Catalyst Regeneration/Reactivation TRIZ Cases

Low-temperature heat treatment and dry-mixed calcination restore spent heavy oil desulfurization catalyst activity without leaching, washing, or drying.

Regeneration plus metal-organic impregnation and drying restores spent hydroprocessing catalyst activity close to fresh performance.

In-situ flushing dissolves ammonium salt deposits during low-temperature hydrotreatment, preventing catalyst deactivation and reactor plugging.

Spent catalyst fines are milled, bound, shaped, and rejuvenated to restore activity while reducing waste and keeping reactor pressure drop acceptable.

Bypassing burn and calcination zones lets a catalyst regeneration gas loop recirculate oxygenated nitrogen to combust coke deposits with lower corrosion and gas use.

O2 and recycled CO2 regenerate coke-fouled acid condensation catalyst while limiting cracking and sustaining hydrocarbon production.

During startup, a heater raises feed temperature and volumetric flow so cyclones can recover catalyst from the product stream.

Ex situ catalyst regeneration adds transport and downtime; this integrated process circulates spent catalyst for in situ combustion during hydroconversion.

Supported metal catalysts shift C-C bond breaking toward C5+ hydrocarbons for lubricant base oils, reducing low-value products.

Controlled oxidizing-gas incineration of catalyst briquettes accelerates activated carbon combustion, reducing energy use and ash loss.

A solid heteropolyacid catalyst polymerizes asphaltenes, regenerates by wash solvent, and routes deasphalted oil to steam cracking.

This case pairs Cu9S5 with nitrogen-doped carbon to improve eNRR yield and restore catalyst activity using Na2S.

Heating the supported heteropolyacid catalyst above 220°C removes bound water, suppressing unwanted alkane formation during alkene synthesis.

A self-activating hydroprocessing catalyst absorbs nickel from heavy feedstocks to boost catalytic activity over time.

Segmented reactor trains allow catalyst replacement without full shutdowns, resolving the trade-off between maintenance reliability and production productivity.

Chlorine gas treatment modifies spent catalyst surfaces, restoring metal dispersion and activity lost to sintering during aromatization reactions.

Hydrofluoric acid-treated amorphous synthetic alumina-silica catalysts decompose ethers into olefins.

A dual catalyst system processes heavy oil feedstocks using a colloidal precursor and porous supported catalyst.

Chelation with xanthate agents extracts metal residues from hydrogenated nitrile rubber, reducing product contamination and disposal costs.

Cyclonic separation in fluidized dehydrogenation reactors reduces platinum costs and nitrogen oxide emissions while maintaining propylene productivity.

Multiple parallel reactor trains enable continuous feed flow through online units during catalyst regeneration steps.

Mixing platinum additive particles with dehydrogenation catalyst enables in situ activation during high temperature oxygen treatment.

Oxidizing silicon carbide within unfired spheroids creates stable ceramic catalysts that eliminate pressure drops and reduce fines release.

A homogeneous catalyst system reactivates through aqueous base addition to restore oxidation activity.

A microchannel reactor process regenerates Fischer-Tropsch catalysts using superheated steam for efficient heat transfer during de-waxing and oxidation steps.

A fluidized bed reactor with a heating jacket activates chromium catalyst precursors through controlled thermal oxidation.

Inert gas buffer prevents uncontrolled combustion in hydrocarbon conversion systems while adsorption zone removes chlorides from flue gas.

Segmented heat transfer structures remove exothermic reaction heat to prevent thermal runaway and suppress methane formation during high productivity synthesis.

Paired oxidation electrolysis removes organic impurities from spent sulfuric acid catalysts without high-temperature combustion, maintaining acid concentration.

A direct burner heats a sealed furnace chamber to pyrolyze carbonaceous materials from precious metal compositions using combustion exhaust gases.

Rejuvenating spent hydrotreating catalysts through low-temperature impregnation restores activity and selectivity without full regeneration.

Semi-continuous fluidized bed reactor system maintains isothermal conditions during catalytic dehydrogenation.

Heat treatment in a fluidized bed activates chromium catalysts, while inert gas flushing prevents reactor fouling during polymerization.

Controlled oxidative post-treatment restores activity while preventing ruthenium loss during sulfur removal.

High-molybdenum trimetallic catalysts upgrade crude bio-oil to low-acidity fuel, resolving yield and acidity trade-offs.

Fluid cobalt fluoride catalysts enable continuous 1,1,1,2,3-pentafluoropropane production while eliminating complex multi-step processing bottlenecks.

Solvent extraction and flameless pyrolysis recover metals from hydrotreatment purge streams, preventing catalyst loss.

Sequential steam and oxidative regeneration restores alumina catalyst activity, resolving passivation bottlenecks in fatty acid conversion.

Dispersed colloidal catalysts upgrade heavy oil feedstocks through direct hydrocracking, preventing asphaltene-derived coke fouling.

A hydrotreating catalyst rejuvenation process uses MoO3 and H3PO4 impregnation to restore metal dispersion on spent supports.

High hydrogen syngas treatment reduces methane selectivity and extends catalyst stability without plant shutdown.

A photo-catalytic system splits water using semiconductor particles to generate hydrogen gas and an oxidized catalyst.

A catalyst recovery system cools concentrated slurry to solidify the liquid medium and extract particles directly from the reactor.

Oxychlorination re-disperses platinum to restore catalyst activity and selectivity while preventing agglomeration during regeneration cycles.

Vaporizing alkali metal salts into steam streams maintains catalyst activity and prevents coke deposition without requiring process shutdowns.