Catalyst Mixing Insert with Segmented Arcuate Sections

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Solution Overview

Problem

The existing methods for mixing carbonized and regenerated catalysts in fluid catalytic cracking (FCC) processes do not ensure thorough mixing, leading to temperature variations that result in non-selective cracking and undesirable product compositions due to inadequate mixing techniques, particularly in the riser section of the FCC unit.

Innovation Solution

Feeding a first catalyst stream downwardly and a second catalyst stream horizontally into the riser, with strategically positioned openings in the insert's wall to facilitate horizontal alignment and minimize erosion, ensuring thorough mixing of the catalyst streams while maintaining a homogeneous temperature.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If inserts with multiple arcuate sections and openings are used in the riser, then catalyst mixing is improved, but erosion of the insert wall increases

Engineering Contradiction:

Improvecatalyst mixing uniformityVSAvoidinsert wall erosion

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The insert wall is segmented into a larger arcuate section and a smaller arcuate section, with openings only in the larger section. This segmentation allows catalyst streams to mix effectively through the openings while the smaller section acts as a protective barrier against erosion from horizontally traveling catalyst particles.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The smaller arcuate section serves as an intermediary protective barrier between the horizontally traveling catalyst stream and the insert wall openings. It blocks direct horizontal catalyst flow that would cause erosion, while still allowing vertical catalyst flow and mixing to occur through the openings in the larger section.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If catalyst streams are fed at different directions into the riser, then mixing efficiency is improved, but temperature control becomes more difficult

Engineering Contradiction:

Improvemixing efficiencyVSAvoidtemperature uniformity

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The insert provides different flow paths for different catalyst streams: the first catalyst stream flows vertically through openings in the larger arcuate section, while the second catalyst stream flows horizontally and is blocked by the smaller arcuate section. This local differentiation in flow paths ensures thorough mixing while the vertical orientation of openings maintains temperature control.

Inventive Principle:

Principle #3Local quality

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

This approach ensures thorough mixing of the catalyst streams, reducing temperature differentials and minimizing erosion, thereby improving the selectivity of the cracking process and enhancing the quality of the product hydrocarbons by maintaining a more uniform catalyst temperature.

Implementation Method 1

feeding a first catalyst stream downwardly to the riser while feeding a second catalyst stream horizontally to the riser fosters thorough mixing

Methodology Applied

Scientific EffectFluid flow:

Data Source

PatentUS8871151B2Apparatus for mixing two streams of catalyst with an insert having aligned openings

Publication Date: 2014.10.28 UOP LLC

AI summary

An apparatus for mixing streams of regenerated and carbonized catalyst utilizes bend provided on only one of the catalyst conduits to provide mixing advantages. A pair of horizontally aligned openings with a band between the pair of openings provided a robust design and superb catalyst mixing performance.