Bulk catalyst extraction system and method of using same

Abstract

A method for processing a chemical stream includes contacting a feed stream with a catalyst in a reactor section of a reactor system to induce a reaction that forms a product stream. The method includes separating the product stream from the catalyst; transferring the catalyst to a catalyst processing section of the reactor system; processing the catalyst in the catalyst processing section; and transferring a portion of the catalyst from the catalyst processing section of the reactor system to a catalyst extraction system, the catalyst extraction system including a catalyst extraction tank and a transfer line connecting the catalyst extraction tank to the catalyst processing section. Each of the catalyst extraction tank and the transfer line includes an outer metal shell and an inner refractory lining. The method further includes cooling the catalyst in the catalyst extraction tank from a temperature greater than or equal to 680°C to a temperature less than or equal to 350°C.

Description

[0001] This application is a divisional application of Chinese patent application No. 201880043362.5 (filed on May 3, 2018, entitled "Bulk Catalyst Extraction System and Method Thereof").

[0002] Cross-references to related applications

[0003] This application claims the benefit of U.S. Provisional Patent Application No. 62 / 502,094, filed May 5, 2017, which is hereby incorporated by reference in its entirety. Technical Field

[0004] This disclosure generally relates to chemical processing systems, and more specifically, to catalyst extraction systems for chemical processing systems. Background Technology

[0005] Light olefins serve as base materials for the production of many types of articles and materials. For example, ethylene can be used to manufacture polyethylene, vinyl chloride, or ethylene oxide. These products are used in product packaging, construction, textiles, and more. Therefore, light olefins, such as ethylene, propylene, and butene, are industrially needed. Light olefins can be produced by different reaction processes based on a given chemical feedstream, which may be a product stream from crude oil refining operations. Many light olefins can be produced via catalytic processes (such as catalytic hydrogenation), where the feedstream is contacted with a fluidized catalyst that promotes the conversion of the feedstream to light olefins. Over time, the catalyst may deactivate and must be removed from the reaction process and replaced. Summary of the Invention

[0006] There is a ongoing need for improved systems and methods for removing catalysts from reactor systems, such as those used to process chemical streams to produce light olefins or other chemical products. Many reactor systems for processing chemical streams to produce light olefins and other chemicals utilize thermal catalysts, such as catalysts heated to temperatures greater than 350°C. Catalysts can be circulated through the reaction system, such as through a reaction section (where the chemical product is prepared) and through a regeneration section (where the catalyst is regenerated, for example, by removing coke or by heating). Over time, these catalysts can become permanently deactivated due to contamination or loss / deterioration of the catalytically active material on the catalyst. In additional embodiments, these deactivated catalysts can be reactivated by processes available only outside the reactor system. Therefore, there may be a need to remove deactivated catalysts from the reactor system continuously, semi-continuously, or intermittently by batch extraction.

[0007] However, removing a hot catalyst from a reactor system can lead to damage and / or rapid deterioration of process equipment, such as transfer fittings, catalyst tanks, catalyst containers, valves, or other equipment used to remove the hot catalyst from the reactor system. For example, removing a hot catalyst at temperatures exceeding 350°C can deform equipment made of carbon steel, stainless steel, or other conventional processing and storage materials.

[0008] To mitigate equipment damage caused by the extraction of hot catalyst from the reactor system, refractory materials can be used as internal linings for tanks and piping. However, refractory materials can still exhibit significant cracking and degradation during thermal cycling during catalyst batch extraction. As used herein, "thermal cycling" refers to the cyclical raising and lowering of the structure's temperature. For example, commonly used refractory materials can crack when exposed to thermal cycling between temperatures equal to or less than 350°C and temperatures exceeding 680°C (i.e., the temperature of the extracted catalyst), which can lead to failure of the metallic components of the extraction equipment.

[0009] According to one or more embodiments, the catalyst extraction systems and methods disclosed herein address these problems by providing an extraction system that may include an extraction tank having an outer metal shell and an inner refractory lining made of a thermal shock resistant refractory material capable of withstanding the temperature of the hot catalyst and the thermal cycling of the extraction tank. The extraction systems and methods disclosed herein reduce damage to the extraction system, and in some embodiments, enable batch and continuous extraction of the catalyst from the reactor system, and allow the extracted catalyst to be cooled without deforming the outer metal shell of the tank.

[0010] According to one embodiment, a method for processing a chemical stream may include contacting a feed stream with a catalyst in a reactor section of a reactor system, wherein contacting the feed stream with the catalyst can induce a reaction to form a product stream. The reactor system may include a reactor section and a catalyst processing section. The method may further include separating at least a portion of the product stream from the catalyst; transferring the catalyst to the catalyst processing section of the reactor system; processing the catalyst in the catalyst processing section of the reactor system; and transferring at least a portion of the catalyst from the catalyst processing section of the reactor system to a catalyst extraction system. The catalyst extraction system may include a catalyst extraction tank and a transfer line connecting the catalyst extraction tank to the catalyst processing section. Each of the catalyst extraction tank and the transfer line may have an outer metal shell and an inner refractory lining. The method may further include cooling the catalyst in the catalyst extraction tank from greater than or equal to 680°C to less than or equal to 350°C.

[0011] In another embodiment, a method for processing a chemical stream may include contacting a feed stream with a catalyst in a reactor section of a reactor system, wherein contacting the feed stream with the catalyst can induce a reaction forming a product stream. The reactor system may include a reactor section and a catalyst processing section. The method may further include separating at least a portion of the product stream from the catalyst; transferring the catalyst to the catalyst processing section of the reactor system; and processing the catalyst in the catalyst processing section of the reactor system. Processing the catalyst may include raising the temperature of the catalyst in a burner of the catalyst processing section of the reactor system, removing coke deposits from the catalyst, or both. The method may further include transferring at least a portion of the catalyst from the catalyst processing section of the reactor system to a catalyst extraction system, the catalyst extraction system including a catalyst extraction tank and a transfer line connecting the catalyst extraction tank to the catalyst processing section. Each of the catalyst extraction tank and the transfer line may include an outer metal shell and an inner refractory lining. The inner refractory lining of the catalyst extraction tank may comprise a thermal shock resistant refractory material comprising at least one of fused silica, glassy silica, cordierite, or combinations thereof. The temperature of the catalyst extracted from the catalyst processing section can be at least 680°C.

[0012] In other embodiments, a system for processing a catalyst may include a burner fluidly coupled to a reactor section of a reactor system, the burner being configured to receive the catalyst from the reactor section of the reactor system and burn fuel gas, coke deposits formed on the catalyst in the reactor section of the reactor system, or both. The system may further include a riser downstream of the burner and a catalyst separation section downstream of the riser. The catalyst separation section may include a catalyst outlet fluidly coupled to an inlet of the reactor section of the reactor system, the inlet being configured to return the combusted catalyst to the reactor section. The system may further include a catalyst extraction system fluidly coupled to the catalyst separation section. The catalyst extraction system may include a catalyst extraction tank and a transfer line connecting the catalyst extraction tank to the catalyst separation section. Each of the catalyst extraction tank and the transfer line may include an outer metal shell and an inner refractory lining. The inner refractory lining of the catalyst extraction tank may include a thermal shock resistant refractory material.

[0013] It should be understood that the foregoing brief overview and the following detailed description present embodiments of the technology and are intended to provide an overview or framework for understanding the nature and characteristics of the claimed technology. Drawings are included to provide a 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.

[0014] Additional features and advantages of the technology disclosed herein will be set forth in the following detailed description and will be recognized in part by those skilled in the art from the description or by practice of the technology as described herein (including the following detailed description, claims and drawings). Attached Figure Description

[0015] The following detailed description of specific embodiments of this disclosure will be best understood when read in conjunction with the accompanying drawings, wherein similar reference numerals indicate similar structures and wherein:

[0016] Figure 1 A reactor system according to one or more embodiments described herein is schematically depicted;

[0017] Figure 2 Schematic depiction of one or more embodiments according to the description herein Figure 1 A cross-sectional view of the catalyst extraction system of the reactor system;

[0018] Figure 3 A flow chart of a reaction system according to one or more embodiments described herein is schematically depicted;

[0019] Figure 4 A schematic diagram of another reaction system flow according to one or more embodiments described herein is provided.

[0020] Figure 5 A schematic flowchart of another reaction system according to one or more embodiments described herein is provided.

[0021] Figure 6 A schematic diagram depicts the platinum content of a hydrogenation catalyst according to one or more embodiments described herein as a function of particle size.

[0022] It should be understood that the accompanying drawings are schematic in nature and do not include some components of reactor systems commonly used in the art, such as, but not limited to, temperature transmitters, pressure transmitters, flow meters, pumps, valves, etc. These components are known to be within the spirit and scope of the disclosed embodiments. However, operating components, such as those described herein, may be added to the embodiments described in this disclosure.

[0023] Reference will now be made in more detail to various embodiments, some of which are illustrated in the accompanying drawings. Wherever possible, the same reference numerals will be used throughout the drawings to refer to the same or similar parts. Detailed Implementation

[0024] The catalyst extraction system disclosed herein may include a catalyst extraction tank tightly coupled to a reactor system, such as a catalyst processing section tightly coupled to the reactor system. The extraction tank may have an internal refractory lining, which may be a thermal shock resistant refractory material that resists cracking and rapid degradation caused by the thermal conditions present during contact with the hot catalyst. In some embodiments, a catalyst extraction system with an internal refractory lining provides improved service life compared to existing catalyst removal devices. The catalyst extraction system disclosed herein also provides the flexibility to extract catalyst in a continuous or batch manner, allowing the catalyst extraction system to be adapted to different reactor system configurations that can be used to convert different feed streams into light olefins or other products. In additional embodiments, the catalyst extraction system disclosed herein may be advantageous for chemical processing systems in which the catalyst deactivation rate in the reaction system is reduced.

[0025] As previously discussed, the catalyst extraction systems disclosed herein can be used to extract / remove catalysts from reactor systems used for processing chemical streams. In a non-limiting example, the reactor system can be used to produce light olefins from a hydrocarbon feed stream. Light olefins can be produced from various feed streams using different catalysts and reaction mechanisms. For example, light olefins can be produced at least through dehydrogenation, cracking, dehydration, and methanol-to-olefins reactions. These reaction types can utilize different feed streams, which are subsequently reacted to form light olefins. Although systems and methods for extracting catalysts are described herein in the context of hydrocarbon processing to form light olefins, it should be understood that it is contemplated that the catalyst extraction systems and methods described herein can be used to extract any solid material, such as any particulate catalyst, from a reactor system. Therefore, the catalyst extraction systems and methods described in this invention should not be limited to use for extracting catalysts from hydrocarbon conversion systems designed to produce light olefins (such as...). Figure 1 Examples of extracting catalysts in the system described.

[0026] Reactor systems and methods for processing chemical streams will now be discussed in detail. The chemical stream being processed, referred to as the feed stream, is treated by reaction to form a product stream. The feed stream may comprise a composition, and depending on the feed stream composition, the contents of the feed stream can be converted into a product stream comprising light olefins or other chemical products using a suitable catalyst. For example, the feed stream may comprise at least one of propane, butane, ethane, or ethylbenzene, and the reaction system may be a dehydrogenation system, wherein the feed stream can be converted into light olefins by dehydrogenation in the presence of a dehydrogenation catalyst (such as a catalyst comprising platinum, palladium, and / or gallium). Other catalysts and reaction mechanisms can be used to form light olefins from hydrocarbon feed streams. Further discussion of suitable catalysts for use with various feed streams is provided subsequently in this disclosure.

[0027] Now refer to Figure 1 The example reactor system 102 is schematically depicted herein. However, it should be understood that the catalyst extraction system 500 and extraction method described herein are applicable for use with other reactor system configurations, including those that do not include the regeneration via circulating catalyst movement described herein. Reactor system 102 generally comprises several system components, such as reactor section 200, catalyst handling section 300, and catalyst extraction system 500. Figure 1 In this context, reactor section 200 generally refers to the portion of reactor system 102 where the main process reaction takes place. For example, reactor system 102 may be a dehydrogenation system in which the feed stream is dehydrogenated in reactor section 200 of reactor system 102 in the presence of a dehydrogenation catalyst.

[0028] Reactor section 200 includes reactor 202, which may include downstream reactor section 230 and upstream reactor section 250. According to one or more embodiments, as in... Figure 1 As depicted herein, reactor section 200 may additionally include a catalyst separation section 210 for separating the catalyst from the chemical products formed in reactor 202. Furthermore, as used herein, catalyst treatment section 300 generally refers to the section of reactor system 102 that processes the catalyst in some way (e.g., by combustion). Catalyst treatment section 300 may include a burner 350 and a riser 330, and may optionally include the catalyst separation section 310. In some embodiments, the catalyst can be regenerated by burning off contaminants (e.g., coke) in catalyst treatment section 300. In additional embodiments, the catalyst may be heated in catalyst treatment section 300. If no coke or other combustible material forms on the catalyst, or if the amount of coke formed on the catalyst is insufficient to burn off enough to heat the catalyst to the desired temperature, supplemental fuel may be used to heat the catalyst in catalyst treatment section 300. In one or more embodiments, catalyst separation section 210 may be in fluid communication with burner 350 (e.g., via riser 426), and catalyst separation section 310 may be in fluid communication with upstream reactor section 250 (e.g., via riser 424 and delivery riser 430). Catalyst extraction system 500 may include catalyst extraction tank 502 and transfer line 504 connecting catalyst extraction tank 502 to catalyst processing section 300.

[0029] Such as about Figure 1As described, the feed stream may enter the conveyor riser 430, and the product stream may exit the reactor system 102 via the conduit 420. According to one or more embodiments, the reactor system 102 may be operated by feeding a chemical feed (e.g., in the feed stream) and a fluidized catalyst into an upstream reactor section 250. The chemical feed contacts the catalyst in the upstream reactor section 250 and each flows upward into and through a downstream reactor section 230 to produce a chemical product. The chemical product and catalyst may be conveyed from the downstream reactor section 230 to a separation device 220 in a catalyst separation section 210. In the separation device 220, the catalyst is separated from the chemical product. The chemical product is conveyed out of the catalyst separation section 210. The separated catalyst is conveyed from the catalyst separation section 210 to a burner 350. In the burner 350, the catalyst may be treated by, for example, combustion. For example, but not limited to, the catalyst may be decoked and / or supplemental fuel may be burned to heat the catalyst. The catalyst is then conveyed from the burner 350 and through a riser 330 to a riser terminal separator 378, where the gaseous and solid components from the riser 330 are at least partially separated. The vapor and residual solids are then conveyed to a secondary separation unit 320 in the catalyst separation section 310, where the remaining catalyst is separated from gases from the catalyst treatment (e.g., gases released by burning spent catalyst or supplemental fuel). The separated catalyst is then conveyed from the catalyst separation section 310 to the upstream reactor section 250 via a riser 424 and a conveyor riser 430, where the catalyst is further used for a catalytic reaction. Thus, in operation, the catalyst can be circulated between the reactor section 200 and the catalyst treatment section 300. Generally, the treated chemical stream, comprising the feed stream and the product stream, can be gaseous, and the catalyst can be a fluidized particulate solid.

[0030] According to one or more embodiments described herein, reactor section 200 may include an upstream reactor section 250, a transition section 258, and a downstream reactor section 230, such as a riser. The transition section 258 connects the upstream reactor section 250 to the downstream reactor section 230. According to one or more embodiments, the upstream reactor section 250 and the downstream reactor section 230 may each have a substantially constant cross-sectional area, while the transition section 258 may taper gradually and not have a constant cross-sectional area. As described herein, unless otherwise explicitly stated, "cross-sectional area" refers to the area of ​​a portion of the reactor component's cross-section in a plane substantially orthogonal to the direction of substantially the flow of reactants and / or products. For example, in Figure 1 In the process, the cross-sectional areas of the upstream reactor section 250, the transition section 258, and the downstream reactor section 230 are oriented by the horizontal direction and the direction of entry into the reactor (orthogonal to the direction of fluid movement, i.e., in... Figure 1 The direction of the plane defined by the vertical upward direction.

[0031] As in Figure 1 As depicted, the upstream reactor section 250 may be located below the downstream reactor section 230. This configuration may be referred to as an upstream configuration in reactor 202. Reactor 202 may also be a downstream reactor, in which the upstream reactor section 250 may be located above the downstream reactor section 230. Other reactor configurations for the reactor section 200 of reactor system 102 are also envisioned.

[0032] As described herein, the upstream reactor section 250 may include a tank, drum, barrel, vessel, or other container suitable for a given chemical reaction. In one or more embodiments, the upstream reactor section 250 may be generally cylindrical (i.e., having a substantially circular cross-sectional shape), or alternatively, non-cylindrical, such as a prism shape with a cross-sectional shape of triangle, rectangle, pentagon, hexagon, octagon, ellipse, or other polygon, or a curved closed shape, or a combination thereof. As used throughout this disclosure, the upstream reactor section 250 may generally include a metal frame and may additionally include a refractory lining or other materials for protecting the metal frame and / or controlling process conditions. Figure 1 As depicted, the upstream reactor section 250 may include a defined delivery riser 430 connected to the catalyst inlet port 252 of the lower reactor section of the upstream reactor section 250.

[0033] The upstream reactor section 250 may be connected to a feed riser 430, which, in operation, provides treated catalyst and / or reactant chemicals in the feed stream to reactor section 200. The treated catalyst and / or reactant chemicals may be mixed using a distributor 260 housed in the upstream reactor section 250. Catalyst entering the upstream reactor section 250 via the feed riser 430 may be conveyed to the feed riser 430 via a riser 424, thereby reaching the catalyst treatment section 300. In some embodiments, the catalyst may be directly from the catalyst separation section 210 via a riser 422 and into the feed riser 430, whereby the catalyst enters the upstream reactor section 250. The catalyst may also be directly fed into the upstream reactor section 250 via 422. This catalyst may be slightly deactivated, but in some embodiments it may still be suitable for reaction in the upstream reactor section 250. As used herein, “deactivation” may refer to catalyst contamination by substances such as coke or a temperature lower than desired. Regeneration may remove contaminants such as coke, raise the temperature of the catalyst, or both.

[0034] Still refer to Figure 1Reactor section 200 may include a downstream reactor section 230 for conveying reactants, products, and / or catalysts from upstream reactor section 250 to catalyst separation section 210. In one or more embodiments, downstream reactor section 230 may be generally cylindrical (i.e., having a substantially circular cross-sectional shape), or alternatively, non-cylindrical, such as prisms, with cross-sectional shapes that are triangular, rectangular, pentagonal, hexagonal, octagonal, elliptical, or other polygonal, or curved closed shapes, or combinations thereof. As used throughout this disclosure, downstream reactor section 230 may generally comprise a metal frame and may additionally include a refractory lining or other materials for protecting the metal frame and / or controlling process conditions.

[0035] According to some embodiments, the downstream reactor section 230 may include an external riser section 232 and an internal riser section 234. As used herein, "external riser section" refers to the portion of the riser outside the catalyst separation section 210, and "internal riser section" refers to the portion of the riser inside the catalyst separation section 210. For example, in Figure 1 In the embodiments depicted, the internal riser section 234 of the reactor section 200 may be located within the catalyst separation section 210, while the external riser section 232 is located outside the catalyst separation section 210.

[0036] As in Figure 1 As depicted, the upstream reactor section 250 may be connected to the downstream reactor section 230 via a transition section 258. The upstream reactor section 250 may generally have a larger cross-sectional area than the downstream reactor section 230. The transition section 258 may gradually taper from the cross-sectional size of the upstream reactor section 250 to the cross-sectional size of the downstream reactor section 230, such that the transition section 258 protrudes inward from the upstream reactor section 250 into the downstream reactor section 230.

[0037] In some embodiments, such as those in which the upstream reactor section 250 and the downstream reactor section 230 have similar cross-sectional shapes, the transition section 258 may be formed as a frustum. For example, in embodiments of reactor portion 200 comprising a cylindrical upstream reactor section 250 and a cylindrical downstream reactor section 230, the transition section 258 may be formed as a conical frustum. However, it should be understood that various shapes of the upstream reactor section 250 are contemplated herein, connecting upstream reactor sections 250 and downstream reactor sections 230 of various shapes and sizes.

[0038] In one or more embodiments, the average cross-sectional area of ​​the upstream reactor section 250 may be at least 150% of the average cross-sectional area of ​​the downstream reactor section 230. As described herein, "average cross-sectional area" refers to the average cross-sectional area of ​​a given system component or section (such as the upstream reactor section 250 or the downstream reactor section 230). If a system component or section has a substantially constant cross-sectional area, such as the cylindrical shape of the depicted upstream reactor section 250 or downstream reactor section 230, then the cross-sectional area at any point is approximately equal to the average cross-sectional area.

[0039] According to one or more embodiments, the average cross-sectional area of ​​the upstream reactor section 250 may be at least 160%, at least 170%, at least 180%, at least 190%, at least 200%, at least 250%, at least 300%, at least 400%, or even at least 500% of the average cross-sectional area of ​​the downstream reactor section 230.

[0040] In one or more embodiments, based on shape, size, and other processing conditions, such as temperature and pressure in the upstream reactor section 250 and downstream reactor section 230, the upstream reactor section 250 may operate in an isothermal or near-isothermal manner, as in a fast fluidizing, turbulent, or bubbling bed reactor, while the downstream reactor section 230 may operate in a more plug flow manner, as in a riser reactor. For example, Figure 1 Reactor 202 may comprise an upstream reactor section 250 operating as a fast fluidized, turbulent, or bubbling bed reactor and a downstream reactor section 230 operating as a dilute phase riser reactor, where the result is that the average catalyst and gas flow move upwards simultaneously. As used herein, “average flow” refers to net flow, i.e., all upward flow minus counterflow or reverse flow, which is typically characteristic of fluidized particle behavior. As described herein, a “fast fluidized” reactor may refer to a reactor utilizing a fluidization mechanism in which the apparent velocity of the gas phase is greater than the choke velocity and can be semi-dense in operation. As described herein, a “turbulent” reactor may refer to a fluidization mechanism in which the apparent velocity is less than the choke velocity and is denser than a fast fluidization mechanism. As described herein, a “bubbling bed” reactor may refer to a fluidization mechanism in which well-defined bubbles in a high-density bed exist in two distinct phases. “Choke velocity” refers to the minimum velocity required to maintain solids in dilute phase mode in a vertical transport line. As described in this article, "dilute phase riser" can refer to a riser reactor operating at a conveying rate in which the gas and catalyst have approximately the same velocity in the dilute phase.

[0041] In one or more embodiments, the pressure range in reactor 202 may be from 6.0 to 44.7 psia (approximately 41.4 kPa to approximately 308.2 kPa), but in some embodiments, a narrower selection range may be used, such as from 15.0 psia to 35.0 psia (approximately 103.4 kPa to approximately 241.3 kPa). For example, the pressure may be from 15.0 psia to 30.0 psia (approximately 103.4 kPa to approximately 206.8 kPa), from 17.0 psia to 28.0 psia (approximately 117.2 kPa to approximately 193.1 kPa), or from 19.0 psia to 25.0 psia (approximately 131.0 kPa to approximately 172.4 kPa). Unit conversions from standard (non-SI) to measurement (SI) expressions herein include “approximately” to indicate rounding that may be present in the measurement (SI) expression due to the conversion.

[0042] In additional embodiments, the weight space-time velocity (WHSV) of the disclosed process can range from 0.1 lb per hour (h) of chemical feed per lb of catalyst in the reactor (lb feed / h / lb catalyst). For example, in the case where reactor 202 comprises an upstream reactor section 250 operating as a fast fluidized, turbulent, or bubbling bed reactor and a downstream reactor section 230 operating as a dilute phase riser reactor, the apparent gas velocity in the upstream reactor section 250 can range from 2 ft / s (about 0.61 m / s) to 10 ft / s (about 3.05 m / s), and the apparent gas velocity in the downstream reactor section 230 can range from 30 ft / s (about 9.14 m / s) to 70 ft / s (about 21.31 m / s). In additional embodiments, reactor configurations designed entirely for riser types can operate at a single high apparent gas velocity, for example, consistently at least 30 ft / s (approximately 9.15 m / s) in some embodiments.

[0043] In an additional embodiment, the ratio of catalyst to feed stream in reactor 202 may be in the range of 5 to 100 based on a weight-to-weight (w / w) ratio. In some embodiments, the ratio may be in the range of 10 to 40, such as 12 to 36, or 12 to 24.

[0044] In an additional embodiment, the catalyst flux in the upstream reactor section 250 can be 1 pound per square foot-second (lb / ft). 2 -s)(approximately 4.89 kg / m 2 -s) to 20 lb / ft 2 -s (to approximately 97.7 kg / m²-s), and in downstream reactor section 230, 10 lb / ft2 -s (approximately 48.9 kg / m²-s) to 100 lb / ft 2 -s (approximately 489 kg / m2-s).

[0045] In operation, the catalyst can move upward through downstream reactor section 230 (from upstream reactor section 250) and enter separation unit 220. The separated vapors can be removed from reactor system 102 via conduit 420 at gas outlet port 216 of catalyst separation section 210. According to one or more embodiments, separation unit 220 can be a cyclone separation system, which may include two or more cyclone separation stages. In embodiments where separation unit 220 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 a secondary cyclone separator for further separation. The primary cyclone separator may include, for example, a primary hydrocyclone and systems commercially available under the names VSS (commercially available from UOP), LD2 (commercially available from Stoneand Webster), and RS2 (commercially available from Stoneand Webster). Primary hydrocyclones 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 hydrocyclone as a primary hydrocyclone separator, one or more additional hydrocyclones, such as secondary and tertiary hydrocyclones, are employed to further separate the catalyst from the product gas. It should be understood that any primary hydrocyclone separator can be used in embodiments of the invention.

[0046] According to some embodiments, after separation from the vapor in the separation unit 220, the catalyst can be moved substantially through the stripper 224 to the reactor catalyst outlet port 222, wherein the catalyst is conveyed via the riser 426 out of the reactor section 200 and into the catalyst treatment section 300. Optionally, the catalyst can also be conveyed directly back to the upstream reactor section 250 via the riser 422. Alternatively, the catalyst can be premixed with the treated catalyst in the delivery riser 430.

[0047] According to Figure 1 As detailed in the embodiments, according to one or more embodiments, the catalyst can be treated by one or more of the following steps: transferring the catalyst from reactor 202 to burner 350; burning a supplemental fuel source in burner 350 or coke from deactivated catalyst; and transferring heated catalyst from burner 350 to reactor 202.

[0048] Now, referring to the catalyst treatment section 300, such as in Figure 1As depicted, the burner 350 of the catalyst treatment section 300 may include one or more lower reactor section inlet ports 352 and may be in fluid communication with a riser 330. The burner 350 may be in fluid communication with the catalyst separation section 210 via a riser 426 that supplies spent catalyst from the reactor section 200 to the catalyst treatment section 300 for regeneration. The burner 350 may include an air inlet 428 connected to an additional lower reactor section inlet port 352 of the burner 350. The air inlet 428 may supply reaction gases that can react with spent catalyst or supplemental fuel to at least partially regenerate the catalyst. For example, the catalyst may be coked after a reaction in the upstream reactor section 250, and the coke may be removed from the catalyst by a combustion reaction (i.e., catalyst regeneration). For example, an oxidant (such as air) may be fed into the burner 350 via the air inlet 428. Alternatively or additionally, supplemental fuel may be injected into the burner 350 when no significant amount of coke is formed on the catalyst; this supplemental fuel may be burned to heat the catalyst. After combustion, the treated catalyst can be separated in the catalyst separation section 310 and delivered back to the reactor section 200 via the riser 424.

[0049] When the catalyst is continuously recirculated through reactor system 102, it can become permanently deactivated, such as due to the loss and / or degradation of the catalytically active material (e.g., platinum, palladium, or gallium). The catalyst can also become permanently deactivated by the accumulation of heavy metals or other contaminants in the catalyst that cannot be removed by combustion, loss of catalyst surface area, or blockage of active sites by compounds. As used herein, the term "permanent deactivation" means that the catalyst's catalytic activity is insufficient to effectively catalyze the conversion reaction carried out in the reaction section, and that the catalytic activity cannot be increased and / or restored by increasing the temperature or burning off coke deposits. In other words, a permanently deactivated catalyst cannot be regenerated in the burner through normal plant operations.

[0050] The rate of permanent deactivation of a catalyst can vary widely depending on the catalyst and reaction mechanism employed in reaction system 102. For example, in a dehydrogenation system, permanent deactivation of the dehydrogenation catalyst can occur primarily due to the loss of catalytically active material (e.g., platinum, palladium, or gallium) from the catalyst surface. The rate of permanent deactivation of the dehydrogenation catalyst due to the loss of catalytically active material from the catalyst surface and the rate of permanent deactivation of the dehydrogenation catalyst can be much slower than the permanent deactivation of a cracking catalyst (which is typically due to the accumulation of heavy metals on the catalyst). The slow rate of permanent deactivation of the dehydrogenation catalyst in a dehydrogenation reactor system may necessitate the extraction and replacement of the entire volume of dehydrogenation catalyst within a period of 9 months or more, such as 9 months to 3 years, 9 months to 2 years, 9 months to 1 year, 1 to 3 years, or 1 to 2 years. For comparison, in fluidized catalytic cracking systems, the high rate of permanent deactivation of the cracking catalyst may require the extraction and replacement of the entire volume of cracking catalyst within 6 months or less, such as 1 to 6 months, 1 to 5 months, 1 to 3 months, 3 to 6 months, 3 to 5 months, or 4 to 6 months.

[0051] Still refer to Figure 1 A catalyst extraction system 500 can be coupled to a catalyst processing section 300 of reactor system 102 for continuously or batch extracting catalyst from reactor system 102. The catalyst extraction system 500 may include a catalyst extraction tank 502 and a transfer line 504 connecting the catalyst extraction system 500 to the catalyst processing section 300 of reactor system 102. In some embodiments, the transfer line 504 may connect the catalyst extraction tank 502 to the catalyst processing section 300 at a catalyst separation section 310 of the catalyst processing section 300. During operation of the catalyst extraction system 500, catalyst can be transferred from the catalyst separation section 310 of the catalyst processing section 300 to the catalyst extraction tank 502 via the transfer line 504, thereby extracting catalyst from reactor system 102.

[0052] Now refer to Figure 2According to one or more embodiments, the catalyst extraction tank 502 may include a catalyst inlet port 510 and at least one catalyst outlet port 512. The catalyst inlet port 510 may be coupled to a transfer line 504 such that the catalyst inlet port 510 is in fluid communication with the catalyst separation section 310 of the catalyst processing section 300 via the transfer line 504. In some embodiments, the catalyst inlet port 510 may be located in the top portion of the catalyst extraction tank 502. The catalyst outlet port 512 may be located at the end of the catalyst extraction tank 502 opposite to the catalyst inlet port 510. In an embodiment, the catalyst outlet port 512 may be located in the bottom portion of the catalyst extraction tank 502. In some embodiments, the catalyst extraction tank 502 may include a continuous catalyst outlet port 514. When the catalyst extraction system 500 operates in a continuous extraction mode, the continuous catalyst outlet port 514 can be used to continuously extract catalyst from the catalyst extraction tank 502. The continuous catalyst outlet port 514 may be located in the side of the catalyst extraction tank 502 at the bottom portion of the catalyst extraction tank 502. The catalyst drawn from the catalyst treatment section 300 into the catalyst extraction tank 502 is drawn downward through the catalyst inlet port 510 in the top part of the catalyst extraction tank 502 by gravity, and exits from the catalyst outlet port 512 and / or the continuous catalyst outlet port 514 located in the bottom of the catalyst extraction tank 502.

[0053] The internal height H of the catalyst extraction vessel 502 may be greater than the internal diameter D of the catalyst extraction vessel 502. The catalyst extraction vessel 502 may have an aspect ratio sufficient to provide adequate heat transfer area to cool the catalyst in the catalyst extraction vessel 502 without causing the temperature of the outer metal shell 506 to reach 350°C. According to one or more embodiments, the catalyst extraction vessel 502 may be designed and operated such that the catalyst is cooled to a temperature below 350°C inside the catalyst extraction vessel 502 before being conveyed out of the catalyst extraction vessel 502. The thermal properties of the catalyst extraction vessel 502 and the residence time of the catalyst in the catalyst extraction vessel 502 ensure that the catalyst undergoes sufficient cooling before being discharged from the reactor system 102. For example, hot catalyst enters the catalyst extraction vessel 502 and is cooled to below 350°C before being removed from the catalyst extraction vessel 502. As used herein, "aspect ratio" refers to the internal height H of the catalyst extraction vessel 502 divided by the internal diameter D of the catalyst extraction vessel 502. In some embodiments, the aspect ratio of the catalyst extraction tank 502 may be greater than or equal to 2, greater than or equal to 2.5, greater than or equal to 3, or greater than or equal to 3.5.

[0054] Reference Figure 2The transfer line 504 extends from the catalyst separation section 310 of the catalyst processing section 300 to the catalyst inlet port 510 of the catalyst extraction tank 502. In some embodiments, the transfer line 504 may be connected to the extraction port 328 of the catalyst separation section 310 of the catalyst processing section 300. The transfer line 504 may extend from the catalyst separation section 310 of the catalyst processing section 300 to the catalyst inlet port 510 of the catalyst extraction tank 502 in a downwardly inclined manner, so that the catalyst may be transferred to the catalyst extraction tank 502 by gravity through the transfer line 504.

[0055] The transfer line 504 can tightly connect the catalyst extraction tank 502 to the catalyst separation section 310. For example, in some embodiments, the outer wall 507 of the outer metal shell 506 of the catalyst extraction tank 502 may be positioned at a distance of less than or equal to 20 feet from the catalyst separation section 310. In other embodiments, the outer wall 507 of the outer metal shell 506 of the catalyst extraction tank 502 may be less than or equal to 50 feet from the catalyst separation section 310, such as less than or equal to 40 feet, less than or equal to 30 feet, less than or equal to 20 feet, less than or equal to 15 feet, less than or equal to 10 feet, or even less than or equal to 5 feet. In some embodiments, the radial distance Z between the outer wall 507 of the catalyst extraction tank 502 and the catalyst separation section 310 may be less than or equal to 50 feet, less than or equal to 40 feet, less than or equal to 30 feet, less than or equal to 20 feet, less than or equal to 15 feet, less than or equal to 10 feet, or even less than or equal to 5 feet. In some embodiments, the length L of the transmission line 504, measured from the extraction port 328 of the catalyst separation section 310 of the catalyst processing section 300 to the catalyst inlet port 510 of the catalyst extraction tank 502, may be less than or equal to 50 feet, less than or equal to 40 feet, less than or equal to 30 feet, less than or equal to 20 feet, less than or equal to 15 feet, less than or equal to 10 feet, or even less than or equal to 5 feet.

[0056] By tightly connecting the catalyst extraction tank 502 to the catalyst separation section 310 using the transfer line 504 (i.e., positioning the catalyst extraction tank 502 close to the catalyst separation section 310), the distance the catalyst travels through the transfer line 504 is reduced, thus reducing the time the catalyst spends in the transfer line 504. This reduces the exposure of the transfer line 504 to the high temperatures of the catalyst, which are above 350°C or even above 680°C. Tightly connecting the catalyst extraction tank 502 to the catalyst handling section 300 of the reactor system 102 also reduces the length of the transfer line 504, thereby reducing the length of the refractory-lined pipe required to transfer the catalyst extracted from the catalyst handling section 300 to the catalyst extraction tank 502. In the event that the transfer line 504 needs to be replaced, the reduced length of the transfer line 504 makes replacement more cost-effective.

[0057] The transfer line 504 may include at least one flow limiter 520 positioned between the catalyst separation section 310 and the catalyst extraction tank 502. The flow limiter 520 may be positioned to adjust and / or control the flow rate of catalyst through the transfer line 504 from the catalyst separation section 310 to the catalyst extraction tank 502. The flow limiter 520 may include at least one or both of a valve and an orifice plate. In some embodiments, the flow limiter 520 may be a valve, such as an Everlasting valve manufactured, for example, by Everlasting Valve Company. TM Valves. Other valves include gate valves, ball valves, or slide valves with steam purging to minimize catalyst accumulation or clogging. In other embodiments, flow limiter 520 may include two or more valves positioned in the delivery line. In other embodiments, flow limiter 520 may include one or more orifice plates that provide flow restriction in delivery line 504 to limit the flow of catalyst through delivery line 504.

[0058] Reference Figure 2The catalyst extraction tank 502 and the transfer line 504 may each include an outer metal shell 506 and an inner refractory lining 508. The outer metal shell 506 may be carbon steel, stainless steel, or other metals. The inner refractory lining 508 may be arranged inside the outer metal shell 506 to slow down heat transfer from the hot catalyst to the outer metal shell 506, thereby preventing the outer metal shell 506 from heating to a temperature exceeding its deformation temperature. The inner refractory lining 508 may have a thickness sufficient to maintain the temperature of the outer metal shell 506 at or below 350°C, which prevents deformation of the outer metal shell 506, but the inner refractory lining 508 may be thin enough to maintain the temperature as high as possible so that heat can be rapidly dissipated from the outer metal shell 506 of the catalyst extraction tank 502 into the ambient air. Maintaining rapid heat dissipation from the outer metal shell 506 to the ambient air sustains a high heat transfer rate through the inner refractory lining 508 and the outer metal shell 506, which allows for more rapid cooling of the catalyst in the catalyst extraction vessel 502. The thickness of the inner refractory lining 508 may depend on its thermal conductivity. In some embodiments, the thickness of the inner refractory lining 508 may be greater than or equal to 1 inch, greater than or equal to 1.5 inches, greater than or equal to 2 inches, greater than or equal to 2.5 inches, or greater than or equal to 3 inches. In some embodiments, the thickness of the inner refractory lining 508 may be 1 inch to 8 inches, 1.5 inches to 6 inches, 2 inches to 6 inches, 2.5 inches to 6 inches, or 3 inches to 6 inches.

[0059] In one embodiment, the internal refractory lining 508 of the catalyst extraction tank 502 may comprise a thermally shock resistant refractory material. In some other embodiments, the internal refractory lining 508 of both the catalyst extraction tank 502 and the transfer line 504 may comprise a thermally shock resistant refractory material. Without being bound by theory, it is believed that the thermal stress experienced by the internal refractory lining 508 can be a function of the linear coefficient of thermal expansion of the internal refractory lining 508, the temperature gradient through the internal refractory lining 508, and the thermal conductivity of the internal refractory lining 508. Without being bound by theory, it is believed that the linear coefficient of thermal expansion and / or thermal shock resistance can be a function of one or more of the following: the grain structure of the refractory material, the type of binder, the heat capacity, the morphology of the pores, or brittleness. When the thermal stress exceeds the fracture strength of the internal refractory lining 508, the internal refractory lining 508 may fracture. As used herein, “thermal shock resistant” refractory material refers to a refractory material that can mechanically withstand (e.g., without cracking or significant degradation) thermal cycles of a process, such as the introduction of a thermal catalyst and subsequent cooling of the catalyst. For example, a thermal shock resistant refractory lining may not excessively crack (e.g., develop cracks at least 0.25 inches or greater) or significantly degrade when repeatedly heated to the temperature of the thermal catalyst (e.g., greater than 680°C) and cooled to the temperature of the extracted catalyst (e.g., less than 350°C).

[0060] The thermal shock resistant refractory material may have a coefficient of thermal expansion (CTE) that is sufficiently small to maintain the thermal stress on the inner refractory lining 508 below its fracture strength during operation of the catalyst extraction system 500. Maintaining the thermal stress on the inner refractory lining 508 below its fracture strength reduces the likelihood of fracture during thermal cycling, thereby reducing cracking and / or deterioration of the inner refractory lining 508. In some embodiments, the CTE of the thermal shock resistant refractory material may be less than or equal to 2.7 × 10⁻⁶. -6 / per Kelvin (K -1 (That is, 1.5 × 10) -6 / per degree Fahrenheit (℉) -1 Or in other embodiments less than or equal to 1.8 × 10 -6 K -1 (i.e., 1.0 × 10) -6 ℉ -1 CTE can be determined according to ASTM E831-14.

[0061] Due to thermal cycling, thermal shock resistant refractories may also experience a strength loss, which is sufficiently low to allow the inner refractory lining 508 to maintain adequate strength when exposed to prolonged thermal cycling. In some embodiments, the strength loss of the thermal shock resistant refractories may be less than or equal to 25% according to ASTM C-1171. In other embodiments, the strength loss of the thermal shock resistant refractories may be less than or equal to 20%, less than or equal to 15%, less than or equal to 10%, or even less than or equal to 5% according to the modulus of rupture (MOR) standard described in ASTM C-1171.

[0062] Thermal shock resistant refractory materials may include at least one of fused silica, glassy silica, cordierite, or combinations thereof. In some embodiments, the thermal shock resistant refractory material may consist of fused silica. Examples of impact-resistant refractory materials may include, but are not limited to, those available from RESCO. ® Product Company (RESCO) ® Products, Inc.'s VIBROCAST FS-6G fused silica refractories, SUREFLOW FS-6LC fused silica refractories, or VIBROCAST FS-6 fused silica refractories. Table 1 below provides the CTE and strength loss for the above materials.

[0063] Table 1: Properties of exemplary impact-resistant refractory materials

[0064]

[0065] When the catalyst extraction system 500 is used in batch operation to extract catalyst from the catalyst separation section 310, a thermal shock resistant refractory material can prevent the internal refractory lining 508 of the catalyst extraction tank 502, transfer line 504, or both from cracking due to excessive thermal stress caused by thermal cycling (i.e., heating and cooling of the catalyst extraction system 500). The use of a thermal shock resistant refractory material can reduce the strength loss of the internal refractory lining 508, which can be caused by continuous and repeated thermal cycling. Maintaining the strength of the internal refractory lining 508 during thermal cycling through multiple catalyst extraction cycles of the catalyst extraction system 500 can prevent the internal refractory lining 508 from cracking and deteriorating over time.

[0066] Still refer to Figure 2 During operation of reactor system 102, at least a portion of the catalyst can be batch-extracted from catalyst processing section 300 of reactor system 102 into catalyst extraction system 500. During batch operation of catalyst extraction system 500, catalyst can be transferred from catalyst separation section 310 of catalyst processing section 300 via transfer line 504 and enter catalyst extraction tank 502 through catalyst inlet port 510. The temperature of the catalyst extracted from catalyst separation section 310 can be greater than 680°C, such as 680°C to 800°C. Catalyst can accumulate in catalyst extraction tank 502. When the catalyst cools, the catalyst can be maintained in catalyst extraction tank 502. The catalyst in catalyst extraction tank 502 can be cooled by heat conduction through internal refractory lining 508 and external metal shell 506 and by heat transfer to ambient air through thermal convection and / or radiation from the outer surface of external metal shell 506. During operation of the catalyst extraction system 500, the temperature of the outer metal shell 506 of the catalyst extraction tank 502 may be less than or equal to 350°C. In some embodiments, the catalyst may be held in the catalyst extraction tank 502 until the catalyst temperature cools from greater than or equal to 680°C to less than or equal to 350°C. In some embodiments, the residence time of the catalyst in the catalyst extraction tank 502 may be a time suitable for allowing the catalyst to cool to a temperature less than or equal to 350°C. For example, the residence time of the catalyst in the catalyst extraction tank 502 may be sufficient to cool the catalyst from greater than or equal to 680°C to less than or equal to 350°C. For example, but not limited to, the residence time may be from 15 minutes to several weeks, such as 30 minutes to 24 hours or 1 hour to 12 hours. In some embodiments, the catalyst may be cooled by means of heat transfer through the internal refractory lining 508 and the outer metal shell 506 of the catalyst extraction tank 502 without additional active cooling of the catalyst, such as quenching the catalyst or using a heat exchanger.

[0067] Once the catalyst in catalyst extraction tank 502 has cooled to less than or equal to 350°C, it can be extracted from catalyst extraction tank 502 through catalyst outlet port 512. The catalyst can be discharged into a catalyst hopper (not shown) or other container, such as a portable transport box, drum, or other container. Alternatively, in some embodiments, the catalyst can be discharged into another process, such as, but not limited to, catalyst classifier 600. Figure 4 ) or catalyst re-impregnation system 620 ( Figure 5 ).

[0068] In some processes carried out in reactor system 102, permanent deactivation of the catalyst may not develop rapidly, and a small amount of catalyst may need to be withdrawn from reactor system 102 per unit time. In these cases, given that the slow rate of catalyst deactivation provides sufficient time for the withdrawn catalyst to remain in catalyst withdrawal tank 502 for cooling, it may be more advantageous to withdraw the catalyst in batches from catalyst separation section 310 of catalyst processing section 300.

[0069] In other processes carried out in reactor system 102, permanent deactivation of the catalyst can develop more rapidly, which may require more rapid removal of the catalyst from reactor system 102. In these embodiments, catalyst extraction system 500 may also be operated to continuously extract catalyst from catalyst separation section 310. As used herein, “continuous” can mean fully continuous or semi-continuous operation. As described herein, fully continuous operation means continuously extracting catalyst during the time that reactor system 102 is operating. For example, catalyst may be continuously extracted from catalyst handling section 300 of reactor system 102 into catalyst extraction system 500 during operation of reactor system 102. As used herein, semi-continuous operation means periodically extracting catalyst for a period of time. For example, catalyst may be transferred to catalyst extraction system 500 for a set period of time, hourly, daily, or weekly, and repeated hourly, daily, or weekly. For example, semi-continuous operation may include transferring catalyst into and out of catalyst extraction system 500 for 10 minutes per hour, and repeating this process hourly during operation. During the remaining time of the one-hour period, extraction may be stopped. For example, in a semi-continuous operation, the catalyst extraction system 500 may operate continuously to extract catalyst from the catalyst processing section 300 of the reactor system 102 during a first time period (e.g., 5 minutes) within a second time period (e.g., 1 hour). During the first time period, the catalyst extraction system 500 may be operated to continuously extract catalyst from the catalyst processing section 300 into the catalyst extraction tank 502, and may continuously remove catalyst from the catalyst extraction tank 502. At the end of the first time period, the continuous operation of the catalyst extraction system 500 may be stopped, and the catalyst may be retained in the catalyst extraction tank 502 until the end of the second time period. At the end of the second time period, the operation of the catalyst extraction tank 502 may switch back to continuous operation of the first time period, and then switch back to no extraction for the remaining time of the second time period, etc. In another example, the first time period may be 2 hours, and the second time period may be one day. In another example, the first time period may be one day, and the second time period may be one week. Other time periods are envisioned for the first and second time periods.

[0070] Reference Figure 2In continuous or semi-continuous operation, catalyst extracted from catalyst separation section 310 can enter catalyst extraction tank 502 via transfer line 504 and catalyst inlet port 510. A flow limiter 520 located in transfer line 504 can be used to control the flow rate of catalyst from catalyst separation section 310 to catalyst extraction tank 502 via transfer line 504. In some embodiments, catalyst can pass through transfer line 504 and enter catalyst extraction tank 502 at a very slow mass flow rate. Catalyst can be continuously conveyed out of catalyst extraction tank 502 via continuous catalyst outlet ports 514, which may be located in the side of catalyst extraction tank 502. In continuous extraction operation, catalyst can be continuously conveyed into, through, and returned from catalyst extraction tank 502 via continuous catalyst outlet ports 514.

[0071] The continuous catalyst outlet port 514 may be coupled to at least one catalyst outlet flow limiter 522, which is configured to control the flow rate of catalyst exiting the continuous catalyst outlet port 514 of the catalyst extraction tank 502. In some embodiments, the catalyst outlet flow limiter 522 may be a valve, such as an Everlasting valve manufactured by Everlasting Valve Company. TM Valves. Other valves may include gate valves, ball valves, or slide valves with steam purging to minimize catalyst accumulation or clogging. In other embodiments, the catalyst outlet flow limiter 522 may include two or more valves located in the continuous catalyst outlet port 514. The flow rate of catalyst through the catalyst outlet flow limiter 522 can be adjusted to regulate catalyst accumulation within the catalyst extraction tank 502 during continuous operation of the catalyst extraction system 500.

[0072] During continuous or semi-continuous operation of the catalyst extraction system 500, the residence time of the catalyst in the catalyst extraction tank 502 can be a time suitable for allowing the catalyst to cool to a temperature less than or equal to 350°C. For example, the residence time of the catalyst in the catalyst extraction tank 502 can be sufficient to cool the catalyst from greater than or equal to 680°C to less than or equal to 350°C. For example, but not limited to, the residence time can be from 15 minutes to several weeks, such as 30 minutes to 24 hours or 1 hour to 12 hours. The space-time velocity of the catalyst conveyed into and out of the catalyst extraction tank 502 can be sufficient to cool the catalyst from greater than or equal to 680°C to less than or equal to 350°C. The space-time velocity is calculated by dividing the mass flow rate of the catalyst in the catalyst extraction tank 502 by the mass of the catalyst in the catalyst extraction tank 502. The space-time velocity is reported as mass of catalyst / hour / mass of catalyst in the catalyst extraction tank 502 (e.g., lb flow rate / hr / lb). In some embodiments, the catalyst extraction system 500 may have an average space-time velocity of the catalyst passing through the catalyst extraction tank 502 of 0.05 lb flow rate / hr / lb to 1.0 lb flow rate / hr / lb. For semi-continuous operation, the average space-time velocity of the catalyst passing through the catalyst extraction tank 502 is acquired during the on-off and off-off times (i.e., throughout the entire duration of the second time period, including the first time period of continuous operation).

[0073] Once the catalyst in the catalyst extraction tank 502 is cooled to less than or equal to 350°C, the catalyst can be extracted from the catalyst extraction tank 502 through the catalyst outlet port 512 (batch extraction) or the continuous catalyst outlet port 514 (continuous extraction). Extracting the catalyst from the catalyst extraction tank 502 removes the catalyst from the reactor system 102.

[0074] In one embodiment, the catalyst extraction tank 502 may be configured to allow fluid to pass through the catalyst extraction tank 502 and the catalyst contained within it. (See also...) Figure 2For example, catalyst extraction tank 502 may have a fluid inlet port 516 and a fluid inlet valve 518. In some embodiments, fluid inlet port 516 may be located at or near catalyst outlet port 512, allowing fluid to be conveyed into catalyst extraction tank 502 through catalyst outlet port 512. Other locations for fluid inlet port 516 are contemplated. The fluid may be a gas, such as nitrogen, argon, air, steam, other gas streams, or combinations thereof. The temperature of the fluid may be lower than the temperature of the catalyst conveyed from catalyst separation section 310 into catalyst extraction tank 502. In some embodiments, the temperature of the fluid may be lower than 350°C. In an embodiment, fluid conveyed into catalyst extraction tank 502 through fluid inlet port 516 may convey catalyst through the internal volume of catalyst extraction tank 502 and into catalyst separation section 310 via transfer line 504. The fluid may then exit catalyst separation section 310 of catalyst processing section 300 together with gases (e.g., flue gas) generated in catalyst processing section 300 of reactor system 102. Alternatively, in other embodiments, the catalyst extraction tank 502 may have a fluid outlet 524 located near the top portion of the catalyst extraction tank 502, such that fluid can be delivered into the catalyst extraction tank 502 through a fluid inlet valve 518, through the catalyst extraction tank 502 and the catalyst contained therein, and can be delivered out of the catalyst extraction tank 502 through the fluid outlet 524.

[0075] In some embodiments, the fluid inlet valve 518 may be a three-way valve. The fluid inlet valve 518 can be controlled to control the flow rate of fluid through the catalyst extraction tank 502 and the flow rate of catalyst contained in the catalyst extraction tank 502. As previously described, the catalyst extraction system 500 may be configured such that fluid is delivered through the fluid inlet port 516 into the catalyst extraction tank 502, and delivered from the catalyst extraction tank 502 via a transfer line 504 into the catalyst separation section 310 of the catalyst processing section 300. During batch operation of the catalyst extraction system 500, the fluid inlet valve 518 may be able to regulate the flow rate of fluid through the catalyst extraction tank 502 between at least two flow rates. For example, when catalyst is not actively extracted from the catalyst separation section 310 of the catalyst processing section 300, the flow rate of fluid through the catalyst extraction tank 502 may be set to a first fluid flow rate. As the guiding fluid flows from the catalyst extraction tank 502 through the transfer line 504 and into the catalyst separation section 310 of the catalyst processing section 300, the first fluid flow rate through the catalyst extraction tank 502 is sufficient to prevent catalyst from being transferred from the catalyst separation section 310 into the transfer line 504. However, the first fluid flow rate may be less than the flow rate required to transfer the catalyst from the catalyst extraction tank 502 back to the catalyst separation section 310 via the transfer line 504. When the batch operation is switched to extracting catalyst from the catalyst separation section 310, the fluid inlet valve 518 can be controlled to reduce the flow rate of the fluid flowing through the catalyst extraction tank 502 to a second fluid flow rate. The second fluid flow rate can be sufficiently reduced relative to the first fluid flow rate to allow the catalyst to be transferred from the catalyst separation section 310 into the transfer line 504 by gravity. Once the batch extraction of catalyst from the catalyst separation section 310 to the catalyst extraction tank 502 is complete, the fluid flow rate can be returned to the first fluid flow rate to prevent further extraction of catalyst from the catalyst separation section 310.

[0076] In some embodiments, the fluid inlet valve 518 may be a control valve. During continuous operation of the catalyst extraction system 500, the fluid inlet valve 518 may be controlled to further control the flow rate of catalyst delivered from the catalyst separation section 310 through the transfer line 504 into the catalyst extraction tank 502. For example, the fluid inlet valve 518 may be controlled to reduce the flow rate of fluid through the catalyst extraction tank 502, which may cause an increase in the flow rate of catalyst delivered from the catalyst separation section 310 through the transfer line 504 into the catalyst extraction tank 502. Alternatively, the fluid inlet valve 518 may be controlled to increase the flow rate of fluid entering the catalyst extraction tank 502, which may cause a decrease in the flow rate of catalyst delivered from the catalyst separation section 310 through the transfer line 504 into the catalyst extraction tank 502.

[0077] Reference Figure 3The diagram schematically depicts a reactor system flow chart for processing a chemical stream in reactor system 102. As previously discussed, reactor system 102 can be used to process a chemical stream (i.e., feed stream 153) to produce a product stream 155 having one or more chemical products (such as, for example, light olefins). Methods of processing the chemical stream in reactor system 102 may include contacting feed stream 153 with a catalyst in reactor section 200 of reactor system 102. Reactor system 102 may include reactor section 200 and catalyst processing section 300, and contacting feed stream 153 with the catalyst may cause a reaction to form product stream 155. The method may further include separating at least a portion of product stream 155 from the catalyst, transferring the catalyst to catalyst processing section 300 of reactor system 102, and processing the catalyst in catalyst processing section 300 of reactor system 102. Processing the catalyst in catalyst processing section 300 may include raising the temperature of the catalyst in burner 350 of catalyst processing section 300 of reactor system 102, removing coke deposits from the catalyst, or both. The method may further include transferring at least a portion of catalyst 530 from catalyst processing section 300 of reactor system 102 to catalyst extraction system 500. As previously discussed, catalyst extraction system 500 may include catalyst extraction tank 502 and transfer line 504 connecting catalyst extraction tank 502 to catalyst processing section 300. Catalyst extraction tank 502 and transfer line 504 may each include an outer metal shell 506 and an inner refractory lining 508. In an embodiment, the inner refractory lining 508 of catalyst extraction tank 502 may include a thermal shock resistant refractory material. In an embodiment, the thermal shock resistant refractory material may include at least one of fused silica, glassy silica, cordierite, or combinations thereof. The temperature of the catalyst extracted from catalyst processing section 300 may be at least 680°C. The method may further include cooling catalyst 530 in catalyst extraction tank 502 from greater than or equal to 680°C to less than or equal to 350°C.

[0078] The method may further include extracting at least a portion of catalyst 530 from catalyst extraction tank 502. As previously described, extracting catalyst 530 from catalyst extraction tank 502 removes catalyst 530 from reactor system 102. Catalyst extraction system 500 may further include a classifier 600, a re-impregnation system 620, or a classifier 600 and a re-impregnation system 620 located downstream of catalyst extraction tank 502. Catalyst 530 may be conveyed to classifier 600, re-impregnation system 620, or both, for further processing downstream of catalyst extraction tank 502.

[0079] Reference Figure 4In some embodiments, the catalyst extraction system 500 may include a classifier 600 located downstream of the catalyst extraction tank 502. Catalyst 530 may be conveyed from the catalyst extraction tank 502 to the classifier 600. The classifier 600 may separate the catalyst 530 into smaller particle size catalyst 602 and larger particle size catalyst 604, wherein the average particle size of the larger particle size catalyst 604 may be larger than the average particle size of the smaller particle size catalyst 602. In some embodiments, the smaller particle size catalyst 602 may be conveyed back to the reactor system 102, and the larger particle size catalyst 604 may be removed from the reactor system 102. Figure 4 As shown, the smaller particle size catalyst 602 can be transferred back to the catalyst processing section 300 of the reactor system 102. Alternatively, the smaller particle size catalyst 602 can be transferred back to the reactor section 200 of the reactor system 102.

[0080] It has been found that the fine catalyst powder present in the smaller particle size catalyst 602 can contain a greater amount of catalytically active material (e.g., platinum, palladium, gallium, or other materials) compared to the larger particle size catalyst 604. (See reference...) Figure 6 This shows that the relative amount of platinum in the dehydrogenation catalysts used in catalyst 640 and the new catalyst 642 varies with the particle size of the catalyst. For example... Figure 6 As shown, for the used catalyst 640, the relative amount of platinum is highest for the smallest catalyst particles and decreases with increasing average particle size. Trend line 644 further shows that the relative amount of platinum for the used catalyst decreases with increasing average particle size. For the new catalyst 642, the relative amount of platinum in the catalyst is consistent with particle size. Compared to the used catalyst 640 with a larger average particle size, it has been shown that increasing the relative amount of platinum in the used catalyst 640 with a lower average particle size improves the conversion of feed stream 153.

[0081] Refer again Figure 4 The smaller particle size catalyst 602 can have a smaller average particle size compared to the larger particle size catalyst 604, and therefore, a larger amount of platinum or other catalytically active material can be expected compared to the larger particle size catalyst 604. Therefore, the smaller particle size catalyst 602 can be fed back to reactor system 102 to enhance the reaction between feed stream 153 and the catalyst to produce product stream 155. A valve 606 or other back pressure device can be installed to adjust the flow rate of the smaller particle size catalyst 602 returning to reactor system 102, which can further adjust the flow rate for continuous or semi-continuous batch extraction. The larger particle size catalyst 604 can be removed from classifier 600, thereby removing the larger particle size catalyst 604 from reactor system 102. The larger particle size catalyst 604 can be fed to collection tank 608, from which it can pass for further processing.

[0082] Reference Figure 5 In some embodiments, catalyst 530 drawn from catalyst extraction tank 502 may be conveyed to reimpregnation system 620. In reimpregnation system 620, catalyst 530 drawn from catalyst extraction tank 502 may be reimpregnated with a catalytically active material (such as, for example, platinum, palladium, or gallium) to produce reimpregnated catalyst 622. The reimpregnated catalyst 622 may then be conveyed back to reactor system 102. Valve 606 or other backpressure devices may be installed to adjust the flow rate of smaller particle size catalyst 602 returning to reactor system 102, which may further adjust the flow rate of continuous or semi-continuous batch extraction. In some embodiments, reimpregnation system 620 may apply additional catalytically active material to the catalyst via an initial wetting impregnation process. In some of these embodiments, catalyst with additional catalytically active material applied to the catalyst via initial wetting impregnation may be conveyed to catalyst processing section 300 of reactor system 102 for catalyst calcination.

[0083] Alternatively, in Figure 5 In other embodiments also shown, catalyst 530 drawn from catalyst extraction tank 502 may be conveyed to classifier 600. In classifier 600, catalyst 530 drawn from catalyst extraction tank 502 may be separated into smaller particle size catalyst 602 and larger particle size catalyst 604. The smaller particle size catalyst 602 may be conveyed back to reactor system 102. Valve 606 or other back pressure devices may be installed to adjust the flow rate of the smaller particle size catalyst 602 returning to reactor system 102, which may further adjust the flow rate of continuous or semi-continuous batch extraction. The larger particle size catalyst 604 may be conveyed to reimpregnation system 620, wherein the larger particle size catalyst 604 may be reimpregnated with a catalytically active material (e.g., platinum, palladium, gallium, etc.) to form a reimpregnated catalyst 622. In embodiments, the reimpregnated catalyst 622 may be conveyed to reactor system 102. In some embodiments, at least a portion of the large-size catalyst 604 may be conveyed to tank 608 for further processing.

[0084] Reference Figure 2In some embodiments, the apparatus for extracting catalyst from the reactor system 102 for processing chemical streams may include a catalyst extraction tank 502 and a transfer line 504. The catalyst extraction tank 502 and the transfer line 504 may each include an outer metal shell 506 and an inner refractory lining 508. The inner refractory lining 508 of the catalyst extraction tank 502 may be a thermal shock resistant refractory material, as previously described herein. The catalyst extraction tank 502 may include a catalyst inlet port 510 located in the top portion of the catalyst extraction tank 502 and a catalyst outlet port 512 located in the bottom portion of the catalyst extraction tank 502. In some embodiments, the catalyst inlet port 510 may be located in the side of the catalyst extraction tank 502 at the top portion of the catalyst extraction tank 502. In some embodiments, the catalyst outlet port 512 may be located in the bottommost portion of the catalyst extraction tank 502. The transfer line 504 may include a flow restrictor 520, which may include at least one of a valve, an orifice plate, or a combination thereof. A transfer line 504 may be connected to the catalyst inlet port 510 of the catalyst extraction tank 502 and may extend generally upward and outward from the catalyst inlet port 510 of the catalyst extraction tank 502. In some embodiments, the catalyst extraction tank 502 may also have a continuous catalyst outlet port 514, which may be located in the side of the catalyst extraction tank 502 at the bottom portion of the catalyst extraction tank 502. The continuous catalyst outlet port 514 may extend generally downward and outward from the catalyst extraction tank 502.

[0085] According to one or more embodiments, the reaction may be a dehydrogenation reaction. According to such embodiments, the feed stream may contain one or more of ethane, propane, n-butane, and isobutane. For example, if the reaction is a dehydrogenation reaction, the feed stream may contain one or more of ethane, propane, n-butane, and isobutane. According to one or more embodiments, the 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 ethane. In additional embodiments, the 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 propane. In an additional embodiment, the 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 n-butane. In an additional embodiment, the 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 an additional embodiment, the 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 ethylbenzene, ethane, propane, n-butane, and isobutane.

[0086] In one or more embodiments, the dehydrogenation reaction may utilize a gallium and / or platinum catalyst as the catalyst. In such embodiments, the catalyst may comprise a gallium and / or platinum catalyst. For example, if the reaction is a dehydrogenation reaction, the catalyst may comprise a gallium and / or platinum catalyst. As described herein, gallium and / or platinum catalysts comprise gallium, platinum, or both. The gallium and / or platinum catalyst may be carried by an alumina or alumina-silica support and may optionally contain 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 to perform the dehydrogenation reaction.

[0087] According to one or more embodiments, the reaction may be a cracking reaction. According to such embodiments, the feed stream may contain one or more of naphtha, n-butane, or isobutane. For example, if the reaction is a cracking reaction, the feed stream may contain one or more of naphtha, n-butane, or isobutane. According to one or more embodiments, the 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. In additional embodiments, the 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 n-butane. In an additional embodiment, the 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 additional embodiment, the 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 naphtha, n-butane, and isobutane.

[0088] In one or more embodiments, the cracking reaction may utilize one or more zeolites as catalysts. In such embodiments, the catalyst may comprise one or more zeolites. For example, if the reaction is a cracking reaction, the catalyst may comprise one or more zeolites. In some embodiments, the one or more zeolites used for the cracking reaction may comprise ZSM-5 zeolite. However, it should be understood that other suitable catalysts may be used to perform the cracking reaction. For example, commercially available suitable catalysts may include Intercat Super Z Excel or Intercat Super Z Exceed. In additional embodiments, in addition to the catalytically active material, the cracking catalyst may comprise platinum. For example, the cracking catalyst may comprise 0.001 wt.% to 0.05 wt.% platinum. Platinum may be sprayed in the form of platinum nitrate and calcined at a high temperature (e.g., about 700°C). Without being bound by theory, it is believed that adding platinum to the catalyst may allow supplemental fuels (such as methane) to burn more easily.

[0089] According to one or more embodiments, the reaction may be a dehydration reaction. According to such embodiments, the feed stream may contain one or more of ethanol, propanol, or butanol. For example, if the reaction is a dehydration reaction, the feed stream may contain one or more of ethanol, propanol, or butanol. According to one or more embodiments, the 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 ethanol. In additional embodiments, the 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 propanol. In an additional embodiment, the 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 butanol. In another additional embodiment, the 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 ethanol, propanol, and butanol.

[0090] In one or more embodiments, the dehydration reaction may utilize one or more acid catalysts. In such embodiments, the catalyst may comprise one or more acid catalysts. For example, if the reaction is a dehydration reaction, the catalyst may comprise one or more acid catalysts. In some embodiments, the one or more acid catalysts used for the dehydration reaction may comprise zeol (such as ZSM-5 zeolite), alumina, amorphous aluminosilicates, acid clay, or combinations thereof. For example, according to one or more embodiments, suitable commercially available alumina catalysts include SynDol (available from Scientific Design Company), V200 (available from UOP), or P200 (available from Sasol). Suitable commercially available zeolite catalysts include CBV 8014 and CBV 28014 (each available from Zeolyst). Suitable commercially available amorphous aluminosilicate catalysts include 135 grade silica-alumina catalyst support (available from Sigma Aldrich). However, it should be understood that other suitable catalysts can be used to perform the dehydration reaction.

[0091] According to one or more embodiments, the reaction may be a methanol-to-olefins reaction. According to such embodiments, the feed stream may contain methanol. For example, if the reaction is a methanol-to-olefins reaction, the feed stream may contain methanol. According to one or more embodiments, the 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 methanol.

[0092] In one or more embodiments, the methanol-to-olefins reaction may utilize one or more zeolites as catalysts. In such embodiments, the catalyst may comprise one or more zeolites. For example, if the reaction is a methanol-to-olefins reaction, the catalyst may comprise one or more zeolites. In some embodiments, the one or more zeolites used for the methanol-to-olefins reaction may comprise one or more of ZSM-5 zeolite or SAPO-34 zeolite. However, it should be understood that other suitable catalysts may be used to perform the methanol-to-olefins reaction.

[0093] For purposes of describing and defining the invention, it should be noted that the term "about" is used herein to indicate the inherent uncertainty attributable to any quantitative comparison, value, measurement, or other representation. The term is also used herein to indicate the extent to which a quantitative representation may vary from a stated reference without causing a change in the fundamental function of the subject matter of interest.

[0094] It should be noted that one or more of the following claims use the term "wherein" as a transitional phrase. For the purpose of limiting the invention, 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 characteristics of the structure and should be interpreted in a similar manner to the more commonly used open leading term "comprising".

[0095] Generally, the terms "inlet port" and "outlet port" for any system unit of reactor system 102 as described herein refer to an opening, orifice, channel, aperture, 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 will define the area of ​​a system unit of reactor system 102 that is attached to a pipe, conduit, tube, hose, material delivery line, or similar mechanical feature, or a portion of a system unit that is directly attached to another system unit. While inlet and outlet ports may sometimes be described herein as functionally operable, they may have similar or identical physical characteristics, and their respective functions within an operable system should not be construed as limiting their physical structure.

[0096] Those skilled in the art will recognize that various modifications and variations can be made to this invention without departing from its spirit and scope. Because those skilled in the art can make modifications, combinations, sub-combinations, and variations of the disclosed embodiments that are incorporated into the spirit and essence of this invention, this invention should be interpreted as encompassing everything within the scope of the appended claims and their equivalents.

[0097] This disclosure also relates to the following implementation schemes:

[0098] 1. A method for processing chemical streams, the method comprising:

[0099] In the reactor section of a reactor system, the feed stream is brought into contact with a catalyst, wherein the reactor system includes a reactor section and a catalyst treatment section, and the contacting of the feed stream with the catalyst causes a reaction that forms a product stream.

[0100] The catalyst is transferred to the catalyst processing section of the reactor system;

[0101] The catalyst is treated in the catalyst treatment section of the reactor system;

[0102] At least a portion of the catalyst is transferred from the catalyst processing section of the reactor system to a catalyst extraction system, the catalyst extraction system comprising a catalyst extraction tank and a transfer line connecting the catalyst extraction tank to the catalyst processing section, each of the catalyst extraction tank and the transfer line comprising an outer metal shell and an inner refractory lining; and

[0103] The catalyst in the catalyst extraction tank is cooled from a temperature greater than or equal to 680°C to a temperature less than or equal to 350°C.

[0104] 2. The method according to claim 1, the method further comprising, after cooling the catalyst to less than or equal to 350°C, extracting at least a portion of the catalyst from the catalyst extraction tank, wherein extracting the catalyst from the catalyst extraction tank removes the catalyst from the reactor system.

[0105] 3. The method according to item 1 or 2, wherein the internal refractory lining of the catalyst extraction vessel is a thermal shock resistant refractory material, the thermal shock resistant refractory material having a thermal shock resistant content of less than or equal to 2.7 × 10⁻⁶ according to ASTM E831-14. -6 °K -1 The linear thermal expansion coefficient (CTE).

[0106] 4. The method according to any one of items 1 to 3, wherein the internal refractory lining of the catalyst extraction vessel is a thermal shock refractory material having a strength loss of less than or equal to 25% according to the modulus of rupture standard described in ASTM C-1171.

[0107] 5. The method according to any one of claims 1 to 4, wherein the catalyst extraction tank is tightly coupled to the catalyst processing section of the reactor system such that the outer wall of the catalyst extraction tank is within 50 feet of the catalyst processing section of the reactor system.

[0108] 6. The method according to any one of claims 1 to 5, wherein at least a portion of the catalyst is extracted from the catalyst processing section of the reactor system into the catalyst extraction system in a batch or semi-continuous manner during operation of the reactor system.

[0109] 7. The method according to any one of claims 1 to 6, the method further comprising conveying fluid through the catalyst extraction tank and the catalyst in the catalyst extraction tank.

[0110] 8. The method according to any one of items 1 to 7, wherein the method further comprises:

[0111] The catalyst removed from the catalyst extraction tank is transferred to a classifier;

[0112] The catalyst is divided into smaller particle size catalyst and larger particle size catalyst, wherein the average particle size of the larger particle size catalyst is larger than that of the smaller particle size catalyst;

[0113] The smaller particle size catalyst is then returned to the reactor system;

[0114] The larger particle size catalyst is re-impregnated with a catalytically active material to form a re-impregnated catalyst; and

[0115] The re-impregnated catalyst is then returned to the reactor system.

[0116] 9. The method according to any one of items 1 to 8, wherein the reaction comprises dehydrogenation.

[0117] 10. A system for processing a catalyst, the system comprising:

[0118] A burner fluidly connected to a reactor section of a reactor system, the burner being configured to receive a catalyst from the reactor section of the reactor system and burn fuel gas, coke deposits formed on the catalyst in the reactor section of the reactor system, or both.

[0119] The riser pipe downstream of the burner;

[0120] Downstream of the riser, in a catalyst separation section, the catalyst separation section includes a catalyst outlet fluidly connected to the inlet of the reactor section of the reactor system, the inlet being configured to return the combusted catalyst to the reactor section; and

[0121] A catalyst extraction system fluidly connected to the catalyst separation section includes a catalyst extraction tank and a transfer line connecting the catalyst extraction tank to the catalyst separation section. Each of the catalyst extraction tank and the transfer line includes an outer metal shell and an inner refractory lining, wherein the inner refractory lining of the catalyst extraction tank contains a thermal shock resistant refractory material.

Claims

1. A method for processing chemical streams, the method comprising: In the reactor section of a reactor system, the feed stream is brought into contact with the catalyst, wherein the reactor system includes a reactor section and a catalyst treatment section, and the contacting of the feed stream with the catalyst causes a reaction to form a product stream comprising the product and spent catalyst. The spent catalyst is transferred to the catalyst treatment section of the reactor system; The spent catalyst is treated in the catalyst treatment section of the reactor system, wherein the treatment of the spent catalyst includes raising the temperature of the spent catalyst, removing coke deposits from the spent catalyst, contacting the spent catalyst with one or more reactive gases, or a combination thereof, to produce a combusted catalyst. At least a portion of the combusted catalyst is transferred from the catalyst processing section of the reactor system to a catalyst extraction system, the catalyst extraction system comprising a catalyst extraction tank and a transfer line connecting the catalyst extraction tank to the catalyst processing section, each of the catalyst extraction tank and the transfer line comprising an outer metal shell and an inner refractory lining. The combusted catalyst in the catalyst extraction tank is cooled from a temperature greater than or equal to 680°C to a temperature less than or equal to 350°C; and After cooling the combusted catalyst to a temperature of less than or equal to 350°C, the combusted catalyst is extracted from the catalyst extraction tank, wherein extracting the combusted catalyst from the catalyst extraction tank removes the combusted catalyst from the reactor system.

2. The method according to claim 1, wherein the internal refractory lining of the catalyst extraction tank, the transfer pipeline, or both are made of a thermal shock resistant refractory material, the thermal shock resistant refractory material having a thermal shock resistantness of less than or equal to 2.7 × 10⁻⁶ according to ASTM E831-14. -6 K -1 The linear thermal expansion coefficient (CTE).

3. The method of claim 1, wherein the internal refractory lining of the catalyst extraction vessel, the transfer pipeline, or both are thermal shock refractory materials having a strength loss of less than or equal to 25% according to the modulus of rupture standard described in ASTM C-1171.

4. The method of claim 1, wherein the catalyst extraction tank is tightly coupled to the catalyst processing section of the reactor system such that the outer wall of the catalyst extraction tank is within 50 feet of the catalyst processing section of the reactor system.

5. The method of claim 1, wherein at least a portion of the combusted catalyst is extracted from the catalyst processing section of the reactor system into the catalyst extraction system in a batch or semi-continuous manner during operation of the reactor system.

6. The method of claim 1, further comprising conveying fluid through the catalyst extraction tank and the combusted catalyst in the catalyst extraction tank.

7. The method according to claim 1, wherein the method further comprises: The combusted catalyst removed from the catalyst extraction tank is conveyed to the classifier; The combusted catalyst is divided into smaller particle size catalyst and larger particle size catalyst, wherein the average particle size of the larger particle size catalyst is larger than that of the smaller particle size catalyst. The smaller particle size catalyst is then returned to the reactor system; The larger particle size catalyst is re-impregnated with a catalytically active material to form a re-impregnated catalyst; and The re-impregnated catalyst is then returned to the reactor system.

8. The method of claim 1, wherein the reaction comprises dehydrogenation.

9. The method according to claim 1, wherein: Treating the spent catalyst includes contacting the spent catalyst with one or more reactant gases; and The one or more reactive gases include air.

10. The method of claim 1, wherein The treatment of the spent catalyst includes raising the temperature of the spent catalyst; and Raising the temperature of the spent catalyst includes burning supplemental fuel in the presence of the spent catalyst.

11. The method of claim 1, wherein the internal refractory lining of the catalyst extraction vessel, the transfer pipeline, or both are made of a thermal shock resistant refractory material, the thermal shock resistant refractory material having a thermal shock resistant content of less than or equal to 1.8 × 10⁻⁶ according to ASTM E831-14. -6 K -1 The linear thermal expansion coefficient (CTE).

12. The method of claim 1, wherein the internal refractory lining of the catalyst extraction vessel, the transfer pipeline, or both are thermal shock refractory materials having a strength loss of less than or equal to 15% according to the modulus of rupture standard described in ASTM C-1171.

13. The method of claim 2, wherein the thermal shock resistant refractory material comprises fused silica, glassy silica, cordierite, or a combination thereof.

14. The method of claim 6, wherein the fluid comprises nitrogen, argon, air, steam, other gas streams or combinations thereof, and wherein the fluid has a temperature of less than 350°C.

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