Entrained-flow reactor compensation gas supply for FCC catalyst testing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for examining Fluid Catalytic Cracking (FCC) catalysts and processes lack efficiency in simulating large-scale process conditions, particularly in terms of controlling process parameters and achieving accurate data with reduced catalyst usage and operational time.
Innovation Solution
A device comprising a hopper, a flight current reactor, and a separator, connected by a compensation gas supply system, which allows for real-time adjustment of gas flows and pressures to maintain constant partial pressures of feed components, thereby simulating large-scale FCC system conditions with reduced catalyst and time requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If existing laboratory and pilot plant scale apparatuses are used to test FCC catalysts, then catalyst testing can be performed, but the simulation of large-scale process conditions is inefficient and requires excessive catalyst usage and time
Solution Approach 1:
The patent applies parameter changes by precisely controlling flow rates, pressures, and temperatures in the entrained-flow reactor to match large-scale FCC process conditions. The differential flow regulator dynamically adjusts gas flow parameters, while the backpressure regulator maintains constant pressure conditions, enabling accurate simulation of industrial-scale cracking processes in a laboratory setting with reduced time and catalyst requirements
2Measurement precision
If existing testing apparatuses are used, then catalyst evaluation can be conducted, but process parameter control is insufficient and data accuracy is compromised
Solution Approach 1:
The patent implements feedback control through the differential flow regulator that continuously monitors and adjusts gas flow rates based on pressure differentials, and the backpressure regulator that maintains constant pressure conditions. These feedback mechanisms dynamically compensate for fluctuations in feed composition and flow rates, ensuring stable and accurate process parameters throughout the catalyst testing process
Solution Approach 2:
The patent uses an intermediary compensation gas stream that is mixed with the main reactant gas flow. This compensation gas, regulated by the differential flow regulator, serves as a mediator to stabilize the total gas flow rate and partial pressures of reactants, thereby improving data accuracy without requiring overly complex direct control of all process parameters
3Productivity
If traditional FCC testing methods are used, then catalyst performance can be assessed, but CO2 emissions are high and operational costs are excessive
Solution Approach 1:
The patent creates a scaled-down copy of the large-scale FCC process using an entrained-flow reactor that replicates the essential hydrodynamic and chemical conditions. By copying the key process parameters (high gas velocity, short residence time, temperature profile) in a laboratory-scale device, the system achieves accurate catalyst evaluation with minimal catalyst and feed consumption, thereby reducing CO2 emissions and operational costs while maintaining high productivity in process development
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 solution enables improved accuracy and efficiency in simulating large-scale FCC process conditions, reducing CO2 emissions, and saving time and costs in process development, while allowing for more precise control of process parameters and reduced catalyst usage.
Implementation Method 1
the connection 9 from the hopper 11 to the entrained-flow reactor 13 comprises a compensation gas feed 21 with a differential flow regulator 25, which is coupled to the measuring and control device of the device in such a way that the flow rates of the supplied and discharged gas streams can be detected by the measuring and control device and compensated by the compensation gas supply 21
Implementation Method 2
downstream of the entrained-flow reactor 13 there is arranged a separator 17 for separating the particulate material from a reaction product containing condensable vapors
Implementation Method 3
Due to the process conditions, a high gas flow velocity is formed, which transports the mixture of catalyst and feed upstream through the riser reactor within a few seconds
Implementation Method 4
The cracking reactions taking place in the reactor are endothermic, so the temperature at the inlet of the riser reactor is 100 to 200 K higher than the temperature at the outlet
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention relates to an apparatus for investigating chemical processes, wherein the apparatus comprises a hopper 11, an entrained-flow reactor 13, a reactant feed 19, and a measuring and control device. The chemical processes relate to the investigation of FCC or other fluid catalysts or related processes. The hopper 11 and the entrained-flow reactor 13 are connected by a connection 9.Particulate material coming from the hopper 11 is transferred through the entrained flow reactor 13 together with a reactant stream into a separator 17, where the particulate material is separated from a reaction product, the device being characterized in that the connection 9 from hopper 11 to the entrained flow reactor 13 comprises a compensation gas supply 21 with a differential flow controller 25, which is coupled to the measuring and control device of the device in such a way that the flow rates of the supplied and discharged gas streams can be detected by the measuring and control device and balanced by the compensation gas supply 21.