Regenerated Catalyst Oxygen Removal via Fuel Combustion
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Solution Overview
Problem
The existing hydrocarbon dehydrogenation processes in fluidized bed reactors face issues with oxygen contamination from regenerated catalysts, leading to degradation of valuable feedstock into less valuable products, and current methods like nitrogen stripping increase capital and operating costs.
Innovation Solution
A process that reacts the oxygen-containing regenerated catalyst stream with a fuel source such as methane, ethane, or coke to form oxides, reducing oxygen levels and producing a usable catalyst stream for injection into the reactor, eliminating the need for nitrogen stripping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If nitrogen stripping is used to remove oxygen from regenerated catalyst, then oxygen content in catalyst stream is reduced, but capital investment and operating costs increase
Solution Approach 1:
The patent converts the harmful oxygen into a useful resource by using it as an oxidizing agent to burn off coke deposits on the catalyst. The oxygen that would otherwise degrade feedstock is now utilized to regenerate catalyst activity through controlled combustion, eliminating the need for nitrogen stripping while maintaining catalyst performance.
Solution Approach 2:
The regenerated catalyst performs self-regeneration by using its own oxygen content to burn off accumulated coke during the fluidized bed reaction process. The catalyst stream naturally consumes its oxygen content through reaction with coke, eliminating the need for external stripping operations or additional oxygen removal equipment.
2Object-affected harmful factors
If nitrogen stripping is implemented to minimize oxygen in regenerated catalyst, then feedstock degradation is prevented, but unit operation complexity increases
Solution Approach 1:
The patent merges the oxygen removal function with the catalyst regeneration function into a single integrated process. Instead of separate stripping and regeneration operations, the catalyst stream undergoes simultaneous regeneration and oxygen consumption through coke combustion, simplifying the overall process flow and eliminating redundant equipment.
Solution Approach 2:
The oxygen present in regenerated catalyst, which would normally be considered a harmful contaminant causing feedstock degradation, is converted into a beneficial oxidizing agent that actively removes coke deposits. This transformation eliminates the need for complex oxygen stripping operations while preventing feedstock degradation.
3Ease of manufacture
If oxygen is not removed from regenerated catalyst stream, then capital and operating costs are reduced, but oxygen transfers to dehydrogenation reactor and degrades feedstock
Solution Approach 1:
The patent transforms the harmful oxygen into a useful combustion agent that burns off coke on the catalyst. The oxygen that would otherwise degrade feedstock in the dehydrogenation reactor is instead consumed in exothermic reactions with coke deposits, preventing both feedstock degradation and eliminating the need for costly oxygen removal equipment.
Solution Approach 2:
The catalyst stream naturally consumes its own oxygen content through reaction with coke during the fluidized bed process. This self-consuming mechanism eliminates the need for external oxygen removal systems while ensuring that oxygen does not reach the dehydrogenation reactor to degrade feedstock.
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 process effectively minimizes oxygen in the catalyst stream, preventing feedstock degradation and reducing operational costs by eliminating the need for nitrogen stripping, thereby enhancing the efficiency and cost-effectiveness of hydrocarbon dehydrogenation processes.
Implementation Method 1
reacting the regenerated catalyst stream with a fuel source such as methane, ethane, ethylene, propane, propylene, hydrogen, or coke thereby forming oxides and reducing the amount of oxygen
Data Source
AI summary
A process to react an oxygen containing regenerated catalyst stream prior to use in a fluidized bed reactor comprising providing a regenerated catalyst stream which comprises at least 0.001 wt % oxygen; reacting the regenerated catalyst stream with a fuel source thereby forming oxides and reducing the amount of oxygen in the regenerated catalyst stream to produce a usable regenerated catalyst stream; and injecting the usable regenerated catalyst stream into a hydrocarbon fluidized bed reactor is provided.