Off-site Catalyst Sulfurization Helical Reactor

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Solution Overview

Problem

Existing methods for sulfurization or presulfurization of catalysts and adsorbents are often limited by the need for on-site processes that require specific operating conditions, which can be difficult to maintain, and result in inadequate sulfur distribution and heat management, leading to inefficiencies and potential reactor damage.

Innovation Solution

An off-site process using a vibrating, tubular helical reactor where particles rise or fall through a temperature profile in the presence of hydrogen sulfide, allowing for efficient sulfur incorporation and heat management, reducing the risk of reactor damage and improving catalyst readiness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If on-site sulfurization is performed under specific operating conditions, then catalyst activation is achieved, but the process requires difficult-to-maintain operating conditions and results in inadequate sulfur distribution

Engineering Contradiction:

Improvecatalyst activationVSAvoidoperating conditions maintenance

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The sulfurization process is performed off-site before catalyst installation, preparing the catalyst in advance under optimized conditions. This preliminary action allows thorough sulfur distribution without the constraints of on-site operating conditions, resolving the contradiction between achieving reliable catalyst activation and maintaining ease of operation.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If on-site sulfurization is performed, then catalyst is activated in place, but heat management becomes problematic leading to potential reactor damage

Engineering Contradiction:

Improvecatalyst readinessVSAvoidreactor damage risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The sulfurization process is extracted from the reactor and performed in a separate off-site facility. This removal eliminates the heat management problems associated with on-site sulfurization, as the exothermic reaction can be controlled in a dedicated sulfurization reactor without risking damage to the hydrocarbon conversion reactor.

Inventive Principle:

Principle #2Taking out (Extraction)

3Manufacturing precision

If off-site sulfurization is performed in a vibrating helical reactor, then homogeneous sulfur distribution is achieved, but the process requires specialized equipment

Engineering Contradiction:

Improvesulfur distribution uniformityVSAvoidreactor structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The helical reactor incorporates vibration mechanisms that agitate the catalyst particles during sulfurization, ensuring homogeneous sulfur distribution throughout the catalyst bed. The vibration prevents channeling and promotes uniform contact between sulfurizing agents and catalyst, achieving high manufacturing precision despite the specialized equipment required.

Inventive Principle:

Principle #18Mechanical vibration

Solution Approach 2:

The helical (curved) geometry of the reactor provides continuous tumbling and mixing of catalyst particles as they move through the sulfurizing agent. This curved path design naturally promotes homogeneous sulfur distribution without requiring complex internal mixing mechanisms, balancing manufacturing precision with relatively simple equipment.

Inventive Principle:

Principle #14Spheroidality (Curvature)

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 enables efficient sulfurization of catalysts and adsorbents, ensuring they are ready for use with optimal catalytic or adsorption properties, simplifying start-up processes and reducing the risk of reactor issues, while allowing for precise temperature control and homogeneous sulfur distribution.

Implementation Method 1

the exothermicity of the reaction makes it possible to heat the particles substantially

Methodology Applied

Scientific EffectExothermic reaction: Exothermic Reaction

Implementation Method 2

said particles are subjected to a temperature profile over the majority of their path in said coil

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

at the end of the path, the particles are cooled by a coolant

Methodology Applied

Scientific EffectHeat exchange: Heat Exchanger

Data Source

PatentUS8088705B2Process for sulfurization or presulfurization of solid particles of a catalyst or an adsorbent

Publication Date: 2012.01.03 EURECAT SA

AI summary

The invention relates to a process for incorporating sulfur in the porosity of the solid particles of a catalyst for the conversion of hydrocarbons or an adsorbent. This process is carried out off-site in the presence of hydrogen sulfide that is pure or diluted in hydrogen or nitrogen, a process in which said particles are made to rise or fall in a sulfur incorporation zone that comprises at least one vibratory helical coil that is essentially tubular in shape and that comprises at least two turns, whereby said particles are subjected to a temperature profile over the majority of their path in said coil and whereby said particles are brought into contact with at least one fluid on at least one portion of their path.