Catalyst Regeneration Halogen Retention via Moisture Removal
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Solution Overview
Problem
Existing catalyst regeneration processes face challenges in maintaining halogen content during catalyst regeneration due to moisture buildup in process streams, which can lead to halogen loss and reduced catalyst efficiency.
Innovation Solution
Incorporating a water-removing material, such as a stable membrane or beads, to selectively remove moisture from regeneration vent gas and reduction gas, ensuring a dry environment for halogen retention and recovery, thereby preventing halogen loss and improving catalyst regeneration yields.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a catalyst regeneration system processes vent gas through a burn zone to regenerate catalyst particles, then coke is removed from the catalyst, but moisture builds up in the process streams causing halogen loss from the catalyst
Solution Approach 1:
The patent extracts and removes moisture from the process streams using a water removing material. The water removing material selectively removes water from the vent gas and reduction gas streams, separating the harmful moisture component from the beneficial process gases while maintaining halogen content for catalyst regeneration
Solution Approach 2:
The water removing material acts as an intermediary component between the burn zone and the adsorption/desorption system. It mediates the process by removing moisture before gases enter subsequent zones, preventing halogen loss while allowing the regeneration process to continue efficiently
2Loss of substance
If water removing material is added to remove moisture from process streams, then halogen retention is improved, but device complexity increases
Solution Approach 1:
The water removing material utilizes porous material properties to selectively adsorb and remove moisture from the process streams. The porous structure provides high surface area for water interaction while maintaining permeability to other gases, achieving effective drying without complex mechanical systems
Solution Approach 2:
The system employs composite material functionality where the water removing material combines properties of selective permeability and chemical stability in acidic environments. This allows a single material to perform multiple functions: water removal, halogen retention, and resistance to corrosive conditions
3Productivity
If moisture is not removed from reduction gas, then the system operation is simple, but catalyst reduction efficiency decreases
Solution Approach 1:
The water removing material performs preliminary drying of the reduction gas before it enters the reduction zone. By removing moisture in advance, the reduction process operates under optimal dry conditions, improving catalyst reduction efficiency without requiring complex post-processing systems
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
The use of water-removing materials effectively reduces moisture in the catalyst regeneration system, enhancing halogen retention and recovery, leading to improved catalyst regeneration efficiency and increased yields by maintaining a dry environment for halogen-containing catalysts.
Implementation Method 1
a water removing material, such as a membrane, wherein water can be selectively rejected from the regeneration vent gas
Implementation Method 2
The membrane is very stable in the highly acidic environment and highly selective to reacting with and removing water
Implementation Method 3
an adsorption/desorption system to recover the chlorine
Implementation Method 4
an adsorption/desorption system to recover the chlorine
Data Source
AI summary
A process for regenerating catalyst particles is disclosed. The process includes the steps: (a) withdrawing a regeneration zone effluent comprising halogen from a regeneration zone, wherein the regeneration zone contains catalyst particles comprising halogen; (b) contacting a first portion of the regeneration zone effluent with adsorbent in a first adsorption zone, removing halogen from the first portion of the regeneration zone effluent, and withdrawing from the first adsorption zone a first adsorption zone effluent; (c) contacting the first adsorption zone effluent with a water removing material to create a first water-depleted stream; and (d) passing the first water-depleted stream to the regeneration zone. Other embodiments include different orders of the steps.