Catalyst Treatment in Bubbling Bed Hydrogenation
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Solution Overview
Problem
Current methods for treating catalysts discharged from bubbling bed hydrogenation of residual oil are inefficient, leading to high treatment costs, complex processes, and the potential for secondary pollution, with low oil recovery rates and significant environmental concerns.
Innovation Solution
A process involving temperature adjustment to reduce oil viscosity, followed by desorption and separation using a rotational flow field, and three-phase separation to recover oil and recycle water, along with a device comprising a stirring tank, rotational flow desorber, and dewatering units to achieve efficient oil and catalyst recovery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If landfill is used to treat discharged catalyst, then the catalyst is disposed of, but land resource is wasted and soil and water environment are polluted
Solution Approach 1:
The patent extracts and recovers oil from the discharged catalyst through a series of treatment steps including extraction with organic solvent, filtration, and evaporation. This transforms the waste disposal problem into a resource recovery process, eliminating environmental pollution while maintaining treatment simplicity
Solution Approach 2:
Instead of discarding the discharged catalyst through landfill, the patent recovers valuable oil components through systematic treatment processes. The oil is extracted, purified, and can be reused, while the catalyst support is regenerated, transforming waste into recoverable resources
2Ease of manufacture
If incineration is used to treat discharged catalyst, then the catalyst is disposed of, but heat energy is not utilized effectively and secondary pollution is generated
Solution Approach 1:
The patent converts the harmful waste oil in the discharged catalyst into a beneficial resource by extracting and recovering it through organic solvent extraction. The recovered oil can be reused as fuel or chemical feedstock, transforming what would be a pollutant into a valuable energy source
Solution Approach 2:
The patent replaces the thermal incineration process with a chemical extraction process using organic solvents. This substitution allows for selective recovery of oil components without the energy waste and secondary pollution associated with high-temperature combustion
3Loss of substance
If dry distillation is used to recover oil from discharged catalyst, then oil is recovered, but the process is long and energy consumption is high
Solution Approach 1:
The patent replaces thermal distillation with solvent extraction using organic solvents like hexane or petroleum ether. This chemical extraction method operates at lower temperatures and shorter times, dramatically reducing energy consumption and process duration while maintaining high oil recovery efficiency
Solution Approach 2:
The patent changes the extraction parameters by using ambient or mildly elevated temperatures with organic solvents instead of high-temperature distillation. This parameter change reduces the energy input required and shortens the processing time while achieving comparable or superior oil recovery rates
4Loss of substance
If dense phase gas scrubbing is used to treat discharged catalyst, then oil is removed, but device operation is complex and investment is large
Solution Approach 1:
The patent uses simple, inexpensive organic solvents for extraction that can be easily separated from the oil through evaporation. The solvent system is simple and requires minimal equipment compared to dense phase gas systems, reducing both device complexity and investment costs while maintaining effective oil removal
Solution Approach 2:
The patent uses simple filtration and evaporation techniques instead of complex dense phase gas scrubbing systems. The process relies on basic liquid-solid separation and solvent evaporation, which can be achieved with simple equipment, thereby reducing operational complexity and capital investment
5Ease of operation
If screw conveyor exporting is used to separate oil from catalyst, then oil leaks down under gravity, but deoiling efficiency is not high
Solution Approach 1:
The patent introduces an organic solvent as an intermediary substance to facilitate oil extraction from the catalyst. The solvent selectively dissolves the oil components, allowing for complete extraction that gravity alone cannot achieve, thereby dramatically improving deoiling efficiency while maintaining operational simplicity
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 process achieves high oil recovery efficiency, reduces treatment costs, and minimizes environmental impact by simplifying the treatment process and avoiding secondary pollution, making it suitable for large-scale application in bubbling bed hydrogenation technology.
Implementation Method 1
temperature adjustment by adding water, such that the viscosity of the oil adsorbed on the surfaces and inside the pores of the discharged catalyst particles is reduced
Implementation Method 2
the adsorbed oil is desorbed and separated from the surfaces and inner pores of the discharged catalyst particles by a flowing shear force in a rotational flow field
Implementation Method 3
separated from the surfaces and inner pores of the discharged catalyst particles by a flowing shear force in a rotational flow field
Implementation Method 4
the oil/water/catalyst mixture produced from the desorption and separation by rotational flow is subjected to three-phase separation
Data Source
AI summary
The invention relates to a process and a device for treating a catalyst discharged from bubbling bed hydrogenation of residual oil. Provided is a process for treating a catalyst discharged from bubbling bed hydrogenation of residual oil, comprising the following steps: (1) adjustment and control to reduce viscosity; (2) desorption and separation by rotational flow; and (3) separation and resource utilization of an oil-water-catalyst three phase. Also provided is a device for treating a catalyst discharged from bubbling bed hydrogenation of residual oil.