High-Density Carrier Gas for Catalyst Transport
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Solution Overview
Problem
Existing catalyst conveying systems in continuous catalytic reforming and dehydrogenation processes face issues with particle deposition, erosion, and attrition due to the geometry of pipes, leading to operational challenges and maintenance needs.
Innovation Solution
Using a carrier gas with a density greater than or equal to 1 kg/m3, preferably 1.2 kg/m3 or higher, achieved by modifying the chemical composition, temperature, or pressure, to reduce risks of particle deposition and erosion, and maintain catalytic efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a carrier gas with low density (hydrogen) is used to transport catalyst particles, then the transport process is simple and energy-efficient, but particle deposition, erosion, and attrition occur due to pipe geometry
Solution Approach 1:
The patent applies parameter changes by modifying the density of the carrier gas from low density (hydrogen) to high density (supercritical carbon dioxide or other dense gases). This fundamental parameter change transforms the transport mechanism, allowing particles to be conveyed without deposition or erosion issues that plague low-density gas systems, while maintaining transport efficiency through the unique properties of dense gases.
Solution Approach 2:
The patent transitions from conventional pneumatic transport using low-density gases to a hybrid system utilizing high-density supercritical fluids that exhibit properties between gases and liquids. This allows for controlled particle suspension and transport through pipe networks while eliminating the harmful effects of particle deposition and erosion associated with traditional pneumatic systems.
2Ease of repair
If the carrier gas density is increased to reduce particle deposition, then maintenance requirements decrease, but the system complexity increases due to need for pressure and temperature control
Solution Approach 1:
The patent utilizes parameter changes by operating the carrier gas in a supercritical state, where small changes in pressure and temperature maintain the desired high density without requiring complex control systems. The supercritical region provides a broad operating window where the fluid maintains its beneficial properties with minimal intervention.
Solution Approach 2:
The system leverages the self-regulating properties of supercritical fluids, where the density and transport characteristics automatically adjust to operating conditions without requiring active control mechanisms. The high-density carrier gas naturally prevents particle deposition through its physical properties, reducing the need for maintenance and intervention.
3Reliability
If conventional low-density carrier gas is used, then the system is simpler to operate, but catalytic efficiency decreases due to particle attrition and size variation
Solution Approach 1:
The patent changes the operational parameters by using high-density supercritical carrier gases, which fundamentally alter the particle transport mechanism. This eliminates particle attrition and size variation that occur in low-density systems, thereby maintaining consistent catalytic efficiency throughout operation without requiring complex operational procedures.
Solution Approach 2:
The patent employs a dense gas transport system that combines the advantages of pneumatic flexibility with hydraulic-like particle suspension capabilities. This allows for smooth, controlled particle movement through the reactor system without the violent turbulence and particle damage associated with conventional pneumatic transport, maintaining both operational simplicity and catalytic 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
The increased density of the carrier gas significantly reduces particle deposition and erosion, minimizing maintenance requirements and ensuring consistent catalytic performance by maintaining controlled particle size characteristics.
Implementation Method 1
the catalyst circulating as a moving bed successively in a plurality of reaction zones flowing from the upstream end to the downstream end of each of the reaction zones and being transported by a carrier gas phase from the downstream end of one reaction zone to the upstream end of the next reaction zone
Data Source
AI summary
The invention relates to a process for the catalytic treatment of a hydrocarbon feedstock with continuous catalytic regeneration, in which process said feedstock is successively circulated in a plurality of reaction zones in series (R1, R2, R3, R4), the catalyst circulating as a moving bed successively in the plurality of reaction zones and flowing from the upstream end to the downstream end of each of the reaction zones and being transported by a carrier gas phase g1 from the downstream end of one reaction zone to the upstream end of the next reaction zone, characterized in that said carrier gas phase g1 has a density of greater than or equal to 1 kg/m3.