Off-site Catalyst Regeneration via Supercritical CO2 Extraction
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Solution Overview
Problem
Current catalyst regeneration processes in petroleum refining and petrochemicals face challenges such as high energy consumption, significant CO2 emissions, and the formation of 'hard' coke, which complicates combustion and reduces catalyst porosity, making them inefficient and environmentally unfriendly.
Innovation Solution
An off-site regeneration process involving a two-stage method: first, using a fluid in the supercritical state, such as carbon dioxide with added water, to extract hydrocarbons from the catalyst, followed by controlled combustion of coke at temperatures between 300°C to 600°C in the presence of oxygen, optimizing conditions to preserve catalyst activity and porosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If evaporation of hydrocarbons is carried out by heating the catalyst in the presence of a carrier gas, then hydrocarbons can be eliminated from the catalyst surface, but energy consumption increases significantly due to heating and incineration
Solution Approach 1:
The invention changes the physical state parameter of the carrier gas from subcritical to supercritical state. By operating above the critical temperature and pressure of CO2 (31.1°C and 7.38 MPa), the gas achieves liquid-like density and solvating power, enabling efficient hydrocarbon extraction without requiring high-temperature heating and subsequent incineration, thus dramatically reducing energy consumption
Solution Approach 2:
The invention replaces the thermal-mechanical system (heating + incineration) with a supercritical fluid extraction system. Instead of using heat to evaporate and then burn hydrocarbons, the process uses the solvating properties of supercritical CO2 to directly extract and remove hydrocarbons in one step, substituting a chemical extraction mechanism for a thermal combustion mechanism
2Loss of substance
If evaporation of hydrocarbons is carried out by heating the catalyst in the presence of a carrier gas, then hydrocarbons can be eliminated from the catalyst surface, but CO2 emissions increase due to incineration
Solution Approach 1:
The invention converts the typically harmful incineration process into a beneficial extraction process. Instead of burning hydrocarbons and generating CO2 emissions, the supercritical CO2 acts as a solvent to extract hydrocarbons, and the CO2 itself is recycled and reused, transforming a harmful combustion process into a benign, recyclable extraction process
Solution Approach 2:
The invention implements a recovery and recycling system for the supercritical CO2 carrier gas. After extraction, the CO2 is depressurized back to gaseous state, separated from extracted hydrocarbons, and then recompressed and reused in the next extraction cycle, eliminating the need for continuous CO2 supply and avoiding emissions associated with incineration
3Loss of substance
If evaporation of hydrocarbons is carried out under inert gas at high temperature, then hydrocarbons can be eliminated, but additional coke is formed on the catalyst surface
Solution Approach 1:
The invention changes the temperature parameter from high temperature (required for thermal evaporation) to moderate temperature (above CO2 critical point but below thermal cracking thresholds). This parameter change prevents thermal cracking and coke-forming reactions while still enabling efficient hydrocarbon extraction through the enhanced solvating power of supercritical CO2
Solution Approach 2:
The supercritical CO2 acts as an intermediary substance that facilitates hydrocarbon removal without causing thermal degradation. Instead of using high-temperature inert gas that causes cracking and coke formation, the supercritical CO2 intermediary provides a gentler extraction mechanism that selectively dissolves and removes hydrocarbons without inducing unwanted side reactions
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 significantly reduces energy consumption, minimizes CO2 emissions, and enhances catalyst regeneration efficiency, restoring activity levels close to new catalysts while maintaining porosity and avoiding additional coke formation.
Implementation Method 1
a first step of washing the catalyst using one or more fluid(s) in the supercritical state, so as to extract from the catalyst at least part of the hydrocarbons present on the surface thereof
Implementation Method 2
followed by a second step of combustion of the coke present on the surface of the catalyst, by heat treatment thereof in the presence of oxygen and at a temperature ranging from 300°C to 600°C
Data Source
AI summary
Process for off-site regeneration of a solid catalyst, comprises: (a) washing the catalyst by using one or more fluid in the supercritical state by extracting from the catalyst at least a part of the hydrocarbons present on the surface of the catalyst; and (b) combustion of at least a part of the coke present on the surface of the catalyst, by heat treatment of the catalyst in the presence of oxygen and at a temperature of 300-600[deg] C.