Dual Catalyst Coolers for Independent Riser Severity Control
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Solution Overview
Problem
Catalytic cracking units with two risers, one for gasoline production and another for propylene co-production, face challenges in simultaneously optimizing operating conditions due to differing severity requirements, leading to inefficient energy use and suboptimal yields.
Innovation Solution
A novel configuration with two independent catalyst cooling systems (cat coolers) allows for separate control of temperature and contact time conditions in each riser, optimizing gasoline production in the principal riser and propylene production in the secondary riser under moderate and high severity conditions respectively, while achieving energy savings by avoiding cooling of combustion air.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single catalyst cooling system is used for both risers, then device complexity is reduced, but the ability to independently optimize operating conditions for each riser is lost
Solution Approach 1:
The single catalyst cooling system is segmented into two independent cooling systems, one for each riser. This allows each riser to have its own dedicated cooling capacity, enabling independent optimization of temperature conditions for gasoline production (moderate severity) and propylene production (high severity) without compromising the other riser's performance.
Solution Approach 2:
Each riser is provided with tailored cooling conditions appropriate to its specific function. The principal riser for gasoline production receives cooling that maintains moderate severity conditions, while the secondary riser for propylene production receives cooling that enables high severity conditions, optimizing each location's performance for its intended purpose.
2Productivity
If separate cooling systems are used for each riser, then independent optimization of operating conditions is achieved, but device complexity and energy consumption increase
Solution Approach 1:
The cooling systems are designed to operate with adjustable parameters that can be independently controlled for each riser. This allows optimization of cooling intensity and timing to match the specific requirements of each riser's reaction conditions, maximizing yield while minimizing unnecessary energy consumption from excessive or mismatched cooling.
3Adaptability or versatility
If catalyst temperature is not independently controlled in each riser, then device complexity is reduced, but the ability to meet different severity requirements for gasoline and propylene production is compromised
Solution Approach 1:
The temperature control function is segmented by providing separate cooling systems for each riser, allowing each system to be optimized for its specific severity requirements without being constrained by the other riser's needs.
Solution Approach 2:
The cooling systems are designed with dynamic control capabilities that allow real-time adjustment of cooling intensity and catalyst temperature to match the varying severity requirements of different production modes, enabling flexible response to changing operational demands for each riser.
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 enables independent optimization of each riser, enhancing propylene and gasoline yields, with a notable 10% energy savings and improved catalyst regeneration conditions, demonstrating improved operational efficiency and productivity.
Implementation Method 1
a first catalyst cooler for cooling the catalyst supplied to the principal riser, and a second catalyst cooler for cooling the catalyst supplied to the secondary riser
Implementation Method 2
catalytic cracking of oil cuts, more particularly cuts termed heavy cuts
Implementation Method 3
The two risers are supplied with regenerated catalyst the temperature of which results from the combustion of coke
Data Source
AI summary
The invention concerns a process for the production of gasoline and for the co-production of propylene using a catalytic cracking unit comprising a catalyst regeneration zone and a reaction zone with two risers functioning in parallel under different severity conditions, the catalyst circulating between the regeneration zone and the reaction zone in two parallel circuits, a circuit termed the principal circuit comprising a first external catalyst cooling system, and a circuit termed the secondary circuit comprising a second external catalyst cooling system.