Systems and methods for regenerating particulate solids - Patents.com

Abstract

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

Description

[Technical field]

[0001] (CROSS REFERENCE TO RELATED APPLICATIONS) This application claims the benefit of and priority to U.S. patent application Ser. No. 63 / 126,089, entitled "Systems and Methods for Regenerating Particulate Solids," filed December 16, 2020, the entire contents of which are incorporated by reference into this disclosure.

[0002] FIELD OF THE DISCLOSURE

[0002] Embodiments described herein relate generally to chemical processing, and more specifically to methods and systems for catalytic chemical conversion. [Background technology]

[0003] Many chemicals may be produced by processes that use particulate solids, such as solid particulate catalysts. During these processes, the particulate solids may become "spent" and become less active in subsequent reactions. Additionally, endothermic processes require heat, and the "spent" catalyst must be reheated. As such, the spent particulate solids may be transferred to a regeneration unit to be reheated and regenerated, increasing the activity of the particulate solids for use in subsequent reactions. Following regeneration in the regeneration unit, the regenerated particulate solids may be returned to the reactor for use in subsequent reactions. Summary of the Invention

[0004] There is a need for improved methods for regenerating, reactivating, or increasing the activity of particulate solids for use in the production of various chemicals, including, but not limited to, light olefins. Many regenerator systems for regenerating particulate solids include a particulate solids treatment vessel located directly below the particulate solids separation section, such that a riser extends from the particulate solids treatment vessel through the bottom of the particulate solids separation section. Such a design can adversely affect the flow of particulate solids through the particulate solids separation section by forming an annular space at the bottom of the particulate solids separation section, where the outlet cannot be located centered at the bottom of the particulate solids separation section.

[0005] One or more of the disclosed methods for reclaiming particulate solids utilize a system that addresses this problem. In one or more embodiments, the riser does not enter the particulate solids separation section through the bottom of the particulate solids separation section. Thus, the particulate solids outlet can be located at the center of the bottom of the particulate solids separation section, resulting in improved flow characteristics for the particulate solids exiting the particulate solids separation section.

[0006] According to one or more embodiments disclosed herein, the particulate solids may be regenerated by a method including regenerating the particulate solids in a particulate solids processing vessel. Regenerating the particulate solids may include one or more of oxidizing the particulate solids by contact with an oxygen-containing gas, burning coke present on the particulate solids, or burning a supplemental fuel to heat the particulate solids. The method may further include passing the particulate solids through a riser. The riser may extend through a riser port of an outer shell of the particulate solids separation section such that the riser comprises an inner riser segment disposed in an interior region of the particulate solids separation section and an outer riser segment disposed outside the outer shell of the particulate solids separation section. The particulate solids separation section may include at least an outer shell defining an interior region of the particulate solids separation section. The outer shell may comprise a gas outlet port, a riser port, and a particulate solids outlet port. The outer shell may house a gas / solids separator and a particulate solids collection area within the interior region of the particulate solids separation section. The riser port may be positioned on a sidewall of the outer shell such that it is not located on a central vertical axis of the particulate solids separation section. The method may further include separating the particulate solids from the gas in a gas / solids separation device and directing the particulate solids separated from the gas to a particulate solids collection area located proximate to a central vertical axis of the particulate solids separation section.

[0007] It should be understood that both the foregoing general description and the following detailed description present embodiments of the present technology and are intended to provide an overview or framework for understanding the nature and features of the present technology as claimed. The accompanying drawings are included to provide a further understanding of the technology, and are incorporated in and constitute a part of this specification. The drawings illustrate various embodiments and, together with the description, serve to explain the principles and operation of the technology. Moreover, the drawings and description are intended to be merely illustrative and are not intended to limit the scope of the claims in any manner.

[0008] Additional features and advantages of the techniques disclosed herein will be set forth in the detailed description which follows, and will be readily apparent in part to those skilled in the art from that description, or will be learned by practicing the techniques as described herein, including the detailed description, claims, and accompanying drawings. [Brief description of the drawings]

[0009] The following detailed description of certain embodiments of the present disclosure can be best understood when read in conjunction with the following drawings, in which like structure is indicated with like reference numerals and in which: [Figure 1] 1 illustrates a schematic of a reactor system including a reactor section and a regenerator section, according to one or more embodiments disclosed herein. [Diagram 2] 1 illustrates a schematic of a particulate solids processing vessel and an external riser segment according to one or more embodiments disclosed herein. [Diagram 3] 1 illustrates a schematic of a particulate solids separation section according to one or more embodiments disclosed herein. [Figure 4] 1 depicts a particulate solids collection area according to one or more embodiments disclosed herein. [Diagram 5] 1 depicts a particulate solids collection area according to one or more embodiments disclosed herein. [Figure 6] 1 graphically illustrates residence time distribution in a particulate solids collection region according to one or more embodiments disclosed herein.

[0010] It should be understood that the drawings are schematic in nature and do not include some components of fluid catalytic reactor systems commonly used in the art, such as, but not limited to, temperature transmitters, pressure transmitters, flow meters, pumps, valves, etc. These components would be known to be within the spirit and scope of the disclosed embodiments. However, operational components such as those described in this disclosure may be added to the embodiments described in this disclosure.

[0011] 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 numbers will be used throughout the drawings to refer to the same or like parts. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] As described herein, the methods for reclaiming particulate solids disclosed herein may be utilized to reclaim particulate solids from a reactor system for treating a chemical stream. Such methods utilize a system having particular characteristics, such as a particular orientation of system components. For example, in one or more embodiments described herein, the particulate solids processing vessel is not directly below the particulate solids separation section. One particular embodiment disclosed in detail herein is shown in FIG. 1. However, it should be understood that the principles disclosed and taught herein may be applicable to other systems utilizing different system components oriented in different ways or different reaction schemes utilizing various catalyst compositions.

[0013] 1, as can be understood with reference to the preceding figures and description, feed chemicals may be reacted by contact with particulate solids, such as a catalyst, in reactor section 200. The particulate solids may be separated from the reaction products in reactor section 200 and sent to regeneration section 300, where the particulate solids may be regenerated. Such regenerated particulate solids may be returned to reactor section 200 for a subsequent reaction cycle.

[0014] Although some embodiments are described herein in the context of reactor system 100, it should be understood that the methods and systems described herein may operate without reactor section 200 or with alternative means for reacting the feed streams. Thus, reactor section 200 should not be construed as necessary or essential in all embodiments of the methods and systems of the present disclosure.

[0015] In a non-limiting example, the reactor system 100 described herein may be utilized to produce light olefins from a hydrocarbon feed stream. Light olefins may be produced from a variety of hydrocarbon feed streams by utilizing a variety of reaction mechanisms. For example, light olefins may be produced by at least dehydrogenation, cracking, dehydration, and methanol to olefins reactions. These reaction types may utilize different feed streams and different particulate solids to produce light olefins. It should be understood that when "catalysts" are referred to herein, they may equally refer to the particulate solids referred to with respect to the system of FIG. 1.

[0016] According to one or more embodiments, the reaction may be a dehydrogenation reaction. According to such embodiments, the hydrocarbon feed stream may comprise one or more of ethylbenzene, ethane, propane, n-butane, i-butane. In one or more embodiments, the hydrocarbon feed stream may comprise at least 50% by weight, at least 60% by weight, at least 70% by weight, at least 80% by weight, at least 90% by weight, at least 95% by weight, or even at least 99% by weight of ethane. In additional embodiments, the hydrocarbon feed stream may comprise at least 50% by weight, at least 60% by weight, at least 70% by weight, at least 80% by weight, at least 90% by weight, at least 95% by weight, or even at least 99% by weight of propane. In additional embodiments, the hydrocarbon feed stream may comprise at least 50% by weight, at least 60% by weight, at least 70% by weight, at least 80% by weight, at least 90% by weight, at least 95% by weight, or even at least 99% by weight of n-butane. In additional embodiments, the hydrocarbon feed stream can comprise at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, at least 95%, or even at least 99% by weight of i-butane. In additional embodiments, the hydrocarbon feed stream can comprise at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, at least 95%, or even at least 99% by weight of the sum of ethane, propane, n-butane, and i-butane.

[0017] In one or more embodiments, the dehydrogenation reaction may utilize gallium and / or platinum particulate solids as catalysts. In such embodiments, the particulate solids may include gallium and / or platinum catalysts. As described herein, the gallium and / or platinum catalysts include gallium, platinum, or both. The gallium and / or platinum catalysts may be supported by an alumina or alumina silica support and may optionally include potassium. Such gallium and / or platinum catalysts are disclosed in U.S. Pat. No. 8,669,406, which is incorporated herein by reference in its entirety. However, it should be understood that other suitable catalysts may be utilized to carry out the dehydrogenation reaction.

[0018] In one or more embodiments, the reaction mechanism may be dehydrogenation (in the same chamber) followed by combustion. In such embodiments, the dehydrogenation reaction may produce hydrogen as a by-product, and the oxygen carrier material may contact the hydrogen to promote combustion of the hydrogen to form water. Examples of such reaction mechanisms contemplated as possible reaction mechanisms for the systems and methods described herein are disclosed in WO2020 / 046978, the teachings of which are incorporated herein by reference in their entirety.

[0019] According to one or more embodiments, the reaction may be a cracking reaction. According to such embodiments, the hydrocarbon feed stream may comprise one or more of naphtha, n-butane, or i-butane. According to one or more embodiments, the hydrocarbon feed stream may comprise at least 50% by weight, at least 60% by weight, at least 70% by weight, at least 80% by weight, at least 90% by weight, at least 95% by weight, or even at least 99% by weight naphtha. In additional embodiments, the hydrocarbon feed stream may comprise at least 50% by weight, at least 60% by weight, at least 70% by weight, at least 80% by weight, at least 90% by weight, at least 95% by weight, or even at least 99% by weight n-butane. In additional embodiments, the hydrocarbon feed stream may comprise at least 50% by weight, at least 60% by weight, at least 70% by weight, at least 80% by weight, at least 90% by weight, at least 95% by weight, or even at least 99% by weight i-butane. In additional embodiments, the hydrocarbon feed stream can comprise at least 50% by weight, at least 60% by weight, at least 70% by weight, at least 80% by weight, at least 90% by weight, at least 95% by weight, or even at least 99% by weight of the total of naphtha, n-butane, and i-butane.

[0020] In one or more embodiments, the cracking reaction may utilize one or more zeolites as a catalyst. In such embodiments, the particulate solids may include one or more zeolites. In some embodiments, the one or more zeolites utilized in the cracking reaction may include ZSM-5 zeolite. However, it should be understood that other suitable catalysts may be utilized to carry out the cracking reaction. For example, suitable catalysts that are commercially available may include Intercat Super Z Excel or Intercat Super Z Exceed. In further embodiments, the cracking catalyst may include platinum in addition to the catalytically active material. For example, the cracking catalyst may include 0.001% to 0.05% by weight of platinum. The platinum may be sprayed as platinum nitrate and calcined at high temperatures, such as about 700° C. Without wishing to be bound by theory, it is believed that the addition of platinum to the catalyst may allow for easier combustion of auxiliary fuels, such as methane.

[0021] According to one or more embodiments, the reaction may be a dehydration reaction. According to such embodiments, the hydrocarbon feed stream may comprise one or more of ethanol, propanol, or butanol. According to one or more embodiments, the hydrocarbon feed stream may comprise at least 50% by weight, at least 60% by weight, at least 70% by weight, at least 80% by weight, at least 90% by weight, at least 95% by weight, or even at least 99% by weight of ethanol. In additional embodiments, the hydrocarbon feed stream may comprise at least 50% by weight, at least 60% by weight, at least 70% by weight, at least 80% by weight, at least 90% by weight, at least 95% by weight, or even at least 99% by weight of propanol. In additional embodiments, the hydrocarbon feed stream may comprise at least 50% by weight, at least 60% by weight, at least 70% by weight, at least 80% by weight, at least 90% by weight, at least 95% by weight, or even at least 99% by weight of butanol. In additional embodiments, the hydrocarbon feed stream can comprise at least 50% by weight, at least 60% by weight, at least 70% by weight, at least 80% by weight, at least 90% by weight, at least 95% by weight, or even at least 99% by weight of the total of ethanol, propanol, and butanol.

[0022] In one or more embodiments, the dehydration reaction may include one or more acid catalysts. In such embodiments, the particulate solid may include one or more acid catalysts. In some embodiments, the one or more acid catalysts utilized in the dehydration reaction may include a zeolite (such as ZSM-5 zeolite), an alumina, an amorphous aluminosilicate, an acid clay, or a combination thereof. For example, commercially available alumina catalysts that may be suitable include SynDol (available from Scientific Design Company), V200 (available from UOP), or P200 (available from Sasol), according to one or more embodiments. Commercially available zeolite catalysts that may be suitable include CBV 8014, CBV 28014 (each available from Zeolyst). Commercially available amorphous aluminosilicate catalysts that may be suitable include silica-alumina catalyst support, grade 135 (available from Sigma Aldrich). However, it should be understood that other suitable catalysts may be utilized to carry out the dehydration reaction.

[0023] According to one or more embodiments, the reaction can be a methanol to olefins reaction. According to such embodiments, the hydrocarbon feed stream can include methanol. According to one or more embodiments, the hydrocarbon feed stream can include 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% methanol.

[0024] In one or more embodiments, the methanol to olefins reaction may utilize one or more zeolites as a catalyst. In such embodiments, the particulate solid may include one or more zeolites. In some embodiments, the one or more zeolites utilized in the methanol to olefins reaction may include one or more of ZSM-5 zeolite or SAPO-34 zeolite. However, it should be understood that other suitable catalysts may be utilized to carry out the methanol to olefins reaction.

[0025] In one or more embodiments, operating a chemical process may include passing a product stream from a reactor. The product stream may include light olefins. As described herein, "light olefins" refers to one or more of ethylene, propylene, or butene. As described herein, butenes may include any isomer of butene, such as α-butylene, cis-β-butylene, trans-β-butylene, and isobutylene. In an embodiment, the product stream may include at least 50% by weight of light olefins. For example, the product stream may include at least 60% by weight of light olefins, at least 70% by weight of light olefins, at least 80% by weight of light olefins, at least 90% by weight of light olefins, at least 95% by weight of light olefins, or even at least 99% by weight of light olefins.

[0026] With further reference to FIG. 1, the reactor system 100 generally includes multiple system components, such as a reactor section 200 and a regeneration section 300. As used herein in the context of FIG. 1, the reactor section 200 generally refers to the portion of the reactor system 100 where the primary process reaction occurs and where the particulate solids are separated from the olefin-containing product stream of the reaction. In one or more embodiments, the particulate solids may be consumed, meaning that the particulate solids are at least partially inactivated. Also, as used herein, the regeneration section 300 generally refers to the portion of the fluid catalytic reactor system where the particulate solids are regenerated, such as by combustion, and the regenerated particulate solids are separated from other process materials, such as materials previously combusted on the spent particulate solids or gases generated from auxiliary fuels. The reactor section 200 generally includes a reaction vessel 250, a riser 230 including an outer riser segment 232 and an inner riser segment 234, and a particulate solids separation section 210. The regeneration section 300 generally includes a particulate solids processing vessel 350, a riser 330 including an outer riser segment 332 and an inner riser segment 334, and a particulate solids separation section 310. Generally, the particulate solids separation section 210 may be in fluid communication with the particulate solids processing vessel 350, for example, by the water tower 126, and the particulate solids separation section 310 may be in fluid communication with the reaction vessel 250, for example, by the water tower 124 and the transport riser 130.

[0027] In general, reactor system 100 may be operated by feeding a hydrocarbon feed and fluidized particulate solids to reaction vessel 250 and reacting the hydrocarbon feed by contacting it with the fluidized particulate solids to produce an olefin-containing product in reaction vessel 250 of reactor section 200. The olefin-containing product and particulate solids may exit reaction vessel 250 through riser 230 and be sent to gas / solids separator 220 in particulate solids separation section 210 where the particulate solids are separated from the olefin-containing product. The particulate solids may be transported from particulate solids separation section 210 to particulate solids treatment vessel 350. In particulate solids treatment vessel 350, the particulate solids may be regenerated by various processes. For example, spent particulate solids may be regenerated by one or more of oxidation of the particulate solids by contact with an oxygen-containing gas, burning of coke present on the particulate solids, and burning an auxiliary fuel to heat the particulate solids. The particulate solids then exit the particulate solids processing vessel 350 and pass through riser 330 to riser termination 378 where the gases and particulate solids from the riser 330 are at least partially separated. The gases and remaining particulate solids from the riser 330 are transported to secondary separation device 320 in particulate solids separation section 310 where the remaining particulate solids are separated from the gases from the regeneration reaction. The particulate solids separated from the gases may be passed to particulate solids collection area 380. The separated particulate solids are then passed from particulate solids collection area 380 to reaction vessel 250 where they are further utilized. Thus, the particulate solids may be circulated between reactor section 200 and regeneration section 300.

[0028] In one or more embodiments, the reactor system 100 can include either a reactor section 200 or a regeneration section 300, but not both. In further embodiments, the reactor system 100 can include a single regeneration section 300 and multiple reactor sections 200.

[0029] Further, as described herein, the structural features of reactor section 200 and regeneration section 300 may be similar or identical in some respects. For example, reaction section 200 and regeneration section 300 each include a reaction vessel (i.e., reaction vessel 250 of reactor section 200 and particulate solids processing vessel 350 of regeneration section 300), a riser (i.e., riser 230 of reactor section 200 and riser 330 of regeneration section 300), and a particulate solids separation section (i.e., particulate solids separation section 210 of reactor section 200 and particulate solids separation section 310 of regeneration section 300). Because many of the structural features of reactor section 200 and regeneration section 300 may be similar or identical in some respects, similar or identical portions of reactor section 200 and regeneration section 300 are provided with reference numbers having the same last two digits throughout this disclosure, and it should be understood that a disclosure regarding one portion of reactor section 200 may be applicable to a similar or identical portion of regeneration section 300, and vice versa.

[0030] As shown in FIG. 1, the reaction vessel 250 can include a reaction vessel particulate solids inlet port 252 that defines a connection of the transport riser 130 to the reaction vessel 250. The reaction vessel 250 can further include a reaction vessel outlet port 254 that is in fluid communication with or directly connected to the external riser segment 232 of the riser 230. As described herein, a reaction vessel refers to a drum, barrel, vat, or other container suitable for a given chemical reaction. The reaction vessel 250 can be generally cylindrical (i.e., having a substantially circular diameter) or non-cylindrical, such as prismatic, having a cross-sectional shape that is triangular, square, pentagonal, hexagonal, octagonal, elliptical, or other polygonal, or closed curved, or combinations thereof. As used throughout this disclosure, a reaction vessel can generally include a metal frame and can further include a refractory lining or other material utilized to protect the metal frame and / or control process conditions.

[0031] Generally, the "inlet port" and "outlet port" of any system unit of the fluid catalytic reactor system 100 described herein refer to an opening, hole, channel, opening, gap, or other similar mechanical feature of the system unit. For example, an inlet port allows for the inflow of material into a particular system unit, and an outlet port allows for the outflow of material from a particular system unit. Generally, an outlet port or inlet port defines an area of ​​a system unit of the fluid catalytic reactor system 100 to which a pipe, conduit, tube, hose, material transfer line, or similar mechanical feature is attached, or a portion of a system unit to which another system unit is directly attached. Although inlet and outlet ports may be described herein functionally during operation, they may have similar or identical physical features, and their respective functions in an operational system should not be construed as limiting their physical structure. Other ports, such as the riser port 218, may include an opening in a given system unit to which another system unit is directly attached, such as when the riser 230 extends into the particulate solids separation section 210 at the riser port 218.

[0032] The reaction vessel 250 may be connected to a transport riser 130, which may provide regenerated particulate solids and chemical feed to the reactor section 200 during operation. Particulate solids entering the reaction vessel 250 via the transport riser 130 may pass through the transport riser 130 through the water column 124 and thus arrive from the regeneration section 300. In some embodiments, particulate solids may enter the transport riser 130 directly from the particulate solids separation section 210 via the water column 122, where they enter the reaction vessel 250. These particulate solids may be slightly inerted, but in some embodiments may still be suitable for use in the reaction vessel 250.

[0033] As shown in FIG. 1, the reaction vessel 250 can be directly connected to the external riser segment 232. In one embodiment, the reaction vessel 250 can include a reaction vessel body section 256 and a reaction vessel transition section 258 disposed between the reaction vessel body section 256 and the external riser segment 232. The reaction vessel body section 256 can generally include a larger diameter than the reaction vessel transition section 258, and the reaction vessel transition section 258 can taper from the size of the diameter of the reaction vessel body section 256 to the size of the diameter of the riser 230 such that the reaction vessel transition section 258 protrudes inwardly from the reaction vessel body section 256 to the external riser segment 232. It should be understood that as used herein, the diameter of a portion of a system unit refers to its general width as shown horizontally in FIG. 1.

[0034] In one or more embodiments, the reactor vessel 250 can have a maximum cross-sectional area that is at least three times the maximum cross-sectional area of ​​the riser 230. For example, the reactor vessel 250 can have a maximum cross-sectional area that is at least three times, at least four times, at least five times, at least six times, at least seven times, at least eight times, at least nine times, or even at least ten times the maximum cross-sectional area of ​​the riser 230. As used herein, unless otherwise specified, "cross-sectional area" refers to the area of ​​a cross section of a portion of a system component in a plane substantially perpendicular to the general direction of flow of reactants and / or products.

[0035] 1 , the reactor section 200 can include a riser 230 that acts to transport reactants, products, and / or particulate solids from the reaction vessel 250 to the particulate solids separation section 210. In one or more embodiments, the riser 230 can be generally cylindrical (i.e., having a substantially circular cross-sectional shape) or non-cylindrical, such as prismatic, having a triangular, square, pentagonal, hexagonal, octagonal, elliptical, or other polygonal, or closed curved, or combinations thereof, cross-sectional shape. As used throughout this disclosure, the riser 230 can generally include a metal frame and can further include a refractory lining or other material utilized to protect the metal frame and / or control process conditions.

[0036] According to some embodiments, the riser 230 can include an outer riser segment 232 and an inner riser segment 234. As used herein, an "outer riser section" refers to a portion of the riser that is outside of the particulate solids separation section, and an "inner riser section" refers to a portion of the riser that is within the particulate solids separation section. For example, in the embodiment shown in Figure 1, the inner riser section 234 of the reactor section 200 can be located within the particulate solids separation section 210, while the outer riser section 232 can be located outside of the particulate solids separation section 210.

[0037] In one or more embodiments, the particulate solids separation section 210 may include an outer shell 212, which may define an interior region 214 of the particulate solids separation section 210. The outer shell 212 may include a gas outlet port 216, a riser port 218, and a particulate solids outlet port 222. Additionally, the outer shell 212 may house a gas / solids separator 220 and a particulate solids collection area 280 within the interior region 214 of the particulate solids separation section 210.

[0038] In one or more embodiments, the outer shell 212 of the particulate solids separation section 210 may define an upper segment 276, a middle segment 274, and a lower segment 272 of the particulate solids separation section 210. Generally, the upper segment 276 may have a substantially constant cross-sectional area such that the cross-sectional area does not vary by more than 20% at the upper segment 276. Additionally, in one or more embodiments, the lower segment 272 of the particulate solids separation section 210 may have a substantially constant cross-sectional area such that the cross-sectional area does not vary by more than 20% at the lower segment 272. The cross-sectional area of ​​the lower segment 272 may be greater than the maximum cross-sectional area of ​​the riser 230 and less than the maximum cross-sectional area of ​​the upper segment 276. The middle segment 274 may be shaped as a frustum such that the cross-sectional area of ​​the middle segment 274 is not constant, but rather the cross-sectional area of ​​the middle segment 274 transitions from the cross-sectional area of ​​the upper segment 276 to the cross-sectional area of ​​the lower segment 272 throughout the middle segment 274.

[0039] 1 , the inner riser segment 234 of the riser 230 can extend through a riser port 218 of the particulate solids separation section 210. The riser port 218 may be any opening in the particulate solids separation section 210 where at least the inner riser segment 234 of the riser 230 protrudes into the interior region 214 of the particulate solids separation section 210. In one or more embodiments, the inner riser segment 234 enters the particulate solids separation section 210 at the middle segment 274 or the upper segment 276 and does not pass through the lower segment 272.

[0040] At the upper segment 276 of the particulate solids separation section 210, the internal riser segment 234 may be in fluid communication with a gas / solids separator 220. The gas / solids separator 220 may be any mechanical or chemical separation device that may be operable to separate particulate solids from a gas or liquid phase, such as a cyclone or multiple cyclones.

[0041] The particulate solids may travel upwardly from the reaction vessel 250 through the riser 230 and enter the gas / solids separator 220. The gas / solids separator 220 may be operable to deposit the separated particulate solids at the bottom of the upper segment 276, or in the middle segment 274 or the lower segment 272. The separated vapor may be removed from the fluid catalytic reactor system 100 at the gas outlet port 216 of the particulate solids separation section 210 via the pipe 120.

[0042] In one or more embodiments, the lower segment 272 of the particulate solids separation section 210 may include a particulate solids collection area 280. In one or more embodiments, the particulate solids collection area 280 may allow for accumulation of particulate solids within the particulate solids separation section 210. The particulate solids collection area 280 may include a stripping section. The stripping section may be utilized to strip the product vapors from the particulate solids prior to sending the product vapors to the regeneration section 300. Because the product vapors transported to the regeneration section 300 are combusted, it may be desirable to remove these product vapors using a stripper that utilizes a gas that is less expensive to combust than the product gases.

[0043] The particulate solids collection area 280 in the lower segment 272 may include a particulate solids outlet port 222. The water tower 126 may be connected to the particulate solids separation section 210 at the particulate solids outlet port 222, and the particulate solids may exit the reactor section 200 via the water tower 126 and be transported to the regeneration section 300. Optionally, the particulate solids may also be transferred directly back to the reactor section 250 via the water tower 122. Alternatively, the particulate solids may be premixed with the regenerated particulate solids in the transport riser 130.

[0044] After separation in particulate solids separation section 210, the spent particulate solids are transferred to regeneration section 300. Regeneration section 300 may share many structural similarities with reactor section 200, as described herein. Accordingly, reference numbers assigned to portions of regeneration section 300 are similar to those used with respect to reactor section 200, and where the last two digits of a reference number are the same, a given portion of reactor section 200 and regeneration section 300 may perform a similar function and may have a similar physical structure. Accordingly, much of the present disclosure regarding regeneration section 300 is equally applicable to reactor section 200.

[0045] Referring now to the regeneration section 300, as shown in Figures 1 and 2, the particulate solids processing vessel 350 of the regeneration section 300 may include one or more reactor vessel inlet ports 352 and reactor vessel outlet ports 354 in fluid communication or even directly connected to the outer riser segment 332 of the riser 330. The particulate solids processing vessel 350 may be in fluid communication with the particulate solids separation section 210 via a water column 126, which may feed spent particulate solids from the reactor section 200 to the regeneration section 300 for regeneration. The particulate solids processing vessel 350 may include an additional reactor vessel inlet port 352 to which an inlet 128 connects to the particulate solids processing vessel 350. The inlet 128 may feed reactive fluids, such as supplemental fuel in liquid or gas form, and oxygen-containing gases (including air, enriched air, and even pure oxygen), which may be used to at least partially regenerate the particulate solids. In one or more embodiments, the particulate solids processing vessel 350 may include multiple additional reactor vessel inlet ports, each of which may supply a different reactive fluid to the particulate solids processing vessel 350. For example, the particulate solids may be coked following reaction in the reaction vessel 250, and the coke may be removed from the particulate solids by a combustion reaction. In the alternative, an oxygen-containing gas, such as air, may be supplied to the particulate solids processing vessel 350 via inlet 128 to oxidize the particulate solids, or a supplemental fuel may be supplied to the particulate solids processing vessel 350 and combusted to heat the particulate solids.

[0046] 1 and 2, the particulate solids processing vessel 350 may be directly connected to the outer riser segment 332 of the riser 330. In one embodiment, the particulate solids processing vessel 350 may include a particulate solids processing vessel body section 356 and a particulate solids processing vessel transition section 358. The particulate solids processing vessel body section 356 may generally include a larger diameter than the particulate solids processing vessel transition section 358, and the particulate solids processing vessel transition section 358 may taper from the size of the diameter of the particulate solids processing vessel body section 356 to the size of the diameter of the outer riser segment 332 such that the particulate solids processing vessel transition section 358 projects inwardly from the particulate solids processing vessel body section 356 to the outer riser segment 332.

[0047] In one or more embodiments, the particulate solids processing vessel 350 may have a maximum cross-sectional area that is at least three times that of the riser 330. For example, the particulate solids processing vessel 350 may have a maximum cross-sectional area that is at least three times, at least four times, at least five times, at least six times, at least seven times, at least eight times, at least nine times, at least ten times, at least eleven times, at least twelve times, at least thirteen times, at least fourteen times, or even at least fifteen times that of the riser 330.

[0048] Additionally, the particulate solids processing vessel body section 356 may generally have a height, where the height of the particulate solids processing vessel body section 356 is measured from the reactor vessel inlet port 352 to the particulate solids processing vessel transition section 358. In one or more embodiments, the diameter of the particulate solids processing vessel body section 356 may be greater than the height of the particulate solids processing vessel body section 356. In one or more embodiments, the diameter to height ratio of the particulate solids processing vessel body section 356 may be between 5:1 and 1:5. For example, the diameter to height ratio of the particulate solids processing vessel body section 356 may be 5:1 to 1:5, 4:1 to 1:5, 3:1 to 1:5, 2:1 to 1:5, 1:1 to 1:5, 1:2 to 1:5, 1:3 to 1:5, 5:1 to 1:4, 5:1 to 1:3, 5:1 to 1:2, 5:1 to 1:1, 5:1 to 2:1, 5:1 to 3:1, 5:1 to 4:1, or any combination or subcombination of these ranges.

[0049] 1 and 3, the particulate solids separation section 310 includes an outer shell 312 that defines an interior region 314 of the particulate solids separation section 310. The outer shell 312 may include a gas outlet port 316, a riser port 318, and a particulate solids outlet port 322. Additionally, the outer shell 312 may house a secondary separation device 320 and a particulate solids collection area 380 within the interior region 314 of the particulate solids separation section 310.

[0050] In one or more embodiments, the outer shell 312 of the particulate solids separation section 310 can define an upper segment 376, a middle segment 374, and a lower segment 372 of the particulate solids separation section 310. Generally, the upper segment 376 can have a substantially constant cross-sectional area, such that the cross-sectional area does not vary by more than 20% in the upper segment 376. In one or more embodiments, the cross-sectional area of ​​the upper segment 376 can be at least three times the maximum cross-sectional area of ​​the riser 330. For example, the cross-sectional area of ​​the upper segment 376 can be at least three times, at least four times, at least five times, at least six times, at least seven times, at least eight times, at least nine times, at least ten times, at least twelve times, at least fifteen times, or even at least twenty times, such as between three and forty times, the maximum cross-sectional area of ​​the riser 330. In further embodiments, the maximum cross-sectional area of ​​the upper segment 376 can be between five and forty times the maximum cross-sectional area of ​​the riser 330. For example, the maximum cross-sectional area of ​​the upper segment 376 may be 5 to 40 times, 10 to 40 times, 15 to 40 times, 20 to 40 times, 25 to 40 times, 30 to 40 times, 35 to 40 times, 5 to 35 times, 5 to 30 times, 5 to 25 times, 5 to 20 times, 5 to 15 times, or even 5 to 10 times the maximum cross-sectional area of ​​the riser 330.

[0051] Additionally, in one or more embodiments, the lower segment 372 of the particulate solids separation section 310 may have a substantially constant cross-sectional area such that the cross-sectional area does not vary by more than 20% across the lower segment 372. The cross-sectional area of ​​the lower segment 372 may be greater than the maximum cross-sectional area of ​​the riser 330 and less than the maximum cross-sectional area of ​​the upper segment 376. The middle segment 374 may be shaped as a frustum such that the cross-sectional area of ​​the middle segment 374 is not constant, but rather the cross-sectional area of ​​the middle segment 374 transitions from the cross-sectional area of ​​the upper segment 376 to the cross-sectional area of ​​the lower segment 372 throughout the middle segment 374.

[0052] 3 , the particulate solids separation section 310 can include a central vertical axis 399. The central vertical axis can extend through the top of the particulate solids separation section 310 and through the bottom of the particulate solids separation section 310 such that the central vertical axis 399 passes through the top segment 376, the middle segment 374, and the bottom segment 372 of the particulate solids separation section 310. In one or more embodiments, the top segment 376, the middle segment 374, and the bottom segment 372 of the particulate solids separation section 310 can be disposed about the central vertical axis 399. For example, in an embodiment in which the top segment 376 and the bottom segment 372 are substantially cylindrical, the central vertical axis 399 can pass through a midpoint of a diameter of the top segment 376 and a midpoint of a diameter of the bottom segment 372.

[0053] 1 and 3, the inner riser segment 334 of the riser 330 can extend through a riser port 318 of the particulate solids separation section 310. The riser port 318 may be any opening in the outer shell 312 of the particulate solids separation section 310 where at least the inner riser segment 334 of the riser 330 protrudes into the interior region 314 of the particulate solids separation section 310. In one or more embodiments, the riser port 318 is not located on a central vertical axis 399 of the particulate solids separation section 310. In such embodiments, the riser port 318 may be located on a sidewall of the outer shell 312 such that the riser port 318 is not located on the central vertical axis 399 and the riser 330 is not oriented to extend into the particulate solids separation section 310 in a direction substantially parallel to the central vertical axis 399.

[0054] In one or more embodiments, the internal riser segment 334 enters the particulate solids separation section 310 at the middle segment 374 of the particulate solids separation section 310. In such embodiments, the internal riser segment 334 passes at least a portion of the middle segment 374 and passes at least a portion of the upper segment 376. In such embodiments, the internal riser segment 334 does not pass through the lower segment 372 of the particulate solids separation section 310. In further embodiments, the internal riser segment 334 may enter the particulate solids separation section 310 in the upper segment 376, and the internal riser segment 334 may pass at least a portion of the upper segment 376. In such embodiments, the internal riser segment 334 does not pass through the lower segment 372 or the middle segment 374.

[0055] 3 , the inner riser segment 334 can include a vertical portion 396, a non-vertical portion 394, and a non-linear portion 395. As described herein, a "non-linear portion" can refer to a portion or riser segment that includes a curved or mitered joint. The non-linear portion 395 can be located between and connect the vertical portion 396 and the non-vertical portion 394. Additionally, the non-vertical portion 394 of the inner riser segment 334 can be proximate to the riser port 318. In one or more embodiments, the non-vertical portion 394 of the inner riser segment 334 can be adjacent to or directly connected to the riser port 318. Thus, the riser 330 can extend in a non-vertical direction through the riser port 318.

[0056] 2 , the external riser segment 332 may include a vertical portion 391, a non-vertical portion 393, and a non-linear portion 392. The non-linear portion 392 may be located between and connect the vertical portion 391 and the non-vertical portion 393. The non-vertical portion 393 of the external riser segment 332 may be proximate to the riser port 318. In one or more embodiments, the non-vertical portion 393 of the external riser segment 332 may be adjacent to or directly connected to the riser port 318. Additionally, the vertical portion 391 of the external riser segment 332 may be proximate to the particulate solids processing vessel 350. In such embodiments, an expansion joint 382, ​​described in more detail herein, may be disposed between the vertical portion 391 of the external riser segment 332 and the particulate solids processing vessel 350.

[0057] In one or more embodiments, the riser 330 may extend at an angle through the riser port 318, the angle being between 15 and 75 degrees from vertical. For example, the diagonal direction may be 15 to 75 degrees from vertical, 20 to 75 degrees from vertical, 25 to 75 degrees from vertical, 30 to 75 degrees from vertical, 35 to 75 degrees from vertical, 40 to 75 degrees from vertical, 45 to 75 degrees from vertical, 50 to 75 degrees from vertical, 55 to 75 degrees from vertical, 60 to 75 degrees from vertical, 65 to 75 degrees from vertical, 70 to 75 degrees from vertical, 15 to 70 degrees from vertical, 15 to 65 degrees from vertical, 15 to 60 degrees from vertical, 15 to 55 degrees from vertical, 15 to 50 degrees from vertical, 15 to 45 degrees from vertical, 15 to 40 degrees from vertical, 15 to 35 degrees from vertical, 15 to 30 degrees from vertical, 15 to 25 degrees from vertical, 15 to 20 degrees from vertical, or any combination or partial combination of these ranges. In one or more alternative embodiments, the riser 330 may pass through the riser port 318 in a substantially horizontal direction. As described herein, a "substantially horizontal" direction may be within 15 degrees of horizontal, within 10 degrees of horizontal, or even within 5 degrees of horizontal.

[0058] 1 , the outer shell 312 may further house a riser termination 378. The riser termination 378 may be disposed proximate to the inner riser segment 334. In one or more embodiments, the riser termination 378 may be directly connected to the vertical portion 396 of the inner riser segment 334. The gas and particulate solids passing through the riser 330 may be at least partially separated by the riser termination 378. The gas and remaining particulate solids may be transported to a secondary separation device 320 in the particulate solids separation section 310. The secondary separation device 320 may be any mechanical or chemical separation device that may be operable to separate particulate solids from a gas or liquid phase, such as a cyclone or multiple cyclones.

[0059] According to one or more embodiments, the separator 320 may be a cyclonic separation system that may include two or more stages of cyclonic separation. In embodiments where the secondary separator 320 includes two or more cyclonic separators, the first separator into which the flowing stream enters is referred to as the primary cyclonic separator. The flowing effluent from the primary cyclonic separator may enter the secondary cyclonic separator for further separation. Primary cyclonic separators may include, for example, primary cyclones and systems commercially available under the names VSS (commercially available from UOP), LD2 (commercially available from Stone and Webster), and RS2 (commercially available from Stone and Webster). Primary cyclones are also taught, for example, in U.S. Pat. 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 utilizing a primary cyclone as the primary cyclone separator, one or more sets of additional cyclones (e.g., secondary cyclones and / or tertiary cyclones) may be utilized to further separate particulate solids from the product gas. It should be understood that any primary cyclone separator may be used in the embodiments disclosed herein.

[0060] The secondary separation device 320 may deposit the separated particulate solids at the bottom of the upper segment 376, the middle segment 374, or the lower segment 372 of the particulate solids separation section 310. Thus, the particulate solids may flow by gravity from the bottom of the upper segment 376 or the middle segment 374 to the lower segment 372. The separated vapor may be removed from the fluid catalytic reactor system 100 via pipe 129 at the gas outlet port 316 of the particulate solids separation section 310.

[0061] 1 and 3, the lower segment 372 of the particulate solids separation section 310 may include a particulate solids collection area 380 that may allow for accumulation of particulate solids within the particulate solids separation section 310. In one or more embodiments, the particulate solids collection area 380 may include one or more of an oxygen soak zone, an oxygen stripping zone, and a reduction zone.

[0062] As described herein, an "oxygen soak zone" may refer to a portion of the particulate solids collection area 380 where the particulate solids are exposed to a flow of oxygen-containing gas. In one or more embodiments, the particulate solids may flow generally downward and the oxygen-containing gas may flow generally upward. The particulate solids may have an average residence time in the oxygen soak zone of greater than 2 minutes, and preferably have a residence time of 2 to 14 minutes. The particulate solids may become oxygen-containing particulate solids in the oxygen soak zone and therefore may have increased activity for one or more reactions occurring in the reactor section 200, including, but not limited to, dehydrogenation reactions.

[0063] The particulate solids collection area 380 may include an oxygen stripping zone. As described herein, "oxygen stripping zone" refers to a zone in the particulate solids collection area 380 where the particulate solids are stripped of oxygen-containing gas molecules. The oxygen-containing gas molecules may be stripped from the particulate solids by contacting the particulate solids with a gas that does not contain more than 0.5 mole percent oxygen. Generally, the particulate solids move downward and the gas moves upward through the oxygen stripping zone. Thus, excess oxygen-containing gas does not have to be passed into the reactor section 200 with the particulate solids.

[0064] As described herein, a "reduction zone" can refer to a zone where a reducing agent, such as hydrogen or methane, is fed into the catalyst stream fluidized with a non-participant gas, such as nitrogen or water vapor. The reducing agent removes oxygen from the particles, thereby increasing the availability of the particles for reaction.

[0065] 1 and 3, the particulate solids collection area 380 may include a particulate solids outlet port 322. In one or more embodiments, the particulate solids outlet port 322 may be located proximate to or even above the central vertical axis 399. In accordance with one or more embodiments, the bottom of the particulate solids collection area 380 may be curved such that the particulate solids outlet port 322 is located at the lowest portion of the particulate solids collection area 380. The water tower 124 may be connected to the particulate solids separation section 310 at the particulate solids outlet port 322, and the particulate solids may be transferred from the regeneration section 300 to the reactor section 200 via the water tower 124. Thus, the particulate solids may be continuously recirculated through the reactor system 100.

[0066] Without being bound by theory, it is believed that if the riser 330 does not pass through the particulate solids collection area 380 and the particulate solids outlet port 322 is located on the central vertical axis 399, the flow of particulate solids through the particulate solids collection area 380 may be improved as compared to designs in which the riser 330 passes through the particulate solids collection area 380. When the riser 330 does not pass through the particulate solids collection area 380, the particulate solids outlet port 322 may be located on the central vertical axis 399 and the particulate solids may move through the particulate solids collection area 380 in a manner that more closely resembles plug flow. This may result in an increase in the minimum residence time of the particulate solids within the particulate solids collection area 380, which may be beneficial when stripping, oxygen soaking, or other contemplated processes are performed within the particulate solids collection area 380.

[0067] As described herein, portions of a system unit, such as a reactor vessel wall, an isolation section wall, or a riser wall, may comprise a metallic material, such as carbon or stainless steel. Additionally, walls of various system units may have portions that are attached to other portions of the same system unit or to another system unit. At times, points of attachment or connection are referred to herein as "attachment points" and may incorporate any known bonding medium, such as, but not limited to, welding, adhesives, solders, etc. It should be understood that components of a system may be "directly connected" at an attachment point, such as a weld.

[0068] To mitigate damage caused by hot particulate solids and gases, fire-resistant materials can be used as internal linings of various system components. Fire-resistant materials may be included in the riser 330 as well as the particulate solids separation section 310. It should be understood that, although specific fire-resistant material configurations and material embodiments are provided, they should not be considered limiting with respect to the physical structure of the disclosed system. For example, a fire-resistant liner may extend within the riser 330 along the interior surface of the riser 330 and along the interior surfaces of the middle segment 374 and the upper segment 376 of the particulate solids separation section 310. The fire-resistant liner may include a hex mesh or other suitable fire-resistant material.

[0069] The mechanical loads placed on the particulate solids processing vessel 350 from the weight of the particulate solids, thermal stresses from differential growth of various components of the regenerator section 300 and other components may be high, and if expansion joints are not utilized, springs may be utilized to allow movement of the particulate solids processing vessel 350 while controlling the nozzle forces within the limits at the 318 joint. For example, the particulate solids processing vessel 350 may be suspended from springs, or springs may be positioned below the particulate solids processing vessel 350 to support its weight and all or a portion of the expected catalyst weight. For example, FIG. 1 shows spring supports 188 mechanically attached to the regenerator section 300 in the particulate solids processing vessel 350, with the regenerator section 300 suspended from a support structure by the spring supports 188.

[0070] In addition, the particulate solids processing vessel 350 and the riser 330 may undergo thermal expansion. Thus, tension between the particulate solids processing vessel 350 and the outer riser segment 332 may be relieved by suspending or supporting the particulate solids processing vessel 350 from the spring supports 188. When springs are used, typically no expansion joints are used. Referring now to FIG. 2, an expansion joint 382 may be disposed between the particulate solids processing vessel 350 and the outer riser segment 332. As described herein, an "expansion joint" may refer to a bellows made of metal or other suitable material that reduces stress between system components joined by the expansion joint. For example, expansion joints may be used to reduce stress between system components due to thermal expansion and contraction. When expansion joints are used, typically the particulate solids processing vessel 350 is supported via fixed supports (without springs) by either rod hangers or skirts. In one or more embodiments, the expansion joint 382 can be used in combination with spring supports to relieve stresses caused by thermal expansion between the particulate solids processing vessel 350 and the outer riser segment 332 . EXAMPLES

[0071] The following examples illustrate features of the present disclosure, but are not intended to limit the scope of the disclosure. The following examples discuss the performance of a particulate solids collection region according to one or more embodiments disclosed herein.

[0072] The flow of particulate solids through two particulate solids collection areas was modeled. The first particulate solids collection area 410 is shown in FIG. 4 and had an annular shape with a single outlet tower 420 located at the bottom of the particulate solids collection area 410. The outlet tower 420 was not located on the central axis 430 of the first particulate solids collection area 410. The first particulate solids collection area 410 also included several cord beam supports covered with a subway grate 440.

[0073] The second particulate solids collection area 510 is depicted in Figure 5 as having a cylindrical shape and an outlet tower 520 located at the bottom of the particulate solids collection area 510. The outlet tower 520 was located on a central axis 530 of the second particulate solids collection area 510. The second particulate solids collection area 510 also includes several cord beam supports covered with a subway grate 540.

[0074] Computational fluid dynamics (CFD) simulations were performed to model the flow of particulate solids through the first and second particulate solids collection areas. The solids residence time distribution (RTD) in each vessel was thus obtained. For the simulations, the diameter of each of the first and second particulate solids collection areas was set to 46 inches. The superficial gas velocity at the bottom of each vessel was 0.3 ft / sec, and the average particulate solids flux was 3.4 lb / ft 2 - seconds. Additionally, the average turnaround time for particulate solids was 8 minutes.

[0075] CFD simulations for the first particulate solids collection area predicted the minimum residence time of the particulate solids to be about 30 seconds due to shorting of the particulate solids at the outlet tower side of the vessel. The CFD simulations also predicted that about 42% of the particulate solids would have a residence time of less than 4 minutes. CFD simulations for the second particulate solids collection area predicted the minimum residence time of the particulate solids to be greater than 1 minute, with only 30% of the particulate solids having a residence time less than 4 minutes.

[0076] The RTD of the first and second particulate solids collection areas are shown graphically in FIG. 6. The RTD of the first particulate solids collection area is shown by line 610 and the RTD of the second particulate solids collection area is shown by line 620. Additionally, for reference, the RTD for one continuous stirred tank reactor (CSTR) and three CSTRs in series are shown in FIG. 6. The RTD of one CSTR is shown by line 630 and the RTD of three CSTRs in series is shown by line 640. As shown in FIG. 6, the RTD for the first particulate solids collection area is comparable to the RTD for a single CSTR and the RTD for the second particulate solids collection area is comparable to the RTD for three CSTRs in series. The second particulate solids collection area offers an advantage over the first particulate solids collection area because the flow of particulate solids through the second particulate solids collection area is more similar to plug flow. Thus, less particulate solids exit the particulate solids collection area more quickly and less particulate solids are retained in the particulate solids collection area for an extended period of time, resulting in more consistent treatment of the particulate solids in the particulate solids collection area.

[0077] In a first aspect of the disclosure, the particulate solids may be regenerated by a method comprising regenerating the particulate solids in a particulate solids processing vessel. Regenerating the particulate solids may comprise one or more of oxidizing the particulate solids by contact with an oxygen-containing gas, burning coke present on the particulate solids, or burning an auxiliary fuel to heat the particulate solids. The method may further comprise passing the particulate solids through a riser. The riser may extend through a riser port of an outer shell of the particulate solids separation section such that the riser comprises an inner riser segment disposed in an interior region of the particulate solids separation section and an outer riser segment disposed outside the outer shell of the particulate solids separation section. The particulate solids separation section may include at least an outer shell defining an interior region of the particulate solids separation section. The outer shell may comprise a gas outlet port, a riser port, and a particulate solids outlet port. The outer shell may house a gas / solids separator and a particulate solids collection area within the interior region of the particulate solids separation section. The riser port may be positioned on a sidewall of the outer shell such that it is not located on a central vertical axis of the particulate solids separation section. The method may further include separating the particulate solids from the gas in a gas / solids separation device and directing the particulate solids separated from the gas to a particulate solids collection area located proximate to a central vertical axis of the particulate solids separation section.

[0078] A second aspect of the present disclosure may include the first aspect, wherein the particulate solids processing vessel has a maximum cross-sectional area that is at least three times the maximum cross-sectional area of ​​the riser.

[0079] A third aspect of the present disclosure may include any of the first or second aspects, where the riser extends non-vertically through the riser port.

[0080] A fourth aspect of the present disclosure may include any of the first to third aspects, wherein the riser extends diagonally through the riser port, the diagonal direction being between 15 and 75 degrees from vertical.

[0081] A fifth aspect of the present disclosure may include any of the first to fourth aspects, wherein the riser extends through the riser port in a substantially horizontal direction.

[0082] A sixth aspect of the present disclosure may include any of the first to fifth aspects, wherein the internal riser segment comprises a vertical portion, a non-vertical portion proximate the riser port, and a non-linear portion connecting the vertical portion and the non-vertical portion.

[0083] A seventh aspect of the present disclosure may include any of the first to sixth aspects, wherein the outer shell further houses a riser termination device, the riser termination device being disposed proximate to the inner riser segment.

[0084] An eighth aspect of the present disclosure may include any of the first through seventh aspects, wherein the external riser segment comprises a vertical portion proximate the particulate solids processing vessel, a non-vertical portion proximate the riser port, and a non-linear portion connecting the vertical portion and the non-vertical portion.

[0085] A ninth aspect of the present disclosure may include any of the first to eighth aspects, wherein the maximum cross-sectional area of ​​the outer shell is at least three times the maximum cross-sectional area of ​​the riser.

[0086] A tenth aspect of the present disclosure may include any of the first to ninth aspects, wherein the maximum cross-sectional area of ​​the outer shell is 5 to 40 times the maximum cross-sectional area of ​​the riser.

[0087] An eleventh aspect of the present disclosure may include any of the first to tenth aspects, wherein the gas / solid separation device comprises one or more cyclones.

[0088] A twelfth aspect of the present disclosure may include any of the first through eleventh aspects, wherein the riser does not pass through the particulate solids collection region.

[0089] A thirteenth aspect of the present disclosure may include any of the first to twelfth aspects, wherein the particulate solids collection region includes an oxygen soak zone, an oxygen stripper, a reduction zone, or a combination thereof.

[0090] A fourteenth aspect of the present disclosure may include any of the first to thirteenth aspects, wherein the particulate solids processing vessel is supported by a spring support.

[0091] A fifteenth aspect of the present disclosure may include any of the first to fourteenth aspects, wherein the particulate solids outlet port is located on a central vertical axis of the particulate solids separation section.

[0092] The subject matter of the present disclosure has been described in detail with reference to certain embodiments. It should be understood that any detailed description of an element or feature of an embodiment does not necessarily mean that the element or feature is essential to the particular embodiment or any other embodiment. It will be apparent to those skilled in the art that various modifications can be made to the described embodiments without departing from the spirit and scope of the subject matter described in the claims.

[0093] It should be noted that for purposes of describing and defining the present invention, the terms "about" or "approximately" are utilized in this disclosure to express the degree of inherent uncertainty that may result from any quantitative comparison, value, measurement, or other representation. The terms "about" and "approximately" are also utilized in this disclosure to express the degree to which a quantitative representation may vary from the stated basis without resulting in a change in the basic functionality of the subject matter at issue.

[0094] It should be noted that one or more of the claims below utilize the term "herein" as a transitional phrase. It should be noted that for purposes of defining the invention, this term is introduced into the claims as an open-ended transitional phrase used to introduce a recitation of a series of features of a structure, and should be interpreted in a similar manner to the more commonly used open-ended preamble term "comprising."

[0095] It should be understood that when a first component is described as "comprising" a second component, in some embodiments, the first component is contemplated to "consist of" or "consist essentially of" that second component. It should be further understood that when a first component is described as "comprising" a second component, in some embodiments, the first component is contemplated to comprise at least 10%, at least 20%, at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, at least 95%, or even at least 99% of that second component (where % can be weight % or mole %).

[0096] In addition, the term "consisting essentially of" is used in this disclosure to refer to quantitative values ​​that do not materially affect the basic and novel characteristic(s) of the disclosure. For example, a chemical composition that "consists essentially of" a particular chemical component or group of chemical components should be understood to mean that the composition contains at least about 99.5% of that particular chemical component or group of chemical components.

[0097] It should be understood that any two quantitative values ​​assigned to a property can constitute a range for that property, and all combinations of ranges formed from all stated quantitative values ​​for a given property are contemplated in this disclosure. It should be understood that compositional ranges of chemical components in a composition should, in some embodiments, be understood to include mixtures of isomers of that component. In further embodiments, compounds may exist in alternative forms, such as derivatives, salts, hydroxides, and the like.

Claims

1. A method for regenerating particulate solids, wherein the method is The regeneration of the particulate solid in a particulate solid processing container, wherein the regeneration of the particulate solid is The particulate solid is oxidized by contacting it with an oxygen-containing gas. Combusting coke present on the particulate solid, or This includes one or more of the following: burning an auxiliary fuel to heat the particulate solid; The particulate solid is to be passed through a riser, the riser extending through the riser port of the outer shell of the particulate solid separation section such that the riser includes an internal riser segment located in the internal region of the particulate solid separation section and an external riser segment located outside the outer shell of the particulate solid separation section, the particulate solid separation section includes at least the outer shell defining the internal region of the particulate solid separation section, the outer shell includes a gas outlet port, the riser port, and the particulate solid outlet port, the outer shell houses a gas / solid separation device and a particulate solid collection region in the internal region of the particulate solid separation section, and the riser port is located on the side wall of the outer shell such that it is not located on the central vertical axis of the particulate solid separation section. To separate the particulate solid from the gas in the gas / solid separation device, The particulate solid separated from the gas is passed through the particulate solid collection area located near the central vertical axis of the particulate solid separation section. Includes, A method wherein the outer shell further houses a riser termination device, and the riser termination device is positioned in close proximity to the internal riser segment.

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

3. The method according to any one of claims 1 to 2, wherein the riser extends in a non-vertical direction through the riser port.

4. The method according to any one of claims 1 to 3, wherein the riser extends obliquely through the riser port, and the oblique direction is 15 to 75 degrees from the vertical.

5. A method for regenerating particulate solid, wherein the method is The regeneration of the particulate solid in a particulate solid processing container, wherein the regeneration of the particulate solid is The particulate solid is oxidized by contacting it with an oxygen-containing gas. Combusting coke present on the particulate solid, or This includes one or more of the following: burning an auxiliary fuel to heat the particulate solid; The particulate solid is to be passed through a riser, the riser extending through the riser port of the outer shell of the particulate solid separation section such that the riser includes an internal riser segment located in the internal region of the particulate solid separation section and an external riser segment located outside the outer shell of the particulate solid separation section, the particulate solid separation section includes at least the outer shell defining the internal region of the particulate solid separation section, the outer shell includes a gas outlet port, the riser port, and the particulate solid outlet port, the outer shell houses a gas / solid separation device and a particulate solid collection region in the internal region of the particulate solid separation section, and the riser port is located on the side wall of the outer shell such that it is not located on the central vertical axis of the particulate solid separation section. To separate the particulate solid from the gas in the gas / solid separation device, The particulate solid separated from the gas is passed through the particulate solid collection area located near the central vertical axis of the particulate solid separation section. Includes, A method wherein the riser extends substantially horizontally through the riser port.

6. The method according to any one of claims 1 to 5, wherein the internal riser segment comprises a vertical portion, a non-vertical portion adjacent to the riser port, and a non-linear portion connecting the vertical portion and the non-vertical portion.

7. A method for regenerating particulate solid, wherein the method is The regeneration of the particulate solid in a particulate solid processing container, wherein the regeneration of the particulate solid is The particulate solid is oxidized by contacting it with an oxygen-containing gas. Combusting coke present on the particulate solid, or This includes one or more of the following: burning an auxiliary fuel to heat the particulate solid; The particulate solid is to be passed through a riser, the riser extending through the riser port of the outer shell of the particulate solid separation section such that the riser includes an internal riser segment located in the internal region of the particulate solid separation section and an external riser segment located outside the outer shell of the particulate solid separation section, the particulate solid separation section includes at least the outer shell defining the internal region of the particulate solid separation section, the outer shell includes a gas outlet port, the riser port, and the particulate solid outlet port, the outer shell houses a gas / solid separation device and a particulate solid collection region in the internal region of the particulate solid separation section, and the riser port is located on the side wall of the outer shell such that it is not located on the central vertical axis of the particulate solid separation section. To separate the particulate solid from the gas in the gas / solid separation device, The particulate solid separated from the gas is passed through the particulate solid collection area located near the central vertical axis of the particulate solid separation section. Includes, A method wherein the external riser segment includes a vertical portion adjacent to the particulate solid processing container, a non-vertical portion adjacent to the riser port, and a non-linear portion connecting the vertical portion and the non-vertical portion.

8. The method according to any one of claims 1 to 7, wherein the maximum cross-sectional area of ​​the outer shell is at least three times the maximum cross-sectional area of ​​the riser.

9. The method according to any one of claims 1 to 8, wherein the maximum cross-sectional area of ​​the outer shell is 5 to 40 times the maximum cross-sectional area of ​​the riser.

10. The method according to any one of claims 1 to 9, wherein the gas / solid separation device includes one or more cyclones.

11. A method for regenerating particulate solid, wherein the method is The regeneration of the particulate solid in a particulate solid processing container, wherein the regeneration of the particulate solid is The particulate solid is oxidized by contacting it with an oxygen-containing gas. Combusting coke present on the particulate solid, or This includes one or more of the following: burning an auxiliary fuel to heat the particulate solid; The particulate solid is to be passed through a riser, the riser extending through the riser port of the outer shell of the particulate solid separation section such that the riser includes an internal riser segment located in the internal region of the particulate solid separation section and an external riser segment located outside the outer shell of the particulate solid separation section, the particulate solid separation section includes at least the outer shell defining the internal region of the particulate solid separation section, the outer shell includes a gas outlet port, the riser port, and the particulate solid outlet port, the outer shell houses a gas / solid separation device and a particulate solid collection region in the internal region of the particulate solid separation section, and the riser port is located on the side wall of the outer shell such that it is not located on the central vertical axis of the particulate solid separation section. To separate the particulate solid from the gas in the gas / solid separation device, The particulate solid separated from the gas is passed through the particulate solid collection area located near the central vertical axis of the particulate solid separation section. Includes, A method wherein the riser does not pass through the particulate solid collection area.

12. A method for regenerating particulate solid, wherein the method is The regeneration of the particulate solid in a particulate solid processing container, wherein the regeneration of the particulate solid is The particulate solid is oxidized by contacting it with an oxygen-containing gas. Combusting coke present on the particulate solid, or This includes one or more of the following: burning an auxiliary fuel to heat the particulate solid; The particulate solid is to be passed through a riser, the riser extending through the riser port of the outer shell of the particulate solid separation section such that the riser includes an internal riser segment located in the internal region of the particulate solid separation section and an external riser segment located outside the outer shell of the particulate solid separation section, the particulate solid separation section includes at least the outer shell defining the internal region of the particulate solid separation section, the outer shell includes a gas outlet port, the riser port, and the particulate solid outlet port, the outer shell houses a gas / solid separation device and a particulate solid collection region in the internal region of the particulate solid separation section, and the riser port is located on the side wall of the outer shell such that it is not located on the central vertical axis of the particulate solid separation section. To separate the particulate solid from the gas in the gas / solid separation device, The particulate solid separated from the gas is passed through the particulate solid collection area located near the central vertical axis of the particulate solid separation section. Includes, A method wherein the particulate solid collection area includes an oxygen immersion zone, an oxygen stripper, a reduction zone, or a combination thereof.

13. A method for regenerating particulate solid, wherein the method is The regeneration of the particulate solid in a particulate solid processing container, wherein the regeneration of the particulate solid is The particulate solid is oxidized by contacting it with an oxygen-containing gas. Combusting coke present on the particulate solid, or This includes one or more of the following: burning an auxiliary fuel to heat the particulate solid; The particulate solid is to be passed through a riser, the riser extending through the riser port of the outer shell of the particulate solid separation section such that the riser includes an internal riser segment located in the internal region of the particulate solid separation section and an external riser segment located outside the outer shell of the particulate solid separation section, the particulate solid separation section includes at least the outer shell defining the internal region of the particulate solid separation section, the outer shell includes a gas outlet port, the riser port, and the particulate solid outlet port, the outer shell houses a gas / solid separation device and a particulate solid collection region in the internal region of the particulate solid separation section, and the riser port is located on the side wall of the outer shell such that it is not located on the central vertical axis of the particulate solid separation section. To separate the particulate solid from the gas in the gas / solid separation device, The particulate solid separated from the gas is passed through the particulate solid collection area located near the central vertical axis of the particulate solid separation section. Includes, A method wherein the particulate solid processing container is supported by a spring support.

14. The method according to any one of claims 1 to 13, wherein the particulate solid outlet port is located on the central vertical axis of the particulate solid separation section.

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