Catalyst Cooler Inverted Manifold Design for After Burn Prevention
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Solution Overview
Problem
After burn phenomenon occurs in regenerators, particularly in advanced two-stage regenerators, due to insufficient catalyst density to absorb heat, leading to potentially damaging higher temperatures and nitrous oxide generation.
Innovation Solution
Venting air from a catalyst cooler downstream or outside of the regenerator prevents after burn by avoiding the mixing of oxygen-containing vent gases with carbon monoxide in the regenerator flue gas. Additionally, locating the manifolds for cooling tubes at the top of the catalyst cooler allows for more efficient cooling tube arrangement, increasing the number of tubes and improving cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If vent gases from catalyst cooler are directed to regenerator, then heat recovery is improved, but after burn occurs due to oxygen mixing with carbon monoxide
Solution Approach 1:
The harmful oxygen component is extracted from the vent gases by directing them away from the regenerator, preventing the harmful after burn reaction while maintaining the beneficial heat recovery function through alternative cooling medium circulation
2Ease of operation
If manifolds for cooling tubes are located at bottom of catalyst cooler, then catalyst distribution is improved, but cooling efficiency decreases due to limited tube arrangement space
Solution Approach 1:
The manifold location is inverted from the conventional bottom position to the top position of the catalyst cooler. This inversion maximizes the available vertical space for arranging cooling tubes, thereby improving cooling efficiency while still maintaining proper catalyst distribution through the cooler
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Prevents after burn in regenerators by ensuring that oxygen-containing vent gases do not enter regions with carbon monoxide, thereby maintaining catalyst density as a heat sink and preventing equipment damage. The improved cooling tube arrangement enhances the cooling efficiency of the catalyst cooler.
Implementation Method 1
The catalyst cooler has nested tubes for providing cooling media
Implementation Method 2
cooling the hot catalyst
Data Source
AI summary
Vent gases from a catalyst cooler are directed downstream or outside of the catalyst regenerator to avoid sending air to a location where after burn may occur. Vent gases contain oxygen that when contacted with carbon monoxide in regenerator flue gas can cause after burn to occur at a location which lacks sufficient catalyst density to serve as a heat sink. Locating the cooling media supply in the top of the catalyst cooler enables cooled catalyst to drain from the bottom of the catalyst cooler and fitting more cooler tubes in the catalyst cooler.