Counter-Current Reactor for Light Olefin Yield
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for producing light olefins, such as thermal cracking and fluid catalytic cracking, are inefficient and result in reduced yields due to undesirable flow patterns and back-mixing, leading to a need for improved catalyst formulations and reactor designs that enhance conversion and production of light olefins.
Innovation Solution
A method involving a counter-current reactor system using multi-zeolite composite catalysts, where the catalyst and hydrocarbon feed stream move in opposite directions, allowing for increased contact and conversion, and the catalyst formulation includes a mixture of 10-member and 12-member ring zeolites with specific binders, fillers, and additives to enhance cracking efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If thermal cracking or fluid catalytic cracking is used to produce light olefins, then light olefins can be produced, but the yield is reduced due to back-mixing and undesirable flow patterns
Solution Approach 1:
The patent inverts the conventional co-current flow arrangement by implementing a counter-current flow system where catalyst moves downward and hydrocarbon feed moves upward through the reactor. This inversion eliminates back-mixing and core-annular flow patterns, improving light olefin yield by optimizing contact patterns between catalyst and feedstock
Solution Approach 2:
The patent employs dynamic flow control by maintaining a controlled downward movement of catalyst particles while hydrocarbon feed moves upward, creating a dynamic counter-current contact system. This dynamic arrangement prevents stagnant zones and undesirable flow patterns, enhancing conversion efficiency and light olefin production
2Productivity
If conventional single-zeolite catalysts are used, then the catalyst structure is simple, but cracking efficiency is reduced
Solution Approach 1:
The patent utilizes composite catalyst formulations combining multiple zeolite types (10-member ring and 12-member ring zeolites) with different pore structures and catalytic properties. This composite approach leverages the complementary strengths of each zeolite type to enhance overall cracking efficiency and light olefin yield, overcoming the limitations of single-zeolite catalysts
Solution Approach 2:
The patent applies local quality by incorporating different zeolite components with specific pore sizes and acid sites at different locations within the catalyst particle structure. The 10-member ring zeolites provide specific cracking functions while 12-member ring zeolites provide other catalytic functions, creating localized functional zones that collectively improve cracking 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 approach increases the yield of light olefins by preventing back-mixing and core-annular flow, allowing more reactive components to crack effectively, resulting in higher conversion rates and improved product distribution.
Implementation Method 1
Contacting the catalyst with the hydrocarbon feed stream may crack one or more components of the hydrocarbon feed stream and form a hydrocarbon product stream
Data Source
AI summary
Light olefins may be produced from hydrocarbons by a method including passing a hydrocarbon feed stream into one or more feed inlets of a reactor, using catalyst formulations or mixtures. Catalyst formulations may include multi-zeolite composite particles, or a mixture that is a physically mixed combination of separate particles of at least first composite particles of a first type of zeolite and second composite particles of a second type of zeolite. The reactor may include an upper reactor portion defining an upper reaction zone and a lower reactor portion defining a lower reaction zone. The catalyst may move in a generally downward direction through the upper reactor portion and the lower reactor portion, and the hydrocarbon feed stream may move in a generally upward direction through the lower reactor portion and upper reactor portion such that the hydrocarbon feed stream and the catalyst move with a counter-current orientation.