Novel circulating metal deactivation unit design for fcc catalyst deactivation

Abstract

A circulating metal deactivation system unit for producing a balanced catalyst material, comprising: a cracker vessel configured for cracking and stripping of a catalyst material; and a regenerator vessel in fluid communication with the cracker vessel, the regenerator vessel configured for regeneration and steam deactivation of the catalyst material.

Description

[0001] This application is a divisional application of international application PCT / US2017 / 029825, filed on April 27, 2017, entitled "Design of a Novel Cyclic Metal Deactivation Unit for FCC Catalyst Deactivation". International application PCT / US2017 / 029825 entered the Chinese national phase on October 26, 2018, with national application number 201780026173.2.

[0002] Cross-reference to related applications

[0003] This application claims priority to U.S. Provisional Patent Application No. 62 / 329,374, filed April 29, 2016, which is incorporated herein by reference in its entirety for any and all purposes. Background Technology

[0004] This section is intended to provide background or context for the invention described in the claims. The descriptions herein may include concepts that can be practiced, but are not necessarily previously conceived or practiced. Therefore, unless otherwise indicated herein, the material described in this section is not prior art to the descriptions and claims in this application, and is not recognized as prior art simply because it is included in this section.

[0005] This invention generally relates to the field of fluidized catalytic cracking (FCC) units (e.g., reactors and regenerator units). More specifically, this invention relates to a circulating metal deactivation unit system for an FCC catalyst deactivation unit. Even more specifically, this invention relates to a circulating metal deactivation unit system for an FCC catalyst deactivation unit, wherein the circulating metal deactivation unit system uses separate containers (e.g., crackers and regenerators) to crack and regenerate the catalyst within the system.

[0006] In industrial applications, FCC units can be used to produce gasoline, middle distillates (e.g., light cycle oil (LCO)), and light petroleum gas (LPG), and additionally to reduce the amount of residue in crude oil through cracking processes, converting the residue into lighter, more valuable products such as light hydrocarbons. FCC catalyst deactivation units can be used in experimental applications to reproduce the environment in which catalysts are exposed in commercial FCC units.

[0007] To predict what might happen in a commercial FCC unit, experiments involving catalyst deactivation aim to simulate, over a relatively long period (e.g., weeks), what might happen to the catalyst in an FCC unit over an accelerated experimental time (e.g., hours). To achieve this, experiments may involve FCC catalyst deactivation devices that can be used to generate a simulated equilibrium catalyst (Ecat) from fresh catalyst to match the commercial Ecat used in the FCC unit. Some FCC catalyst deactivation devices use a single vessel in which the catalyst is metallized and deactivated within a single container, where the cracking and regeneration / hydrothermal deactivation conditions of the FCC process are repeatedly simulated in an alternative manner. However, using a single vessel introduces thermal stress within the vessel due to the repetitive temperature variations required in the process. This thermal stress within the vessel over a period of time can lead to a shortened vessel lifespan. Additionally, in a single-vessel configuration, the amount of time spent heating and cooling the vessel results in relatively long non-productive periods during the experiment. This lost time can lead to inefficient sample production. Summary of the Invention

[0008] One embodiment of the present invention relates to a circulating metal deactivation system unit for producing a balanced catalyst material. The circulating metal deactivation system unit includes: a cracker vessel configured for cracking and stripping the catalyst material; and a regenerator vessel in fluid communication with the cracker vessel, the regenerator vessel being configured for regenerating and steam deactivating the catalyst material.

[0009] Another embodiment of the present invention relates to a method for catalyst deactivation. The method includes: cracking the catalyst through a cracker vessel; regenerating the catalyst through a regenerator vessel; distributing the catalyst through a lifetime distribution vessel, at least in part based on the catalyst's lifetime; and conveying the catalyst between the cracker vessel, the regenerator vessel, and the lifetime distribution vessel through one or more extraction tubes to deactivate the catalyst.

[0010] In general, the present invention relates to the following embodiments.

[0011] 1. A circulating metal deactivation system unit for producing equilibrium catalyst materials, comprising: A cracker vessel configured for cracking and stripping a catalyst material; and A regenerator container, which is in fluid communication with the cracker container, is configured for regenerating and steam deactivating the catalyst material.

[0012] 2. The circulating metal deactivation system according to embodiment 1, wherein the cracker vessel and the regenerator vessel are in fluid communication with each other via a pneumatic valve system, the pneumatic valve system comprising a first draw-in pipe in the cracker vessel and a second draw-in pipe in the regenerator vessel.

[0013] 3. The circulating metal deactivation system according to embodiment 1, wherein the cracker vessel includes a first porous plate disposed in the lower region of the cracker vessel.

[0014] 4. The circulating metal deactivation system according to embodiment 3, wherein the first porous plate defines a first gas distribution zone and a first gas inlet disposed within the first gas distribution zone, the first gas distribution zone including the inner bottom surface of the cracker vessel, wherein the first gas inlet is configured to introduce a first gas source into the cracker vessel.

[0015] 5. The circulating metal deactivation system according to embodiment 1, wherein the regenerator container includes a second perforated plate disposed in the lower region of the regenerator container.

[0016] 6. The circulating metal deactivation system according to embodiment 5, wherein the second porous plate defines a second gas distribution zone and a second gas inlet disposed within the second gas distribution zone, the second gas distribution zone including the inner bottom surface of the regenerator container, wherein the second gas inlet is configured to introduce a second gas source into the regenerator container.

[0017] 7. The circulating metal deactivation system according to embodiment 4, wherein the first gas inlet is fluidly connected to a first gas conduit within the first gas distribution zone of the cracker vessel, the first gas conduit including a coiled configuration for preheating the incoming gas within the first gas distribution zone of the cracker vessel.

[0018] 8. The circulating metal deactivation system according to embodiment 6, wherein the second gas inlet is fluidly connected to a second gas conduit within the second gas redistribution zone of the regenerator container, the second gas conduit including a coiled configuration for preheating the incoming gas within the second gas redistribution zone of the regenerator container.

[0019] 9. The circulating metal deactivation system according to embodiment 1, further comprising a lifetime distribution container in fluid communication with the regenerator container, the lifetime distribution container being configured to distribute the catalyst material based on the lifetime of the catalyst material.

[0020] 10. The circulating metal deactivation system according to embodiment 7, wherein the cracker, the regenerator and the lifetime distribution vessel are in fluid communication with each other via a pneumatic valve system.

[0021] 11. The circulating metal deactivation system according to embodiment 10, wherein the pneumatic valve system includes a first draw-in pipe in the cracker vessel, a second draw-in pipe in the regenerator vessel, and a third draw-in pipe in the lifetime distribution vessel.

[0022] 12. The circulating metal deactivation system according to embodiment 9, wherein each of the cracker vessel, the regenerator vessel, and the lifetime distribution vessel includes a temperature maintaining device, wherein the temperature maintaining device maintains a predetermined process temperature in each respective vessel.

[0023] 13. A method for catalyst deactivation, the method comprising: The catalyst is cracked through a cracker container; The catalyst is regenerated through a regenerator container; The catalyst is distributed via a lifetime distribution vessel, at least in part, based on the catalyst's lifetime; and The catalyst is delivered between the cracker vessel, the regenerator vessel, and the lifetime distribution vessel via one or more extraction tubes to deactivate the catalyst.

[0024] 14. The method according to embodiment 13, wherein the cracker vessel and the regenerator vessel are in fluid communication with each other via a pneumatic valve system, the pneumatic valve system comprising a first draw-in pipe in the cracker vessel and a second draw-in pipe in the regenerator vessel.

[0025] 15. The method according to embodiment 13, wherein the cracker container includes a first porous plate disposed in the lower region of the cracker container.

[0026] 16. The method according to embodiment 15, wherein the first porous plate defines a first gas distribution area comprising an inner bottom surface of the cracker container, and a first gas inlet is disposed within the first gas distribution area, wherein the first gas inlet is configured to introduce a first gas source into the cracker container.

[0027] 17. The method according to embodiment 13, wherein the regenerator container includes a second perforated plate disposed in the lower region of the regenerator container.

[0028] 18. The method according to embodiment 17, wherein the second porous plate defines a second gas distribution region comprising an inner bottom surface of the regenerator container, and a second gas inlet is disposed within the second gas distribution region, wherein the second gas inlet is configured to introduce a second gas source into the regenerator container.

[0029] 19. The method according to embodiment 16, wherein the first gas inlet is fluidly connected to a first gas conduit within the first gas distribution zone of the cracker vessel, the first gas conduit including a coiled configuration for preheating the incoming gas within the first gas distribution zone of the cracker vessel.

[0030] 20. The method according to embodiment 18, wherein the second gas inlet is fluidly connected to a second gas conduit within the second gas redistribution zone of the regenerator container, the second gas conduit including a coiled configuration for preheating the incoming gas within the second gas redistribution zone of the regenerator container. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of a cyclic metal deactivation unit according to an exemplary embodiment.

[0032] Figure 1A This is a schematic diagram of a cyclic metal deactivation unit according to an exemplary embodiment.

[0033] Figure 1B This is a graphical representation of the operating time of the cyclic metal deactivation unit according to an exemplary embodiment.

[0034] Figure 1C This is a graphical representation comparing the operating times of two cyclic metal deactivation systems according to an exemplary embodiment.

[0035] Figure 2 According to exemplary embodiments Figure 1 A cross-sectional view of the container during the fluidization process.

[0036] Figure 3 According to exemplary embodiments Figure 1 A cross-sectional view of the container during the gas preheating process. Detailed Implementation

[0037] Various embodiments are described below. It should be noted that the specific embodiments are not intended to be an exhaustive description or a limitation on the broader aspects discussed herein. One aspect described in connection with a particular embodiment is not necessarily limited to that embodiment and can be implemented with any other embodiment.

[0038] As used herein, “about” will be understood by one of ordinary skill in the art and will vary to some extent depending on the context of its use. If a term is not clear to one of ordinary skill in the art, then, taking into account the context of its use, “about” will mean plus or minus 10% of the specific term.

[0039] Unless otherwise indicated herein or clearly contradicted by the context, the use of the terms "a / an" and "the," and similar references, in the context of describing elements (especially in the appended claims), shall be construed as covering both the singular and plural. Unless otherwise indicated herein, descriptions of ranges of values ​​herein are intended only as a shorthand method for individually referring to each individual value belonging to the range, and each individual value is incorporated into this specification as if individually described herein. Unless otherwise indicated herein or clearly contradicted by the context, all methods described herein may be performed in any suitable order. Unless otherwise stated, the use of any and all example or exemplary language (e.g., "as") provided herein is intended only to better illustrate the embodiments and does not limit the scope of the claims. No language in the specification should be construed as indicating that any unclaimed element is essential.

[0040] As used herein, the term “fresh catalyst” refers to a catalyst that has never been exposed to reactants under reaction conditions, such as a new catalyst received from a supplier.

[0041] The term "used catalyst" refers to any catalyst that exhibits less activity under the same reaction conditions (e.g., temperature, pressure, inlet flow rate) than it did when initially exposed to the process. This can be due to a variety of reasons, and several non-limiting examples of catalyst deactivation are adsorption or accumulation of coking or carbonaceous materials, adsorption or accumulation of metals (and ash), wear, morphological changes including pore size changes, cation or anion substitution, and / or chemical or compositional changes.

[0042] The term "regenerated catalyst" refers to a spent catalyst as defined above, which then undergoes a process that increases its activity, as defined above, to a level higher than it possessed as a spent catalyst. This may involve, for example, reversing conversion or removing the aforementioned contaminants as a possible cause of reduced activity. The activity of a regenerated catalyst is typically equal to or less than that of a fresh catalyst.

[0043] Referring generally to the accompanying drawings, a circulating metal deactivation system and its components according to an exemplary embodiment are shown. The circulating metal deactivation system can be used in an industrial or laboratory environment to produce E-cat materials. The circulating metal deactivation system includes a cracker vessel, a regenerator vessel, and a lifetime distribution vessel.

[0044] Advantageously, using two or more containers for cyclic metal deactivation offers several advantages over conventional deactivation systems. For example, compared to a deactivation system using a single container for all steps of the deactivation process, using two or more containers for cyclic metal deactivation significantly reduces the thermal stress in each container. Temperature variations between steps in the deactivation process require conventional deactivation systems to heat and cool the containers between process steps. Repeated temperature variations also lead to low sample efficiency due to long non-productive periods during container heating and cooling. Furthermore, the cyclic metal deactivation system of this disclosure incorporates improved fluidization uniformity through the use of perforated plates located in each of the cracker and regenerator containers. The perforated plates function to improve fluidization uniformity relative to conventional deactivation systems due to the redirection of the incoming gas flow. These and other advantages of cyclic metal deactivation systems with multiple containers are described in more detail below.

[0045] Now for reference Figure 1 This illustrates a circulating metal deactivation system according to an exemplary embodiment. The circulating metal deactivation system 10 is shown as a three-vessel system having a cracker vessel 12, a regenerator vessel 14, and a lifetime distribution vessel 16. In some embodiments, the circulating metal deactivation system 10 may include only the cracker vessel 12 and the regenerator vessel 14. In other embodiments, a lifetime distribution vessel 16 may be additionally included. In still other embodiments, the system 10 includes more than one regenerator vessel 14.

[0046] The cracker vessel 12 is shown as a cylindrical vessel having a bottom 18, a fluidization chamber 22, a gas distribution chamber 24, and a perforated plate 20 positioned centrally between the fluidization chamber 22 and the gas distribution chamber 24, thereby separating the two chambers. The fluidization chamber 22 may include a feedstock 30, in which a preheated feedstock consisting of long-chain hydrocarbon molecules is combined with recycled slurry and enters the cracker vessel 12, such as... Figure 1 As shown in the figure. In some embodiments, the oil supply device 30 may use a single oil injection nozzle positioned horizontally relative to the container 12 to supply oil to the cracker container 12.

[0047] The feedstock is presented either as entering the fluidization chamber 22 near the material bed 26 or as entering the material bed 26 itself. The fluidization chamber 22 can be configured to evaporate and crack the feedstock into smaller vapor molecules by contacting and mixing it with a hot, powdered catalyst. The hydrocarbon vapor fluidizes the powdered catalyst, which in turn fluidizes the material bed 26.

[0048] The gas distribution chamber 24 may include a gas feedstock 28, a gas redirector 32, and a bottom 18. Gas can enter the gas distribution chamber 24 through the gas feedstock 28 and can be redirected toward the bottom 18 through the gas redirector 32.

[0049] The gas redirector 32 can be configured to redirect incoming gas from the gas feedstock 28 to the bottom 18 of the gas distribution chamber 24, wherein the incoming gas can be distributed over the entire cross-sectional area of ​​the bottom 18. In this respect, the gas redirector 32 can be positioned at or near the vertical axis 50 of the cracker vessel 12 so that the gas can be uniformly distributed over the bottom 18.

[0050] The porous plate 20 can be configured as a sieve plate having a plurality of orifices in the plate 20. The size of the orifices can be customized. According to an exemplary embodiment, the orifice size is configured to allow feed particles to pass through the orifices while preventing catalyst particles from passing through the orifices. Thus, the porous plate 20 can separate the catalyst from the feed. The porous plate 20 can be configured to provide contact between any downward-flowing catalyst in the fluidization chamber 22 and an upward-flowing gas (e.g., steam) in the gas distribution chamber 24. In this respect, the porous plate 20 can act as a catalyst stripping tower to remove any hydrocarbon vapors from the catalyst before it is returned to any other component of the circulating metal deactivation system 10 (e.g., regenerator container 14). The porous plate 20 can be removable and replaceable, as described herein. Figure 3 Further description.

[0051] The circulating metal deactivation system 10 is shown having a draw-in tube 34 for each container. One or more draw-in tubes 34 may be configured to pneumatically deliver catalyst material between each of the containers. The delivery of catalyst material is due to the pressure difference and volumetric flow rate between each of the containers. Thus, the container delivering catalyst material can have a higher pressure and therefore a higher volumetric flow rate than the container receiving the catalyst material. As an example, if the catalyst is delivered from cracker container 12 to regenerator container 14, then that stage of the process in cracker container 12 will be at a higher pressure relative to regenerator container 14, causing the catalyst to flow into regenerator container 14.

[0052] Catalyst material containing spent catalyst may be sent to regenerator container 14 (e.g., a regeneration unit), where the spent catalyst is regenerated by burning any residual (e.g., remaining, leftover, etc.) carbonaceous material to produce a majority of the regenerated catalyst and ash residues of the burned carbonaceous material. In some embodiments, a portion of the spent catalyst may be sent back to cracker container 12 without regeneration, or may be discarded. An oxygen-carrying gas, such as air, may be introduced into regenerator container 14 to regenerate the spent catalyst and burn any remaining carbonaceous material in regenerator container 14.

[0053] The regenerator container 14 can be configured to burn off any deposited coke on the catalyst, supply the heat requirements of the process, and restore the activity of the catalyst. In some embodiments, the regenerator container 14 may be similar in configuration to the cracker container 12. Thus, the regenerator container 14 is shown as a cylindrical container with a bottom 18 and a perforated plate 20. Figure 1 As shown, the regenerator container also includes two chambers, a gas redistribution chamber 24 and a catalyst regeneration chamber 36.

[0054] A gas redistribution chamber 24, enclosed by a bottom 18 and a perforated plate 20, can be similarly configured as the gas redistribution chamber 24 in the cracker vessel 12. Therefore, the gas redistribution chamber 24 includes a gas feedstock 28, a gas redirector 32, and a bottom 18. Gas can enter the gas redistribution chamber 24 through the gas feedstock 28 and can be redirected towards the bottom 18 through the gas redirector 32.

[0055] As mentioned, the catalyst regeneration chamber 36 may be configured to receive spent catalyst from other components of the circulating metal deactivation unit 10 (e.g., from the cracker vessel 12) via a pneumatic conveying system and one or more draw-in pipes 34, and regenerate the catalyst by burning off any deposited coke that may have accumulated on it. The regenerated catalyst may then be recycled through the circulating metal deactivation system 10 by re-entering the cracker vessel 12.

[0056] Advantageously, and as mentioned above, each of the cracker vessel 12 and the regenerator vessel 14 can be maintained at a constant temperature. The process conditions for each of the vessels can be maintained as follows. In some embodiments, the cracker vessel 12 can be maintained at a maximum operating pressure of approximately 10 psi (0.7 bar) and a maximum operating temperature of approximately 1000℉ (538°C). Additionally, in some embodiments, the regenerator vessel 14 can be maintained at a maximum operating pressure of approximately 10 psi (0.7 bar) and a maximum operating temperature of approximately 1650℉ (899°C). In other embodiments, the vessels can be maintained at different constant or variable temperatures sufficient for the process within the circulating metal deactivation system 10.

[0057] The lifetime distribution container 16 is shown to have a gaseous feedstock 38, a material feedstock 40, and a material removal section 42. The lifetime distribution container 16 further utilizes one or more extraction pipes 34 to deliver the catalyst in a manner similar to that of the regenerator container 14 and the cracker container 12. The lifetime distribution container 16 can introduce the catalyst into the circulating metal deactivation system 10 via the material feedstock 40. The lifetime distribution container 16 can further remove the catalyst from the system 10 via the material removal section 42.

[0058] The lifetime distribution container 16 is shown having a top portion 44 and a bottom portion 46, wherein the catalyst present in the system 10 is distributed within the lifetime distribution container 16. In some embodiments, the top portion 44 may be cylindrical and the bottom portion may be conical to facilitate the removal of catalyst material. As an example, older spent catalyst may settle to the bottom portion 46 of the container 16, while fresher catalyst may be located near the top portion 44 of the container 16. The bottom portion 46 may include one or more outlets, such as a material removal section 42. The top portion 44 may include one or more inlets, such as a material feed 40. To further illustrate, as older catalyst moves toward the bottom portion 46, the catalyst can be removed by the material removal section 42, and newer catalyst (e.g., fresh catalyst, regenerated catalyst, or combinations thereof) replaces the older catalyst at or near the top portion 44 of the container 16 via the material feed 40.

[0059] Now for reference Figure 1A This illustrates a circulating metal deactivation system according to an exemplary embodiment. In this embodiment, the circulating metal deactivation system 11 is shown as a five-vessel system having a cracker vessel 12, three regenerator vessels 13, 14, and 15, and a lifetime distribution vessel 16. In some other embodiments, the circulating metal deactivation system 11 includes more or fewer than three regenerator vessels. In some embodiments, the circulating metal deactivation system 11 may include only the cracker vessel 12 and one regenerator vessel 14. In other embodiments, a lifetime distribution vessel 16 may be additionally included.

[0060] Figure 1A The additional regenerator containers 13 and 15 shown in the diagram have structures similar to those described above. Figure 1 The regenerator container 14 is described. Therefore, regenerator containers 13, 15 are configured to burn off any deposited coke on the catalyst, supply the heat requirements of the process, and restore the activity of the catalyst. In some embodiments, regenerator containers 13, 15 may be similar in configuration to cracker container 12. Thus, regenerator containers 13, 15 are shown as cylindrical containers with a bottom 18 and a perforated plate 20. Figure 1A As shown, the regenerator containers 13 and 15 also include two chambers, a gas redistribution chamber 24 and a catalyst regeneration chamber 36.

[0061] refer to Figure 1AThe catalyst is delivered in a manner similar to that of a system with one regenerator container, using two or more regenerator containers. A circulating metal deactivation system 11 pneumatically delivers the catalyst material between each of the containers using a draw tube 34. The catalyst material, containing spent catalyst, is sent to regenerator containers 13, 14, and 15, where the spent catalyst is regenerated by burning any remaining carbonaceous material to produce a majority of the regenerated catalyst and the ash residue of the burned carbonaceous material. In some embodiments, each of the regenerator containers 13, 14, and 15 is configured to deliver material (e.g., catalyst) directly to and from cracker container 12, each of the regenerator containers having a separate material delivery connection, such as... Figure 1A As shown in the diagram, oxygen-carrying gases such as air can be introduced into regenerator containers 13, 14, and 15 to regenerate the spent catalyst and burn the remaining carbonaceous materials in regenerator containers 13, 14, and 15.

[0062] like Figure 1B As shown, for each cycle of system 11, processes occurring in the regenerator vessel (e.g., regeneration, deactivation) require significantly more completion time compared to processes occurring in the cracker vessel (e.g., cracking, stripping). Using... Figure 1 The single regenerator design shown in the figure allows the cracker container 12 to remain idle for a period of time while the catalyst is processed by the regenerator container 14 in each cycle of system 10.

[0063] Beneficial and as Figure 1C As shown, adding regenerator containers 13 and 15 can shorten or eliminate the idle time of cracker 12. Therefore, more than one regenerator container can be used to further reduce the total operating time. Comparing the diagram of a system with one regenerator container (shown as "1R x 1C") with that of a system with three regenerator containers (shown as "3R x 1C"), for 12 cycles of operation, the system with three regenerator containers takes approximately four hours less total operating time than the system with only one regenerator container. It should be understood that... Figure 1C This is merely illustrative, and the system can produce a variety of other arrangements and / or results.

[0064] Now for reference Figure 2This illustrates a fluidization system 100 according to an exemplary embodiment. The fluidization system 100 is shown to be performed within a cracker vessel 12. In one embodiment, fluidization is performed within the cracker vessel 12. In some other embodiments, fluidization may be performed in both a regenerator vessel 14 and the cracker vessel 12. Incoming gas 102 may enter the gas redistribution chamber 24 of the cracker vessel 12 at a relatively high velocity. The incoming gas 102 may be redirected towards the bottom 18 of the chamber 24 by a gas redirector 32. The incoming gas 102 is distributed across a cross-sectional area of ​​the cracker vessel 12 and then moves upward to contact the perforated plate 20. The redirection of the incoming gas 102 reduces the velocity of the gas 102 and results in a uniformly distributed gas flow 104 contacting the perforated plate 20. The gas flow 104 may then pass through the perforated plate 20 and enter the fluidization chamber 22.

[0065] Now for reference Figure 3 A gas preheating system 200 according to an exemplary embodiment is shown. The gas preheating system 200 is shown to be performed in a cracker vessel 12. Gas preheating can be performed in both the cracker vessel 12 and the regenerator vessel 14. The gas preheating system 200 may include a conduit coil 220 positioned inside a gas distribution chamber 24. The gas feedstock 28 can be preheated inside the conduit coil 220 before entering a gas redirector 32 for redirecting and distributing the gas.

[0066] Now see Figures 1 to 3 Each of the cracker vessel 12 and the regenerator vessel 14 may include a top portion 202 and a bottom portion 204. The top portion 202 may include a top chamber (e.g., a fluidization chamber 22, catalyst regeneration chamber 36) closed by a top chamber wall 206. The bottom portion 204 may include a gas distribution chamber 24 closed by a gas distribution chamber wall 208. The top chamber wall 206 may be connected to the gas distribution chamber wall 208 by one or more perforated plate supports 210 and a sealing device 212 that separates the top chamber wall 206 from the perforated plate supports 210. The sealing device 212 is configured to seal and separate the top portion 202 of the vessel from the bottom portion 204 of the vessel.

[0067] like Figure 3As shown, the perforated plate support 210 connects the perforated plate 20 to the gas distribution chamber wall 208 and the top chamber wall 206. In some embodiments, the gas distribution chamber wall 208 is spring-loaded to the bottom flange 216 of the container via springs 214 that contact the bottom flange 216. In other embodiments, the gas distribution chamber wall 208 can be otherwise mounted to the bottom flange 216 of the container via any other means. Each of the springs 214 provides sufficient force to press one or more perforated plate supports 210 and sealing devices 212 against the top chamber wall 206, thereby sealingly separating the top portion 202 of the container from the bottom 204 of the container. The sealing device 212 is additionally configured to block material in the top chamber of the container (e.g., fluidization chamber 22, catalyst regeneration chamber 36). An additional seal is provided by sealing the bottom flange 216 of the container. Unlike the sealing device 212, this additional seal provides a gas seal for the bottom flange 216 of the container, thereby containing gas in the gas distribution chamber 24.

[0068] Although the diagram illustrates a specific order of method steps, the order of steps may differ from the depicted order. Furthermore, two or more steps may be performed simultaneously or partially simultaneously. Such variations will depend on the chosen hardware and software system and the designer's choices. All such variations are within the scope of this disclosure. Similarly, software implementations can be implemented using standard programming techniques that incorporate rule-based logic and other logic for implementing various connection steps, processing steps, comparison steps, and decision steps.

[0069] Numerous specific details are described to provide a thorough understanding of this disclosure. However, in some cases, well-known or conventional details are omitted to avoid obscuring the description. References to “some embodiments,” “one embodiment,” “exemplary embodiment,” and / or “various embodiments” in this disclosure may be, but are not necessarily, references to the same embodiments, and such references mean at least one of the said embodiments.

[0070] Alternative languages ​​and synonyms may be used for any one or more of the terms discussed herein. Whether a term is described or discussed in detail herein should not be of particular significance. Synonyms for certain terms are provided. The recitation of one or more synonyms does not preclude the use of other synonyms. Examples of use anywhere in this specification (including examples of any term discussed herein) are merely illustrative and are not intended to further limit the scope and meaning of this disclosure or any of the exemplified terms. Similarly, this disclosure is not limited to the various embodiments given in this specification.

[0071] Components and assemblies are made of any of a wide variety of materials that provide sufficient strength or durability, and in any of a wide variety of colors, textures, and combinations. Furthermore, components presented as a single unit may consist of multiple parts or elements.

[0072] As used herein, the term “exemplary” is intended to serve as an example, illustration, or description. Any embodiment or design described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments or designs. In fact, the use of the term “exemplary” is intended to present a concept in a specific manner. Therefore, all such modifications are intended to be included within the scope of this disclosure. Other substitutions, modifications, alterations, and omissions may be made in the design, operating conditions, and arrangement of preferred and other exemplary embodiments without departing from the scope of the appended claims.

[0073] As used herein, the terms “generally,” “approximately,” “substantially,” and similar terms are intended to have a broad meaning consistent with common usage and accepted by one of ordinary skill in the art to which the subject matter of this disclosure pertains. Those skilled in the art who examine the subject matter of this disclosure will understand that these terms are intended to allow for the description of certain features described and claimed, without limiting the scope of these features to the precise numerical ranges provided. Therefore, these terms should be interpreted as indicating that non-substantial or irrelevant modifications or alterations to the described and claimed subject matter are considered to be within the scope of the invention as set forth in the appended claims.

[0074] As used herein, the term "connection" means that two components are joined together directly or indirectly. Such connections may be stable or movable in nature, and / or such connections may allow the flow of fluids, electricity, electrical signals, or other types of signals, or communication between the two components. Such connections may be achieved by the integral formation of two components or two components and any additional intermediate components into a single monolithic entity, or by the attachment of two components or two components or any additional intermediate components to each other. Such connections may be permanent in nature, or they may be detachable or releasable in nature.

[0075] Other embodiments are described in the appended claims.

Claims

1. A circulating metal deactivation system unit for producing equilibrium catalyst materials, comprising: Cracker vessel, configured for cracking feedstock and stripping catalyst material; More than one regenerator vessel, each in fluid communication with the cracker vessel, the more than one regenerator vessel being configured for regenerating and steam deactivating the catalyst material; and A lifetime distribution container in fluid communication with the more than one regenerator container, the lifetime distribution container being configured to distribute the catalyst material based on the lifetime of the catalyst material; The cracker vessel, the more than one regenerator vessel, and the lifetime distribution vessel are in fluid communication with each other via a pneumatic valve system.

2. The circulating metal deactivation system unit of claim 1, wherein the cracker vessel and the more than one regenerator vessel are in fluid communication with each other via the pneumatic valve system, the pneumatic valve system comprising a first draw-in pipe in the cracker vessel and a second draw-in pipe in the regenerator vessel.

3. The circulating metal deactivation system unit according to claim 1, wherein the cracker container includes a first porous plate disposed in the lower region of the cracker container.

4. The circulating metal deactivation system unit of claim 3, wherein the first porous plate defines a first gas distribution zone and a first gas inlet disposed within the first gas distribution zone, the first gas distribution zone including the inner bottom surface of the cracker vessel, wherein the first gas inlet is configured to introduce a first gas source into the cracker vessel.

5. The circulating metal deactivation system unit according to claim 1, wherein each of the more than one regenerator container includes a second perforated plate disposed in the lower region of the regenerator container.

6. The circulating metal deactivation system unit of claim 5, wherein the second porous plate defines a second gas distribution region and a second gas inlet disposed within the second gas distribution region, the second gas distribution region including the inner bottom surface of each of the more than one regenerator container, wherein the second gas inlet is configured to introduce a second gas source into the more than one regenerator container.

7. The circulating metal deactivation system unit of claim 4, wherein the first gas inlet is fluidly connected to a first gas conduit within the first gas distribution zone of the cracker vessel, the first gas conduit comprising a coiled configuration for preheating the incoming gas within the first gas distribution zone of the cracker vessel.

8. The circulating metal deactivation system unit of claim 6, wherein the second gas inlet is fluidly connected to a second gas conduit within the second gas redistribution zone of the regenerator container, the second gas conduit comprising a coiled configuration for preheating the incoming gas within the second gas redistribution zone of the regenerator container.

9. The circulating metal deactivation system unit according to claim 1, wherein the pneumatic valve system comprises a first draw-in pipe in the cracker vessel, a second draw-in pipe in the regenerator vessel, and a third draw-in pipe in the lifetime distribution vessel.

10. The circulating metal deactivation system unit of claim 1, wherein each of the cracker vessel, the more than one regenerator vessel, and the lifetime distribution vessel includes a temperature maintenance device, wherein the temperature maintenance device maintains a predetermined process temperature in each respective vessel.

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