Catalyst Regenerator Partial Oxidation Burner Hot Spot Prevention
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Solution Overview
Problem
In the process of producing olefin from naphtha using a catalyst cracking system, the regeneration of coked catalysts often results in hot spots due to non-uniform mixing of fuel oil with the catalyst, leading to catalyst damage and the need for frequent replenishment.
Innovation Solution
A catalyst regenerator system that uses a partial oxidation burner to produce a high-temperature gas containing solid carbon, which is uniformly distributed across the catalyst layer through strategically placed supply nozzles, preventing hot spots by ensuring uniform coking and burning of the catalyst.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If liquid-phase fuel oil is sprayed to a catalyst layer having a high density, then the fuel oil is mixed with the catalyst while being evaporated, but mixing non-uniformity occurs and hot spots are formed
Solution Approach 1:
The patent changes the physical state of the fuel from liquid-phase to gas-phase by introducing it in a vaporized form. This parameter change allows the fuel to distribute more uniformly throughout the catalyst layer without forming liquid droplets that would cause localized overheating and mixing non-uniformity.
Solution Approach 2:
The patent introduces an intermediary gas phase medium to carry the fuel uniformly through the catalyst layer. Instead of directly spraying liquid fuel onto the catalyst, the fuel is first vaporized and then introduced as a gas that can penetrate and distribute evenly throughout the catalyst bed, preventing hot spot formation.
2Power
If liquid-phase fuel oil is sprayed to regenerate coked catalyst, then the coke is burned to generate heating value, but hot spots are formed causing catalyst damage
Solution Approach 1:
The patent changes the physical state of fuel introduction from liquid spray to gas phase injection. This parameter change ensures that the fuel burns more uniformly throughout the catalyst layer, converting localized hot spots into distributed, controlled exothermic reactions that regenerate the catalyst without causing thermal damage.
Solution Approach 2:
The patent converts the potentially harmful effect of localized fuel concentration into a beneficial uniform distribution. By vaporizing the fuel before introduction, the system transforms what would be localized hot spots from liquid droplet combustion into uniform heat generation across the entire catalyst bed, turning a potential damage mechanism into a controlled regeneration process.
3Productivity
If conventional cracking is performed at high temperature, then olefin is produced from naphtha, but a significantly large amount of coke is generated
Solution Approach 1:
The patent implements continuous catalyst regeneration by introducing fuel in a form that allows uniform burning throughout the catalyst layer. This continuous, uniform combustion process removes coke deposits as they form, maintaining catalyst activity and enabling continuous olefin production without interruption for catalyst replacement or extensive regeneration.
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 uniform distribution of solid carbon in the catalyst layer prevents hot spots, reducing catalyst damage and extending the interval between replacements by ensuring consistent regeneration.
Implementation Method 1
a partial oxidation burner producing a high-temperature gas containing solid carbon
Implementation Method 2
supply nozzles connected to the partial oxidation burner, installed on a bottom of the vessel toward the falling catalyst and the catalyst layer, and spraying the high-temperature gas containing the solid carbon to the catalyst and the catalyst layer
Implementation Method 3
a first step of supplying a high-temperature gas containing solid carbon to a catalyst layer; and a second step of coking a catalyst of the catalyst layer by the high-temperature gas
Implementation Method 4
burning the solid carbon coked on the catalyst to regenerate the catalyst
Data Source
AI summary
A catalyst regenerator for regenerating a coked catalyst produced along with a olefin by mixing naphtha and a catalyst with each other to cause a naphtha cracking reaction, and falling from a cyclone which separates the coked catalyst and the olefin produced from the naphtha cracking reaction, includes: a vessel accommodating a catalyst layer formed by stacking the catalyst; a partial oxidation burner producing a high-temperature gas containing solid carbon; and supply nozzles connected to the partial oxidation burner, installed on a bottom of the vessel toward the falling catalyst and the catalyst layer, and spraying the high-temperature gas containing the solid carbon to the catalyst and the catalyst layer.