees the activity and service life of the regenerated catalyst, and improves the qualified rate of catalyst regeneration.

Description

Technical Field

[0001] This invention belongs to the field of catalyst regeneration, specifically a catalyst regeneration device. Background Technology

[0002] Catalysts are core materials in industrial processes such as catalytic cracking, hydrotreating, and flue gas denitrification. During long-term operation, catalyst activity continuously declines and eventually deactivates due to factors such as carbon buildup, alkali metal / arsenic / heavy metal poisoning, fly ash blockage, and high-temperature sintering. With the increasing weight and quality of crude oil and increasingly stringent environmental standards, the rate of catalyst deactivation accelerates, leading to a significant increase in replacement frequency.

[0003] Traditional methods for treating deactivated catalysts primarily involve landfilling and stockpiling. This not only results in a significant waste of precious metal resources such as vanadium, tungsten, molybdenum, and nickel, but also poses a risk of soil and groundwater pollution due to the fact that many deactivated catalysts are classified as hazardous waste. Therefore, developing efficient and low-cost catalyst regeneration technologies to extend catalyst lifespan has become an urgent need for resource recycling and the green and low-carbon transformation of industries.

[0004] Currently, industrial catalyst regeneration equipment is mainly divided into two categories:

[0005] (1) Offline regeneration device: For fixed bed reactors, the catalyst needs to be completely disassembled and transported to a professional plant for cleaning, impregnation and calcination. The process is long, energy consumption is high and there is a risk of secondary pollution.

[0006] (2) Online continuous regeneration equipment: mainly applicable to moving bed or fluidized bed processes (such as catalytic cracking regenerators). The regeneration process is accompanied by a large amount of waste gas and wastewater, and has limited adaptability to deactivation mechanisms.

[0007] The above-mentioned equipment has the following problems:

[0008] (1) The regenerated gas is mainly air or oxygen-enriched air. The carbon dioxide concentration in the combustion exhaust gas is low. If it needs to be reused, the capture cost is high.

[0009] (2) The lack of effective coupling with upstream and downstream industries makes it difficult to utilize by-products of the recycling process as resources;

[0010] (3) Insufficient control over the risk of high-temperature sintering of catalyst support, which can easily cause irreversible damage during the regeneration process;

[0011] (4) Cross-industry coupling has become an important direction for industrial development, namely, using upstream by-products as downstream raw materials to achieve a closed-loop industrial chain.

[0012] Therefore, the present invention provides a catalyst regeneration device. Summary of the Invention

[0013] In order to overcome the shortcomings of the prior art, at least one technical problem raised in the background art is solved.

[0014] The technical solution adopted by the present invention to solve its technical problem is as follows: The catalyst regeneration equipment of the present invention includes a bucket elevator, a screw feeder and a reaction kiln body. The reaction kiln body is provided with a reaction kiln rotary drum. The rear end of the reaction kiln rotary drum is provided with a screw feeder. The top of the screw feeder is provided with a weighing hopper. The rear end of the screw feeder is provided with a bucket elevator. The rear end of the bottom of the reaction kiln rotary drum is provided with a discharge hopper. The front end of the reaction kiln rotary drum is provided with a pipeline rotary joint. The front end of the bottom of the reaction kiln rotary drum is provided with a drive device. The middle position inside the reaction kiln rotary drum is provided with an air inlet pipe.

[0015] Furthermore, the intake pipe is connected to the pipeline rotary joint, and a set of small holes is set every 100mm within a 1000mm length range at the end of the intake pipe, with four small holes evenly distributed along the circumference of the intake pipe in each set.

[0016] Furthermore, the inner wall of the rotary drum of the reaction kiln is provided with several reaction kiln turning plates, which are staggered and spirally arranged along the length of the inner wall of the rotary drum.

[0017] Furthermore, the main body of the reaction kiln is equipped with a reaction kiln-shaped steel frame, and the bottom of the reaction kiln rotary drum is equipped with a reaction kiln resistance heating flat strip.

[0018] Furthermore, a regenerative combustion system is installed on both sides of the bottom of the main body of the reaction kiln, and the regenerative combustion system is symmetrically distributed on both sides of the center line of the main body of the reaction kiln.

[0019] Furthermore, a heat insulation layer is provided on the inner side of the main body of the reaction kiln, and the heat insulation layer is located on the outer periphery of the rotating cylinder of the reaction kiln.

[0020] Furthermore, a blind flange is installed at the rear end of the rotary drum of the reaction kiln, which is used to seal the material inlet at the rear end of the rotary drum of the reaction kiln.

[0021] Furthermore, the port at the top of the discharge hopper corresponds to the material outlet at the rear end of the rotary drum of the reaction kiln, and the discharge hopper is used to collect the material discharged from the rotary drum of the reaction kiln.

[0022] The beneficial effects of this invention are as follows:

[0023] 1. The catalyst regeneration equipment of the present invention introduces carbon dioxide and oxygen to form a regeneration reaction gas, regulates the reaction temperature in the reaction furnace, avoids the problem of local high temperature that is easy to occur in the pure oxygen regeneration process, solves the problem of irreversible damage to the catalyst support caused by high temperature sintering in the prior art, ensures the activity and service life of the regenerated catalyst, and improves the qualification rate of catalyst regeneration.

[0024] 2. The catalyst regeneration equipment described in this invention employs a closed structure in the reaction furnace, maintaining a stable micro-positive pressure environment of 2–3 kPa inside the furnace. This ensures the stable progress of the regeneration reaction and also ensures that the carbon dioxide concentration in the exhaust gas produced after the reaction reaches over 95%. This exhaust gas does not require a high-energy-consuming purification process and can be directly used as a raw material for downstream hydrogenation to produce aviation fuel, thus achieving the coupling of upstream by-product oxygen, the regeneration reaction process, and downstream raw material demand.

[0025] 3. The catalyst regeneration equipment described in this invention achieves low-energy operation of the catalyst regeneration process through a full-chain resource recycling design. At the same time, the reaction tail gas can be directly utilized as a resource, achieving the environmental protection effect of zero tail gas emissions. This solves the defects of existing regeneration equipment, such as the difficulty in treating tail gas and environmental pollution. In addition, by extending the service life of the catalyst and realizing resource recycling, it reduces the raw material costs of downstream industries, promotes the green management of the entire life cycle of the catalyst from use to regeneration and reuse, and helps the green and low-carbon transformation of the industrial sector. Attached Figure Description

[0026] The invention will now be further described with reference to the accompanying drawings.

[0027] Figure 1 This is a front view of the structure in this invention;

[0028] Figure 2 This is a partial frontal view of the structure in this invention;

[0029] Figure 3 This is a side view of the structural cross-section in this invention;

[0030] Figure 4 This is a structural diagram of the reaction kiln in this invention.

[0031] In the diagram: 1. Bucket elevator; 2. Screw feeder; 3. Weighing hopper; 4. Discharge hopper; 5. Main body of the reaction kiln; 51. Rotary drum of the reaction kiln; 52. Insulation layer of the reaction kiln; 53. Tilting plate of the reaction kiln; 54. Regenerative combustion system of the reaction kiln; 55. Resistance heating flat strip of the reaction kiln; 56. Steel frame of the reaction kiln; 6. Air inlet pipe; 7. Pipeline rotary joint; 8. Drive unit. Detailed Implementation

[0032] To make the technical means, creative features, objectives and effects of this invention easier to understand, the invention will be further described below in conjunction with specific embodiments.

[0033] like Figures 1 to 4 As shown, a catalyst regeneration device according to an embodiment of the present invention includes a bucket elevator 1, a screw feeder 2, and a reaction kiln body 5. A reaction kiln rotary drum 51 is arranged inside the reaction kiln body 5. The screw feeder 2 is arranged at the rear end of the reaction kiln rotary drum 51. A weighing hopper 3 is arranged at the top of the screw feeder 2. The bucket elevator 1 is arranged at the rear end of the screw feeder 2. A discharge hopper 4 is arranged at the rear end of the bottom of the reaction kiln rotary drum 51. A pipeline rotary joint 7 is arranged at the front end of the reaction kiln rotary drum 51. A drive device 8 is arranged at the front end of the bottom of the reaction kiln rotary drum 51. An air inlet pipe 6 is arranged in the middle position inside the reaction kiln rotary drum 51.

[0034] Specifically, the main body 5 of the reaction kiln adopts a rotary kiln structure. The working temperature inside the main body 5 of the reaction kiln is 500℃, the pressure is 2-3kPa, and the cylinder material is S30408, which meets the requirements of temperature and media corrosion characteristics.

[0035] like Figure 2 As shown, the intake pipe 6 is connected to the pipe rotary joint 7. A set of small holes is provided every 100mm within a 1000mm length range at the end of the intake pipe 6. Each set of small holes has four holes evenly distributed along the circumference of the intake pipe 6.

[0036] Specifically, the multiple small holes designed on the intake pipe 6 enable uniform gas distribution along the axial and circumferential directions, and the gas movement is as follows: Figure 2 As indicated by the middle arrow.

[0037] like Figure 3 and Figure 4 As shown, the inner wall of the rotary drum 51 of the reaction kiln is provided with a number of reaction kiln turning plates 53. The number of reaction kiln turning plates 53 are staggered and spirally arranged along the length direction on the inner wall of the rotary drum 51 of the reaction kiln.

[0038] Specifically, the reaction kiln turning plate 53 on the inner wall of the reaction kiln rotary drum 51 can be used to push the material forward or backward in conjunction with the rotation of the reaction kiln rotary drum 51; the drive device 8 drives the reaction kiln rotary drum 51 to rotate smoothly, and the reaction kiln rotary drum 51 can achieve forward and reverse rotation, forward rotation for feeding, and reverse rotation for discharging.

[0039] like Figure 3 As shown, the main body 5 of the reaction kiln is equipped with a reaction kiln-shaped steel frame 56, and the bottom of the reaction kiln rotary drum 51 is equipped with a reaction kiln resistance heating flat strip 55. The reaction kiln resistance heating flat strip 55 is used to assist in the rapid adjustment of the furnace temperature.

[0040] like Figure 3 As shown, a regenerative combustion system 54 is provided on both sides of the bottom of the main body 5 of the reaction kiln, and the regenerative combustion system 54 is symmetrically distributed on both sides of the center line of the main body 5 of the reaction kiln.

[0041] Specifically, a heat storage chamber is set around the regenerative combustion system 54 of the reaction kiln to make full use of thermal energy, and a baffle plate is set nearby to prevent flames from spraying directly onto the cylinder and causing uneven heating.

[0042] like Figure 3 As shown, a reaction kiln insulation layer 52 is provided on the inner side of the reaction kiln body 5, and the reaction kiln insulation layer 52 is located on the outer periphery of the reaction kiln rotating cylinder 51.

[0043] A blind flange is provided at the rear end of the rotary drum 51 of the reaction kiln. The blind flange is used to seal the material inlet at the rear end of the rotary drum 51 of the reaction kiln.

[0044] The top port of the discharge hopper 4 corresponds to the material outlet at the rear end of the rotary drum 51 of the reaction kiln. The discharge hopper 4 is used to collect the material discharged from the rotary drum 51 of the reaction kiln.

[0045] During operation, the catalyst to be regenerated is lifted by the bucket elevator 1 into the weighing hopper 3 to complete quantitative metering, ensuring that the amount processed in a single batch is accurate and controllable;

[0046] The metered material is conveyed directionally to the feed inlet of the rotary drum 51 of the reaction kiln via the screw feeder 2;

[0047] After the feeding is completed, the screw feeder 2 is withdrawn, and the feed inlet of the rotary drum 51 of the reaction kiln is sealed with a blind plate to create a closed environment for the reaction inside the furnace.

[0048] The rotary drum 51 of the reaction kiln is the core working unit. The drive device 8 drives the rotary drum 51 of the reaction kiln to rotate in the forward and reverse directions. The forward rotation is used for feeding and propulsion, and the reverse rotation is used for discharging and unloading.

[0049] The inner wall of the rotary drum 51 of the reaction kiln is arranged with alternating spirals along the length direction. The turning plates 53 of the reaction kiln rotate synchronously with the rotary drum 51 of the reaction kiln, continuously turning the material and pushing it along the axial direction to ensure that the material is in full contact with the reaction gas.

[0050] The rotating drum 51 of the reaction kiln rotates smoothly, and together with the turning plate 53 of the reaction kiln, it ensures that the material is heated and reacted evenly, avoiding local accumulation or incomplete reaction.

[0051] The equipment employs a combination of main and auxiliary heating methods and multi-source temperature control to maintain an internal operating temperature of 500℃ while ensuring uniform heating.

[0052] Multiple natural gas regenerative combustion systems are symmetrically arranged on both sides of the furnace body, combined with a regenerator to recover waste heat, improving thermal energy utilization and providing a core heat source for the reaction. A baffle plate is installed around the rotary drum 51 of the reaction kiln to prevent flames from directly spraying into the drum and to prevent uneven heating caused by local overheating. A resistance heating flat strip is installed at the bottom of the furnace body, which can quickly assist in adjusting the furnace temperature and achieve precise and stable temperature control. The outside of the rotary drum is covered with an insulation layer, which, together with the steel frame 56 of the reaction kiln and the powder-coated decorative panel shell, greatly reduces heat loss and improves energy utilization efficiency.

[0053] The equipment uses an overall sealed structure to maintain the pressure inside the furnace at a stable 2–3 kPa slightly positive pressure.

[0054] A slightly positive pressure environment can effectively prevent external air from entering the furnace, avoiding interference with the tail gas components and affecting the reaction process, while preventing gas leakage from the furnace and ensuring operational safety.

[0055] Carbon dioxide, oxygen and other reactive gases are premixed outside the furnace in a set ratio to avoid the risk of localized high temperatures caused by uneven mixing inside the furnace;

[0056] The mixed gas is transported to the rotary drum 51 of the reaction kiln through the inlet pipe 6. Multiple sets of circumferentially distributed small holes are opened at fixed intervals in a specific section at the end of the inlet pipe 6 to achieve uniform gas dispersion along the axial and circumferential directions of the drum.

[0057] The air inlet pipe 6 is flexibly connected to the rotary kiln through the pipe rotary joint 7, ensuring continuous, stable and leak-free air intake during the continuous rotation of the cylinder.

[0058] The material undergoes a regeneration reaction under high temperature, slightly positive pressure, and a uniform reaction gas environment;

[0059] After regeneration is completed, the catalyst is sampled and tested. If it passes the test, the cylinder is reversed and the reaction kiln tipping plate 53 pushes the material to the front of the furnace in the opposite direction.

[0060] Open the blind flange and unload the regenerated qualified catalyst into the discharge hopper 4 to complete the entire regeneration process.

[0061] The exhaust gas produced after the reaction is mainly composed of high-concentration carbon dioxide (≥95%). After being discharged from the rotary joint 7 of the pipeline into the rotary drum 51 of the reaction kiln, it only needs to undergo simple dust removal and cooling treatment before it can be directly used as the feed gas for the downstream hydrogenation aviation fuel unit. There is no need for a high-energy-consuming purification process, thus realizing the efficient resource utilization of the exhaust gas.

[0062] This invention addresses the problems of high energy consumption, difficult tail gas treatment, and lack of coupling with upstream and downstream industries in the catalyst regeneration process during the implementation of the National Key Research and Development Program "Research and Demonstration of High-Efficiency Coupling Technology between Wind Power / Photovoltaic Hydrogen Production and Chemical Processes (Project No.: 2024YFB4006400)". It designs and develops equipment suitable for catalyst regeneration.

[0063] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. A catalyst regeneration device, comprising a bucket elevator (1), a screw feeder (2), and a reaction furnace body (5), characterized in that: The main body (5) of the reaction kiln is equipped with a reaction kiln rotary drum (51). A screw feeder (2) is provided at the rear end of the reaction kiln rotary drum (51). A weighing hopper (3) is provided at the top of the screw feeder (2). A bucket elevator (1) is provided at the rear end of the screw feeder (2). A discharge hopper (4) is provided at the rear end of the bottom of the reaction kiln rotary drum (51). A pipeline rotary joint (7) is provided at the front end of the reaction kiln rotary drum (51). A drive device (8) is provided at the front end of the bottom of the reaction kiln rotary drum (51). An air inlet pipe (6) is provided in the middle position inside the reaction kiln rotary drum (51).

2. The catalyst regeneration equipment according to claim 1, characterized in that: The intake pipe (6) is connected to the pipe rotary joint (7). A set of small holes is provided every 100 mm within a 1000 mm length range at the end of the intake pipe (6). Four small holes are evenly distributed along the circumference of the intake pipe (6).

3. The catalyst regeneration equipment according to claim 1, characterized in that: The inner wall of the rotary drum (51) of the reaction kiln is provided with a number of reaction kiln turning plates (53). The number of reaction kiln turning plates (53) are staggered and spirally arranged along the length direction on the inner wall of the rotary drum (51).

4. The catalyst regeneration equipment according to claim 1, characterized in that: The main body (5) of the reaction kiln is provided with a reaction kiln steel frame (56) on the outside, and the bottom of the reaction kiln rotary drum (51) is provided with a reaction kiln resistance heating flat strip (55).

5. The catalyst regeneration equipment according to claim 1, characterized in that: The regenerative combustion system (54) of the reaction kiln body (5) is provided on both sides of the bottom. The regenerative combustion system (54) of the reaction kiln body (5) is symmetrically distributed on both sides of the center line of the reaction kiln body (5).

6. The catalyst regeneration equipment according to claim 1, characterized in that: The inner side of the main body (5) of the reaction kiln is provided with a reaction kiln insulation layer (52), which is located on the outer periphery of the reaction kiln rotating cylinder (51).

7. The catalyst regeneration equipment according to claim 1, characterized in that: A blind plate is provided at the rear end of the rotary drum (51) of the reaction kiln, which is used to seal the material inlet at the rear end of the rotary drum (51).

8. The catalyst regeneration equipment according to claim 1, characterized in that: The top port of the discharge hopper (4) corresponds to the material outlet at the rear end of the rotary drum (51) of the reaction kiln. The discharge hopper (4) is used to collect the material discharged from the rotary drum (51) of the reaction kiln.

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