System and method for regenerating particulate solids

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 and priority of U.S. Patent Application No. 63 / 126,089, filed on December 16, 2020, entitled "Systems and Methods for Regenerating Particulate Solids", the entire content of which is incorporated herein by reference.

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

Background Art

[0003] Many chemical substances can be produced by processes that use particulate solids such as solid - particle catalysts. During these processes, the particulate solids can become "spent" and their activity may decrease in subsequent reactions. Further, endothermic processes require heat, and "spent" catalysts must be reheated. Therefore, spent particulate solids can be transferred to a regeneration unit for reheating and regeneration to increase the activity of the particulate solids for use in subsequent reactions. Following regeneration in the regeneration unit, the regenerated particulate solids can be returned to a reactor for use in subsequent reactions.

Summary of the Invention

[0004] Improved methods are needed to regenerate, reactivate, or increase the activity of particulate solids for use in the manufacture of various chemicals (e.g., light olefins). Many regenerator systems for regenerating particulate solids include a particulate solid processing vessel positioned directly beneath a particulate solid separation section, such that a riser extends from the particulate solid processing vessel through the bottom of the particulate solid separation section. Such a design can adversely affect the flow of particulate solids through the particulate solid separation section by forming an annular space at the bottom of the particulate solid separation section, in which case the outlet cannot be located at the center of the bottom of the particulate solid separation section.

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

[0006] According to one or more embodiments disclosed herein, particulate solids can be regenerated by a method that includes regenerating the particulate solids in a particulate solids processing vessel. Regeneration of particulate solids may include one or more of the following: 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 include passing the particulate solids through a riser. The riser may extend through a riser port in the outer shell of the particulate solids separation section, such that the riser comprises an internal riser segment located in the internal region of the particulate solids separation section and an external riser segment located outside the outer shell of the particulate solids separation section. The particulate solids separation section may include at least an outer shell that defines the internal region of the particulate solids separation section. The outer shell may include a gas outlet port, a riser port, and a particulate solids outlet port. The outer shell can house a gas / solids separation device and a particulate solids collection area within the internal region of the particulate solids separation section. The riser port may be positioned on the side wall of the outer shell so as not to be located on the central vertical axis of the particulate solid separation section. The method may further include separating particulate solid from a gas in a gas / solid separation apparatus and sending the particulate solid separated from the gas to a particulate solid collection area located close to the central vertical axis of the particulate solid separation section.

[0007] It should be understood that both the above summary and the following detailed description present embodiments of the present technology and are intended to provide an overview or framework for understanding the claimed nature and features of the present technology. The accompanying drawings are included to provide a further understanding of the technology and are incorporated into and form part of this specification. The drawings illustrate various embodiments and, together with the description, help to illustrate 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.

[0008] Additional features and advantages of the technology disclosed herein will be described in the subsequent detailed description and will be readily apparent to those skilled in the art from that description, or will be recognized by practicing the technology as described herein, including the subsequent detailed description, the claims, and the accompanying drawings. [Brief explanation of the drawing]

[0009] The following “Modes for Carrying Out the Invention” of specific embodiments of this disclosure will be best understood in conjunction with the following drawings, in which similar structures are shown with similar reference numerals. [Figure 1] A schematic diagram of a reactor system including a reactor section and a regenerator section according to one or more embodiments disclosed herein is shown. [Figure 2] A schematic diagram of a particulate solid processing container and an external riser segment according to one or more embodiments disclosed herein is shown. [Figure 3] A schematic diagram of a particulate solid separation section according to one or more embodiments disclosed herein is shown. [Figure 4] This represents a particulate solid collection area according to one or more embodiments disclosed herein. [Figure 5] This represents a particulate solid collection area according to one or more embodiments disclosed herein. [Figure 6] The residence time distribution of the particulate solid collection area according to one or more embodiments disclosed herein is shown graphically.

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

[0011] Herein, various embodiments are referred to in more detail, 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. [Modes for carrying out the invention]

[0012] As described herein, the methods for regenerating particulate solids disclosed herein may be used to regenerate particulate solids from reactor systems for processing chemical flows. Such methods utilize systems having specific features, such as specific orientations of system components. For example, in one or more embodiments described herein, the particulate solid processing vessel is not directly below the particulate solid separation section. One particular embodiment disclosed in detail herein is shown in Figure 1. However, it should be understood that the principles disclosed and taught herein may be applicable to other systems utilizing different reaction schemes that utilize different system components oriented in different ways or various catalyst compositions.

[0013] Referring here to Figure 1, as can be understood by referring to the figures and descriptions above, the supply chemical can be reacted in reactor section 200 by contact with particulate solids such as catalysts. The particulate solids may be separated from the reaction products in reactor section 200 and sent to regeneration section 300. In regeneration section 300, the particulate solids can be regenerated. Such regenerated particulate solids may be returned to reactor section 200 for subsequent reaction cycles.

[0014] While several embodiments are described herein in relation to 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 stream. Therefore, reactor section 200 should not be construed as necessary or essential in all embodiments of the methods and systems of this disclosure.

[0015] In non-limiting examples, the reactor system 100 described herein may be used to produce light olefins from a hydrocarbon feedstream. Light olefins can be produced from various hydrocarbon feedstreams by utilizing various reaction mechanisms. For example, light olefins can be produced by at least dehydrogenation, decomposition, dehydration, and methanol-to-olefin reactions. These reaction types may utilize different feedstreams and different particulate solids to produce light olefins. Where “catalyst” is referred to herein, it should be understood that they may be equivalent to the particulate solids referred to in relation to the system in Figure 1.

[0016] According to one or more embodiments, the reaction may be a dehydrogenation reaction. According to such embodiments, the hydrocarbon feed stream may include one or more of ethylbenzene, ethane, propane, n-butane, and i-butane. In one or more embodiments, the hydrocarbon feed stream may include 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 at least 99% by weight of ethane. In additional embodiments, the hydrocarbon feed stream may include 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 at least 99% by weight of propane. In additional embodiments, the hydrocarbon feed stream may include 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 at least 99% by weight of n-butane. In additional embodiments, the hydrocarbon feed stream may contain 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 further at least 99% by weight of i-butane. In additional embodiments, the hydrocarbon feed stream may contain 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 further at least 99% by weight of ethane, propane, n-butane, and i-butane in total.

[0017] In one or more embodiments, the dehydrogenation reaction can utilize gallium and / or platinum particulate solid as a catalyst. In such embodiments, the particulate solid may include a gallium and / or platinum catalyst. As described herein, the gallium and / or platinum catalyst comprises gallium, platinum, or both. The gallium and / or platinum catalyst may be supported by alumina or alumina-silica holder and may optionally contain potassium. Such a gallium and / or platinum catalyst is 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 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 byproduct, and the oxygen carrier material may come into contact with the hydrogen to facilitate the combustion of the hydrogen and form water. Examples of such reaction mechanisms, intended as possible reaction mechanisms for the systems and methods described herein, are disclosed in International Publication No. 2020 / 046978, the teachings thereof incorporated herein in their entirety by reference.

[0019] According to one or more embodiments, the reaction may be a decomposition reaction. According to such embodiments, the hydrocarbon feed stream may include one or more of naphtha, n-butane, or i-butane. According to one or more embodiments, the hydrocarbon feed stream may include 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 at least 99% by weight of naphtha. In additional embodiments, the hydrocarbon feed stream may include 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 at least 99% by weight of n-butane. In additional embodiments, the hydrocarbon feed stream may include 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 at least 99% by weight of i-butane. In additional embodiments, the hydrocarbon feed stream may include a total of 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 more than 99% by weight of naphtha, n-butane, and i-butane.

[0020] In one or more embodiments, the decomposition reaction can utilize one or more zeolites as catalysts. In such embodiments, the particulate solid may include one or more zeolites. In some embodiments, the one or more zeolites used in the decomposition reaction may include ZSM-5 zeolite. However, it should be understood that other suitable catalysts can be used to carry out the decomposition reaction. For example, suitable commercially available catalysts include Intercat Super Z Excel or Intercat Super Z Exceed. In further embodiments, the decomposition catalyst may include platinum in addition to the catalytically active material. For example, the decomposition catalyst may contain 0.001% to 0.05% by weight of platinum. The platinum may be sprayed as platinum nitrate and calcined at a high temperature such as about 700°C. Although not bound by theory, it is thought that the addition of platinum to the catalyst may enable easier combustion of auxiliary fuels such as methane.

[0021] According to one or more embodiments, the reaction can be a dehydration reaction. According to such embodiments, the hydrocarbon feed stream may include one or more of ethanol, propanol, or butanol. 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% ethanol. In additional 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% propanol. In additional 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% butanol. In additional 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% 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 used in the dehydration reaction may include zeolites (such as ZSM-5 zeolite), alumina, amorphous aluminosilicates, acid clay, or combinations thereof. For example, suitable commercially available alumina catalysts may include, according to one or more embodiments, SynDol (available from Scientific Design Company), V200 (available from UOP), or P200 (available from Sasol). Suitable commercially available zeolite catalysts may include CBV 8014 and CBV 28014 (both available from Zeolyst). Suitable commercially available amorphous aluminosilicate catalysts may include silica-alumina catalyst support, grade 135 (available from Sigma Aldrich). However, it should be understood that other suitable catalysts may be used to carry out the dehydration reaction.

[0023] According to one or more embodiments, the reaction may be a reaction from methanol to an olefin. According to such embodiments, the hydrocarbon feed stream may contain methanol. According to one or more embodiments, the hydrocarbon feed stream may contain 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 more than 99% by weight of methanol.

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

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

[0026] Referring further to Figure 1, the reactor system 100 generally includes several system components, such as a reactor section 200 and a regeneration section 300. As used herein in the context of Figure 1, the reactor section 200 generally refers to the portion of the reactor system 100 where the main process reaction takes place and 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 particulate solids are regenerated, such as by combustion, and the regenerated particulate solids are separated from materials previously burned on the spent particulate solids or from other process materials, such as gases generated from auxiliary fuels. The reactor section 200 generally includes a reaction vessel 250, a riser 230 including an external riser segment 232 and an internal riser segment 234, and a particulate solids separation section 210. The regeneration section 300 generally includes a particulate solid processing container 350, a riser 330 including an external riser segment 332 and an internal riser segment 334, and a particulate solid separation section 310. Generally, the particulate solid separation section 210 is, for example, Piping 126 may also be in fluid communication with the particulate solid processing container 350, and the particulate solid separation section 310 may be, for example Piping (standpipe) The reaction vessel 250 may be in fluid communication with the transport riser 130.

[0027] Generally, the reactor system 100 can be operated by supplying a hydrocarbon feed and a fluidized particulate solid to a reaction vessel 250, and reacting the hydrocarbon feed with the fluidized particulate solid to produce an olefin-containing product within the reaction vessel 250 of the reactor section 200. The olefin-containing product and particulate solid may exit the reaction vessel 250 and be sent through a riser 230 to a gas / solid separator 220 in the particulate solid separation section 210, where the particulate solid is separated from the olefin-containing product. The particulate solid can be transported from the particulate solid separation section 210 to a particulate solid processing vessel 350. In the particulate solid processing vessel 350, the particulate solid can be regenerated by various processes. For example, spent particulate solid can be regenerated by one or more of the following: oxidation of the particulate solid by contact with an oxygen-containing gas, combustion of coke present on the particulate solid, and combustion of auxiliary fuel to heat the particulate solid. Next, the particulate solid exits the particulate solid processing vessel 350 and passes through the riser 330 to the riser termination unit 378, where the gas and particulate solid are at least partially separated from the riser 330. The gas and remaining particulate solid from the riser 330 are transported to the secondary separation unit 320 in the particulate solid separation section 310, where the remaining particulate solid is separated from the gas from the regeneration reaction. The particulate solid separated from the gas may be sent to the particulate solid collection area 380. The separated particulate solid is then sent from the particulate solid collection area 380 to the reaction vessel 250, where it is further utilized. Thus, the particulate solid can circulate between the reactor section 200 and the regeneration section 300.

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

[0029] Furthermore, as described herein, the structural features of the reactor section 200 and the regeneration section 300 may be similar or identical in some respects. For example, each of the reaction section 200 and the regeneration section 300 includes a reaction vessel (i.e., the reaction vessel 250 of the reactor section 200 and the particulate solid processing vessel 350 of the regeneration section 300), a riser (i.e., the riser 230 of the reactor section 200 and the riser 330 of the regeneration section 300), and a particulate solid separation section (i.e., the particulate solid separation section 210 of the reactor section 200 and the particulate solid separation section 310 of the regeneration section 300). Since many of the structural features of reactor section 200 and regeneration section 300 may be similar or identical in some respects, similar or identical parts of reactor section 200 and regeneration section 300 are provided with the same last two digits reference number throughout this disclosure, and it should be understood that the disclosure relating to one part of reactor section 200 may be applicable to a similar or identical part of regeneration section 300, and vice versa.

[0030] As shown in Figure 1, the reaction vessel 250 may include a reaction vessel particulate solid inlet port 252 that defines the connection of the transport riser 130 to the reaction vessel 250. The reaction vessel 250 may 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 is generally cylindrical (i.e., having a substantially circular diameter) or non-cylindrical, such as a prismatic shape having a cross-sectional shape of a triangle, square, pentagon, hexagon, octagon, ellipse, or other polygon, or a closed curve, or a combination thereof. When used throughout this disclosure, the reaction vessel may generally include a metal frame and further include a refractory lining or other material used to protect the metal frame and / or control process conditions.

[0031] In general, 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 material to flow into a particular system unit, and an outlet port allows material to flow out of a particular system unit. Generally, an outlet port or inlet port defines an area of ​​the 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 part of the system unit to which another system unit is directly attached. Although inlet and outlet ports may be functionally described herein during operation, they may have similar or identical physical features, and their respective functions in the operating system should not be interpreted as limiting their physical structure. Other ports, such as the riser port 218, may include openings in a given system unit to which other system units are directly attached, such as when the riser 230 extends into the particulate solid separation section 210 at the riser port 218.

[0032] The reaction vessel 250 may be connected to a transport riser 130, which can supply the regenerated particulate solids and chemical feed to the reactor section 200 during operation. The particulate solids entering the reaction vessel 250 via the transport riser 130 are Piping It can pass through 124 and then through the transfer riser 130, and thus arrive from the regeneration section 300. In some embodiments, particulate solids are separated from the particulate solid separation section 210. Piping The material can enter the transfer riser 130 directly via 122, and there it enters the reaction vessel 250. These particulate solids may be slightly inactivated, but in some embodiments they may still be suitable for use in the reaction vessel 250.

[0033] As shown in Figure 1, the reaction vessel 250 can be directly connected to the external riser segment 232. In one embodiment, the reaction vessel 250 may include a reaction vessel body section 256 and a reaction vessel transition section 258 positioned between the reaction vessel body section 256 and the external riser segment 232. The reaction vessel body section 256 may generally have a larger diameter than the reaction vessel transition section 258, and the reaction vessel transition section 258 may taper from the diameter of the reaction vessel body section 256 to the diameter of the riser 230 so that the reaction vessel transition section 258 protrudes inward from the reaction vessel body section 256 to the outer riser segment 232. When used herein, the diameter of a part of a system unit should be understood to refer to its general width, as shown horizontally in Figure 1.

[0034] In one or more embodiments, the reaction vessel 250 may have a maximum cross-sectional area that is at least three times the maximum cross-sectional area of ​​the riser 230. For example, the reaction vessel 250 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, or even at least ten times the maximum cross-sectional area of ​​the riser 230. As described herein, unless otherwise specified, “cross-sectional area” refers to the area of ​​the cross-section of a portion of the system components in a plane substantially perpendicular to the general flow direction of the reactants and / or products.

[0035] Referring further to Figure 1, the reactor section 200 may 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 may generally be cylindrical (i.e., having a substantially circular cross-sectional shape) or non-cylindrical, such as a prismatic shape having a triangular, quadrilateral, pentagonal, hexagonal, octagonal, elliptical, or other polygonal, closed curve, or combination thereof cross-sectional shape. When used throughout this disclosure, the riser 230 may generally include a metal frame and may further include a refractory lining or other material used to protect the metal frame and / or control process conditions.

[0036] According to some embodiments, the riser 230 may include an external riser segment 232 and an internal riser segment 234. As used herein, “external riser section” refers to a portion of the riser located outside the particulate solid separation section, and “internal riser section” refers to a portion of the riser located inside the particulate solid separation section. For example, in the embodiment shown in Figure 1, the internal riser section 234 of the reactor section 200 may be located within the particulate solid separation section 210, while the external riser section 232 may be located outside the particulate solid separation section 210.

[0037] In one or more embodiments, the particulate solid separation section 210 may include an outer shell 212 that can define an internal region 214 of the particulate solid separation section 210. The outer shell 212 may include a gas outlet port 216, a riser port 218, and a particulate solid outlet port 222. Furthermore, the outer shell 212 can house a gas / solid separation device 220 and a particulate solid collection region 280 within the internal region 214 of the particulate solid separation section 210.

[0038] In one or more embodiments, the outer shell 212 of the particulate solid separation section 210 can define an upper segment 276, an intermediate segment 274, and a lower segment 272 of the particulate solid separation section 210. Generally, the upper segment 276 may have a substantially constant cross-sectional area, and as a result, the cross-sectional area does not vary by more than 20% in the upper segment 276. In addition, in one or more embodiments, the lower segment 272 of the particulate solid separation section 210 may have a substantially constant cross-sectional area such that the cross-sectional area does not vary by more than 20% in 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 intermediate segment 274 may have an inconsistent cross-sectional area and may be shaped as a frustum where the cross-sectional area of ​​the intermediate segment 274 transitions from the cross-sectional area of ​​the upper segment 276 to the cross-sectional area of ​​the lower segment 272 across the entire intermediate segment 274.

[0039] As shown in Figure 1, the internal riser segment 234 of the riser 230 may extend through the riser port 218 of the particulate solid separation section 210. The riser port 218 may be any opening in the particulate solid separation section 210 through which at least the internal riser segment 234 of the riser 230 protrudes into the internal region 214 of the particulate solid separation section 210. In one or more embodiments, the internal riser segment 234 enters the particulate solid separation section 210 at the intermediate segment 274 or the upper segment 276 and does not pass through the lower segment 272.

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

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

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

[0043] The particulate solid collection area 280 within the lower segment 272 can include a particulate solid outlet port 222. Piping 126 may be connected to the particulate solid separation section 210 at the particulate solid outlet port 222, and the particulate solid is Piping It may exit the reactor section 200 via 126 and be transferred to the regeneration section 300. Optionally, particulate solids may also be Piping It can also be directly transferred back to the reaction vessel section 250 via 122. Alternatively, the particulate solid may be pre-mixed with the regenerated particulate solid in the transport riser 130.

[0044] After separation in the particulate solid separation section 210, the spent particulate solid is transferred to the regeneration section 300. The regeneration section 300 can share many structural similarities with the reactor section 200, as described herein. Therefore, if the reference numbers assigned to parts of the regeneration section 300 are similar to those used for the reactor section 200, and the last two digits of the reference numbers are the same, then given parts of the reactor section 200 and the regeneration section 300 can perform similar functions and have similar physical structures. Thus, much of this disclosure relating to the regeneration section 300 can be equally applied to the reactor section 200.

[0045] Referring here to the regeneration section 300, as shown in Figures 1 and 2, the particulate solid processing vessel 350 of the regeneration section 300 may include one or more reactor vessel inlet ports 352 and reactor vessel outlet ports 354 that are in fluid communication with, or further directly connected to, the external riser segment 332 of the riser 330. The particulate solid processing vessel 350 is Piping The particulate solid separation section 210 may be in fluid communication with the particulate solid separation section 210 via 126. Piping126 may supply spent particulate solid from reactor section 200 to regeneration section 300 for regeneration. The particulate solid processing vessel 350 may include an additional reactor vessel inlet port 352, the inlet 128 of which is connected to the particulate solid processing vessel 350. The inlet 128 can supply reactive fluids, such as auxiliary fuels in liquid or gaseous form, and oxygen-containing gases (including air, enriched air, and even pure oxygen), which can be used to regenerate the particulate solid at least partially. In one or more embodiments, the particulate solid processing vessel 350 may have a plurality of additional reactor vessel inlet ports, each of which may supply a different reactive fluid to the particulate solid processing vessel 350. For example, the particulate solid may be coked following the reaction in the reaction vessel 250, and the coke may be removed from the particulate solid by a combustion reaction. Alternatively, an oxygen-containing gas such as air may be supplied to the particulate solid processing container 350 via the inlet 128 to oxidize the particulate solid, or an auxiliary fuel may be supplied to the particulate solid processing container 350 and burned to heat the particulate solid.

[0046] As shown in Figures 1 and 2, the particulate solid processing container 350 may be directly connected to the external riser segment 332 of the riser 330. In one embodiment, the particulate solid processing container 350 may include a particulate solid processing container body section 356 and a particulate solid processing container transition section 358. The particulate solid processing container body section 356 may generally have a larger diameter than the particulate solid processing container transition section 358, and the particulate solid processing container transition section 358 may taper from the diameter of the particulate solid processing container body section 356 to the diameter of the external riser segment 332, such that the particulate solid processing container transition section 358 protrudes inward from the particulate solid processing container body section 356 to the external riser segment 332.

[0047] In one or more embodiments, the particulate solid processing container 350 may have a maximum cross-sectional area that is at least three times the maximum cross-sectional area of ​​the riser 330. For example, the particulate solid processing container 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 the maximum cross-sectional area of ​​the riser 330.

[0048] In addition, the particulate solid processing vessel body section 356 may generally have height, which is measured from the reactor vessel inlet port 352 to the particulate solid processing vessel transition section 358. In one or more embodiments, the diameter of the particulate solid processing vessel body section 356 may be greater than the height of the particulate solid processing vessel body section 356. In one or more embodiments, the diameter-to-height ratio of the particulate solid processing vessel body section 356 may be 5:1 to 1:5. For example, the diameter-to-height ratio of the particulate solid processing container body section 356 may be 5:1-1:5, 4:1-1:5, 3:1-1:5, 2:1-1:5, 1:1-1:5, 1:2-1:5, 1:3-1:5, 5:1-1:4, 5:1-1:3, 5:1-1:2, 5:1-1:1, 5:1-2:1, 5:1-3:1, 5:1-4:1, or any combination or partial combination within these ranges.

[0049] Referring to Figures 1 and 3, the particulate solid separation section 310 includes an outer shell 312 that defines the internal region 314 of the particulate solid separation section 310. The outer shell 312 may include a gas outlet port 316, a riser port 318, and a particulate solid outlet port 322. Furthermore, the outer shell 312 can accommodate a secondary separation device 320 and a particulate solid collection area 380 within the internal region 314 of the particulate solid separation section 310.

[0050] In one or more embodiments, the outer shell 312 of the particulate solid separation section 310 can define the upper segment 376, the middle segment 374, and the lower segment 372 of the particulate solid separation section 310. Generally, the upper segment 376 may have a substantially constant cross-sectional area, and as a result, 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 may 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 may 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 more than 20 times, for example, three to forty times, the maximum cross-sectional area of ​​the riser 230. In further embodiments, the maximum cross-sectional area of ​​the upper segment 376 may be five to 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] In addition, in one or more embodiments, the lower segment 372 of the particulate solid separation section 310 may have a substantially constant cross-sectional area such that the cross-sectional area does not change by more than 20% in 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 intermediate segment 374 may not have a constant cross-sectional area, and may be shaped as a frustum where the cross-sectional area of ​​the intermediate segment 374 transitions from the cross-sectional area of ​​the upper segment 376 to the cross-sectional area of ​​the lower segment 372 over the entire intermediate segment 374.

[0052] Referring again to Figure 3, the particulate solid separation section 310 may include a central vertical axis 399. The central vertical axis may extend through the top and bottom of the particulate solid separation section 310, such that the central vertical axis 399 passes through the upper segment 376, the middle segment 374, and the lower segment 372 of the particulate solid separation section 310. In one or more embodiments, the upper segment 376, the middle segment 374, and the lower segment 372 of the particulate solid separation section 310 may be positioned around the central vertical axis 399. For example, in embodiments where the upper segment 376 and the lower segment 372 are substantially cylindrical, the central vertical axis 399 may pass through the midpoint of the diameter of the upper segment 376 and the midpoint of the diameter of the lower segment 372.

[0053] As shown in Figures 1 and 3, the internal riser segment 334 of the riser 330 may extend through the riser port 318 of the particulate solid separation section 310. The riser port 318 may be any opening in the outer shell 312 of the particulate solid separation section 310, through which at least the internal riser segment 334 of the riser 330 protrudes into the internal region 314 of the particulate solid separation section 310. In one or more embodiments, the riser port 318 is not located on the central vertical axis 399 of the particulate solid separation section 310. In such embodiments, the riser port 318 may be located on the side wall 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 solid 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 solid separation section 310 in the intermediate segment 374 of the particulate solid separation section 310. In such embodiments, the internal riser segment 334 passes through at least a portion of the intermediate segment 374 and 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 solid separation section 310. In further embodiments, the internal riser segment 334 may enter the particulate solid separation section 310 in the upper segment 376, and the internal riser segment 334 may pass through 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 intermediate segment 374.

[0055] Referring here to Figure 3, the internal riser segment 334 may comprise a vertical portion 396, a non-vertical portion 394, and a non-linear portion 395. As described herein, “non-linear portion” may refer to a portion or riser segment that includes a curve or miter joint. The non-linear portion 395 is located between the vertical portion 396 and the non-vertical portion 394 and may connect the vertical portion 396 and the non-vertical portion 394. In addition, the non-vertical portion 394 of the internal riser segment 334 may be adjacent to the riser port 318. In one or more embodiments, the non-vertical portion 394 of the internal riser segment 334 may be adjacent to or directly connected to the riser port 318. Thus, the riser 330 may extend non-vertically through the riser port 318.

[0056] Referring again to Figure 2, the external riser segment 332 may comprise a vertical section 391, a non-vertical section 393, and a nonlinear section 392. The non-linear section 392 is located between the vertical section 391 and the non-vertical section 393 and can connect the vertical section 391 and the non-vertical section 393. The non-vertical section 393 of the external riser segment 332 may be close to the riser port 318. In one or more embodiments, the non-vertical section 393 of the external riser segment 332 may be adjacent to or directly connected to the riser port 318. Furthermore, the vertical section 391 of the external riser segment 332 may be close to the particulate solid processing container 350. In such embodiments, an expansion joint 382, ​​which is described in more detail herein, may be positioned between the vertical section 391 of the external riser segment 332 and the particulate solid processing container 350.

[0057] In one or more embodiments, the riser 330 may extend obliquely through the riser port 318, where the oblique direction is 15 to 75 degrees from the vertical. For example, the diagonal directions may be 15-75 degrees from the vertical, 20-75 degrees from the vertical, 25-75 degrees from the vertical, 30-75 degrees from the vertical, 35-75 degrees from the vertical, 40-75 degrees from the vertical, 45-75 degrees from the vertical, 50-75 degrees from the vertical, 55-75 degrees from the vertical, 60-75 degrees from the vertical, 65-75 degrees from the vertical, 70-75 degrees from the vertical, 15-70 degrees from the vertical, 15-65 degrees from the vertical, 15-60 degrees from the vertical, 15-55 degrees from the vertical, 15-50 degrees from the vertical, 15-45 degrees from the vertical, 15-40 degrees from the vertical, 15-35 degrees from the vertical, 15-30 degrees from the vertical, 15-25 degrees from the 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, the “substantially horizontal” direction may be within 15 degrees from the horizontal, within 10 degrees from the horizontal, or further within 5 degrees from the horizontal.

[0058] Referring to Figure 1, the outer shell 312 can further accommodate a riser termination device 378. The riser termination device 378 may be positioned in close proximity to the internal riser segment 334. In one or more embodiments, the riser termination device 378 may be directly connected to the vertical section 396 of the internal riser segment 334. The gas and particulate solid passing through the riser 330 can be at least partially separated by the riser termination device 378. The gas and remaining particulate solid may be transported to a secondary separator 320 in the particulate solid separation section 310. The secondary separator 320 may be any mechanical or chemical separator that can operate to separate particulate solid from the gas phase or liquid phase, such as a cyclone or multiple cyclones.

[0059] According to one or more embodiments, the separation unit 320 may be a cyclone separation system that includes two or more stages of cyclone separation. In embodiments in which the secondary separation unit 320 includes two or more cyclone separation units, the first separation unit into which the fluid flow enters is called the primary cyclone separation unit. The fluid effluent from the primary cyclone separation unit can enter the secondary cyclone separation unit for further separation. The primary cyclone separation unit may include, for example, a primary cyclone 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 in, for example, U.S. Patent Nos. 4,579,716, 5,190,650, and 5,275,641, each of which is incorporated herein by reference in whole. In some separation systems that utilize a primary cyclone as a primary cyclone separator, one or more additional sets of cyclones (e.g., secondary and / or tertiary cyclones) can be used to further separate particulate solids from the product gas. It should be understood that any primary cyclone separator can be used in the embodiments disclosed herein.

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

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

[0062] As described herein, the “oxygen immersion zone” may refer to a portion of the particulate solid collection area 380 in which particulate solids are exposed to a flow of oxygen-containing gas. In one or more embodiments, the particulate solids may generally flow downward and the oxygen-containing gas may generally flow upward. The particulate solids may have an average residence time of more than 2 minutes in the oxygen immersion zone, preferably 2 to 14 minutes. The particulate solids may become oxygen-containing particulate solids in the oxygen immersion 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 solid collection area 380 may include an oxygen stripping zone. As described herein, “oxygen stripping zone” refers to a zone in the particulate solid collection area 380 from which particulate solid is stripped of oxygen-containing gas molecules. Oxygen-containing gas molecules can be stripped from the particulate solid by bringing it into contact with a gas that does not contain more than 0.5 mol% oxygen. Generally, the particulate solid moves downward and the gas moves upward through the oxygen stripping zone. Therefore, excess oxygen-containing gas does not need to be passed through the reactor section 200 together with the particulate solid.

[0064] As described herein, the “reducing zone” may refer to the zone in which a reducing agent, such as hydrogen or methane, is supplied into a catalytic flow that has been fluidized by a non-participating gas, such as nitrogen or water vapor. The reducing agent removes oxygen from the particles, thereby increasing the effectiveness of the particles for the reaction.

[0065] Referring again to Figures 1 and 3, the particulate solid collection area 380 may include a particulate solid outlet port 322. In one or more embodiments, the particulate solid outlet port 322 may be located near or even above the central vertical axis 399. According to one or more embodiments, the bottom of the particulate solid collection area 380 may be curved such that the particulate solid outlet port 322 is located at the lowest part of the particulate solid collection area 380. Piping 124 may be connected to the particulate solid separation section 310 at the particulate solid outlet port 322, and the particulate solid is discharged from the regeneration section 300. Piping The particulate solid may be transferred to the reactor section 200 via 124. Thus, the particulate solid can be continuously recycled through the reactor system 100.

[0066] While not bound by theory, if the riser 330 does not pass through the particulate solid collection area 380 and the particulate solid outlet port 322 is located on the central vertical axis 399, the flow of particulate solid through the particulate solid collection area 380 may be improved compared to a design in which the riser 330 passes through the particulate solid collection area 380. When the riser 330 does not pass through the particulate solid collection area 380, the particulate solid outlet port 322 may be located on the central vertical axis 399, and the particulate solid may move through the particulate solid collection area 380 in a manner more closely similar to plug flow. This can result in an increase in the minimum residence time of particulate solid within the particulate solid collection area 380, which may be beneficial if stripping, oxygen immersion, or other intended processes are performed within the particulate solid collection area 380.

[0067] As described herein, parts of a system unit, such as reaction vessel walls, separation section walls, or riser walls, may include metallic materials such as carbon or stainless steel. Furthermore, the walls of various system units may have parts that are attached to other parts of the same system unit or to another system unit. Sometimes, the points of attachment or connection are referred to herein as “attachment points” and may incorporate any known bonding medium, such as welding, adhesive, or solder, though not limited to these. It should be understood that the components of the system may also be “directly connected” at attachment points such as welding.

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

[0069] The mechanical load applied to the particulate solid processing vessel 350 from the weight of the particulate solid, the thermal stress from the various components of the regeneration section 300 and the different growth of other components may be high, and if expansion joints are not used, springs may be used to allow movement of the particulate solid processing vessel 350 while controlling the nozzle force within the limits of the joint 318. For example, the particulate solid processing vessel 350 may be suspended from a spring, or the spring may be positioned below the particulate solid processing vessel 350 to support all or part of its weight and the expected catalyst weight. For example, Figure 1 shows a spring support 188 mechanically attached to the regeneration section 300 in the particulate solid processing vessel 350, and the regeneration section 300 is suspended from the support structure by the spring support 188.

[0070] In addition, the particulate solid processing container 350 and the riser 330 may undergo thermal expansion. Therefore, the tension between the particulate solid processing container 350 and the external riser segment 332 can be relieved by suspending the particulate solid processing container 350 from the spring support 188 or by supporting the particulate solid processing container 350 on the spring support 188. When springs are used, expansion joints are generally not used. Referring here to Figure 2, an expansion joint 382 may be placed between the particulate solid processing container 350 and the external riser segment 332. As described herein, “expansion joint” may refer to a bellows made of metal or other suitable material that reduces stress between system components joined by an 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, the particulate solid processing container 350 is generally supported via a fixed support (without springs) by either a rod hanger or a skirt. In one or more embodiments, the expansion joint 382 can be used in combination with a spring support to relieve stress caused by thermal expansion between the particulate solid processing container 350 and the external riser segment 332. [Examples]

[0071] The following examples illustrate the features of the present disclosure but are not intended to limit the scope of the present disclosure. The following examples examine the performance of particulate solid collection areas by one or more embodiments disclosed herein.

[0072] The flow of particulate solids through two particulate solid collection regions was modeled. The first particulate solid collection region 410 is shown in Figure 4 and has a single outlet located at the bottom of the particulate solid collection region 410. Piping It had an annular shape with 420. Piping 420 was not positioned on the central axis 430 of the first particulate solid collection area 410. The first particulate solid collection area 410 is also Subway grating Includes several code beam supports covered with 440.

[0073] The second particulate solid collection area 510, shown in Figure 5, is cylindrical in shape and has an outlet located at the bottom of the particulate solid collection area 510. Piping It had 520 and, exit. Piping 520 is positioned on the central axis 530 of the second particulate solid collection area 510. The second particulate solid collection area 510 is also metal plate grid Includes several code beam supports covered with 540.

[0074] Computational fluid dynamics (CFD) simulations were performed to model the flow of particulate solids through the first and second particulate solid collection regions. In this way, the solid residence time distribution (RTD) in each container was obtained. For the simulation, the diameters of the first and second particulate solid collection regions were set to 46 inches. The surface gas velocity at the bottom of each container was 0.3 ft / s, and the average particulate solid flux was 3.4 lb / ft. 2 It was - seconds. Furthermore, the average turnaround time for particulate solids was 8 minutes.

[0075] CFD simulations for the first particulate solid collection region show that the shortest residence time of the particulate solid is at the container outlet. Piping The short circuit of particulate solids on the side was predicted to be approximately 30 seconds. The CFD simulation also predicted that approximately 42% of the particulate solids would have a residence time of less than 4 minutes. The CFD simulation for the second particulate solid collection area predicted that the shortest residence time of the particulate solids would exceed 1 minute, and that only 30% of the particulate solids would have a residence time shorter than 4 minutes.

[0076] The RTDs for the first and second particulate solid collection regions are graphically shown in Figure 6. The RTD for the first particulate solid collection region is indicated by line 610, and the RTD for the second particulate solid collection region is indicated by line 620. Furthermore, for reference, Figure 6 shows the RTDs for one continuous stirred tank reactor (CSTR) and three CSTRs in series. The RTD for one CSTR is indicated by line 630, and the RTD for three CSTRs in series is indicated by line 640. As shown in Figure 6, the RTD for the first particulate solid collection region is comparable to the RTD for a single CSTR, and the RTD for the second particulate solid collection region is comparable to the RTD for three CSTRs in series. The second particulate solid collection region offers advantages over the first particulate solid collection region because the flow of particulate solids through the second particulate solid collection region is more similar to a plug flow. Therefore, fewer particulate solids are released quickly from the particulate solid collection area, and fewer particulate solids are retained in the particulate solid collection area for a longer period. This results in more consistent processing of particulate solids in the particulate solid collection area.

[0077] In a first aspect of this disclosure, particulate solids may be regenerated by a method that includes regenerating the particulate solids in a particulate solids processing vessel. Regeneration of particulate solids may include one or more of the following: 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 include passing the particulate solids through a riser. The riser may extend through a riser port in the outer shell of the particulate solids separation section, such that the riser comprises an internal riser segment located in the internal region of the particulate solids separation section and an external riser segment located outside the outer shell of the particulate solids separation section. The particulate solids separation section may include at least an outer shell that defines the internal region of the particulate solids separation section. The outer shell may include a gas outlet port, a riser port, and a particulate solids outlet port. The outer shell can house a gas / solids separation device and a particulate solids collection area within the internal region of the particulate solids separation section. The riser port may be positioned on the side wall of the outer shell so as not to be located on the central vertical axis of the particulate solid separation section. The method may further include separating particulate solid from a gas in a gas / solid separation unit, and sending the particulate solid separated from the gas to a particulate solid collection area located close to the central vertical axis of the particulate solid separation section.

[0078] A second aspect of the present disclosure may include the first aspect, 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.

[0079] A third aspect of this disclosure may include either the first or second aspect, wherein 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 obliquely through the riser port, and the oblique direction is 15 to 75 degrees from the vertical.

[0081] A fifth aspect of this disclosure may include any of the first to fourth aspects, wherein the riser extends substantially horizontally through the riser port.

[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 adjacent to a 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, and the riser termination device is positioned in close proximity to the internal riser segment.

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

[0085] A ninth aspect of this 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 this 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 this 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 this disclosure may include any of the first to eleventh aspects, wherein the riser does not pass through the particulate solid collection area.

[0089] A thirteenth aspect of this disclosure may include any of the first to twelfth aspects, wherein the particulate solid collection area includes an oxygen immersion zone, an oxygen stripper, a reduction zone, or a combination thereof.

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

[0091] A 15th aspect of this disclosure may include any of the first to 14th aspects, wherein the particulate solid outlet port is located on the central vertical axis of the particulate solid separation section.

[0092] The subject matter of this disclosure is described in detail with reference to specific embodiments. It should be understood that any detailed description of the components or features of the embodiments does not necessarily imply that such components or features are essential to the specific 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 set forth in the claims.

[0093] For the purposes of describing and defining the present invention, the terms “about” or “approximately” are used in this disclosure to express the degree of inherent uncertainty that may arise from any quantitative comparison, value, measurement, or other expression. The terms “about” and “approximately” are also used in this disclosure to express the degree to which a quantitative expression may deviate from the stated standard without altering the fundamental function of the subject matter in question.

[0094] Note that one or more of the following claims utilize the term “here” as a transitional clause. Note that, for the purpose of defining the present invention, this term is introduced into the claims as an unrestricted transitional clause used to introduce an enumeration of a set of structural features and should be interpreted similarly to the more commonly used unrestricted preamble term “including.”

[0095] Where a first component is described as "containing" a second component, it should be understood that in some embodiments, the first component is intended to "consist of" or "essentially consist of" that second component. Where a first component is described as "containing" a second component, it should be further understood that in some embodiments, the first component is intended to contain 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 more than 99% of that second component (where % can be by weight or by moles).

[0096] In addition, the term “essentially consisting of” is used in this disclosure to refer to a quantitative value that does not substantially affect the basic and novel features of the disclosure. For example, a chemical composition “essentially consisting 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] Any two quantitative values ​​assigned to a property can constitute a range for that property, and it should be understood that all combinations of ranges formed from all stated quantitative values ​​of a given property are intended in this disclosure. It should be understood that the compositional range of a chemical component in a composition includes, in some embodiments, a mixture of isomers of that component. In further embodiments, the compound may exist in alternative forms such as derivatives, salts, or hydroxides.

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 area 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 area 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 area 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 area 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 area 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 area 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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