Chlorination Zone Baffles for Catalyst Regeneration
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Solution Overview
Problem
Existing catalyst regeneration processes face challenges in effectively redistributing platinum metal and replacing chloride compounds in reforming catalysts, particularly after coke combustion, which affects the catalyst's activity and requires additional reconditioning steps.
Innovation Solution
The system includes a chlorination zone with an outer and inner mixing chamber and a catalyst bed, utilizing air and chlorine nozzles to facilitate mixing and distribution of gases, ensuring efficient chlorination and drying of the catalyst, followed by a reducing step to restore the catalyst's activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional single-chamber chlorination is used, then the structure is simple, but the redistribution of platinum metal and replacement of chloride compounds is insufficient
Solution Approach 1:
The chlorination zone is divided into an outer mixing chamber and an inner mixing chamber, each performing specific functions. The outer chamber handles initial mixing of chlorine with catalyst, while the inner chamber provides secondary mixing and redistribution, thereby improving reconditioning effectiveness through staged processing.
Solution Approach 2:
A baffle structure is introduced as an intermediary element between the outer and inner mixing chambers. This baffle controls gas flow patterns and catalyst movement, facilitating efficient mass transfer and mixing while maintaining structural organization between the two chambers.
2Productivity
If intense burning is used to remove coke, then coke removal efficiency is high, but catalyst requires additional reconditioning to restore noble metal activity and chloride
Solution Approach 1:
The chlorination process is performed as a preliminary reconditioning step immediately following coke combustion. By introducing chlorine-containing compounds to the hot catalyst bed right after burning, the system preemptively restores chloride compounds and platinum metal distribution before the catalyst enters the drying and reducing zones, ensuring catalyst activity is maintained.
3Ease of operation
If multiple mixing chambers with baffles are used, then gas flow control and mixing efficiency are improved, but the device complexity increases
Solution Approach 1:
The baffle structure and dual-chamber configuration are designed to utilize the natural buoyancy and flow patterns of the gas streams. The chlorine-containing gas and drying air automatically mix and distribute through the catalyst bed without requiring external control mechanisms, allowing the structure to self-regulate gas flow and mixing efficiency.
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 configuration enhances the redistribution of platinum metal and replacement of chloride compounds, improving the catalyst's catalytic state and maintaining its effectiveness by controlling gas flow and mixing within the regeneration vessel.
Implementation Method 1
at least one air nozzle that injects a drying air stream into the outer mixing chamber
Implementation Method 2
at least one chlorine input nozzle that injects a chlorine input stream into the outer mixing chamber
Implementation Method 3
utilizing air and chlorine nozzles to facilitate mixing and distribution of gases
Implementation Method 4
finally a reducing step to change the platinum metal from various oxidized states to a reduced metallic condition
Implementation Method 5
contacts the coke containing catalyst at high temperature with an oxygen-containing gas to combustively remove the coke
Data Source
AI summary
Catalyst regeneration vessels including a chlorination zone that includes an outer mixing chamber, an inner mixing chamber, and a catalyst bed. The outer mixing chamber can include a lower portion and an upper portion, the lower portion of the outer mixing chamber including at least one air nozzle that injects a drying air stream into the outer mixing chamber, at least one chlorine input nozzle that injects a chlorine input stream into the outer mixing chamber, and at least a first baffle. The chlorination zone can also contain a second baffle that directs the mixed drying air stream and chlorine input stream from the outer mixing chamber to the inner mixing chamber.