Catalyst Cooler Venting to Regenerator Lower Chamber
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Solution Overview
Problem
After burn phenomenon occurs in regenerators due to insufficient catalyst presence as a heat sink in the dilute phase, leading to potentially damaging temperatures and nitrous oxide generation, and existing air utilization in catalyst coolers does not efficiently support combustion in regenerators.
Innovation Solution
Venting air from the catalyst cooler to the combustor chamber in the regenerator vessel, rather than the upper chamber, allows it to be consumed in the combustion of coke on spent catalyst, minimizing after burn and optimizing air utilization for efficient regeneration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If air is vented to the upper chamber of the regenerator vessel, then the air can be used to fluidize catalyst in the catalyst cooler, but after burn occurs due to insufficient catalyst presence as a heat sink
Solution Approach 1:
The patent introduces an intermediary approach by venting air to the lower chamber where catalyst is present, rather than directly to the upper chamber. This intermediary location allows the air to first interact with catalyst for combustion before potentially reaching the upper chamber, thus preventing after burn while maintaining efficient air utilization.
Solution Approach 2:
The patent applies preliminary action by ensuring that air is consumed in the lower chamber where catalyst is available for combustion, before the air can reach the upper chamber. This preliminary combustion prevents the conditions necessary for after burn to occur in the upper chamber.
2Device complexity
If air is vented to the upper chamber, then the system operates with simple air routing, but potentially damaging temperatures and nitrous oxide generation occur
Solution Approach 1:
The patent converts the potentially harmful air that would cause after burn and nitrous oxide generation into a beneficial resource by directing it to the lower chamber where it supports complete combustion of coke on spent catalyst. This transforms a harmful effect into a beneficial combustion process.
3Productivity
If air is vented to the lower chamber, then coke combustion efficiency is enhanced, but the air routing becomes more complex
Solution Approach 1:
The patent applies universality by using the lower chamber to serve multiple functions: it acts as both the catalyst cooler and the combustion chamber. This multi-functionality allows air to be efficiently used for combustion without requiring separate complex routing systems, as the lower chamber inherently handles both cooling and combustion processes.
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
Venting air to the lower chamber reduces after burn occurrences and enhances coke combustion efficiency, maintaining equipment safety and reducing nitrous oxide generation by ensuring sufficient air is used in the combustion process.
Implementation Method 1
Catalyst is fluidized in the catalyst cooler with air
Implementation Method 2
hot regenerated catalyst is cooled by indirect heat exchange with water which vaporizes to steam
Implementation Method 3
combusting coke from catalyst in a combustor chamber of a regenerator vessel
Implementation Method 4
hot regenerated catalyst is cooled by indirect heat exchange with water
Data Source
AI summary
The process herein provide a catalyst cooler with a vent that communicates fluidizing gas to a lower chamber of a regenerator. Air that is used as fluidizing gas can then be consumed in the regenerator without promoting after burn in the upper chamber.