FCC Catalyst Regeneration Using Biomass Charcoal Fuel

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Solution Overview

Problem

Existing catalytic cracking catalyst regeneration methods fail to fundamentally reduce carbon dioxide emissions from fossil energy sources, leading to high carbon footprints and inefficient energy utilization, while existing carbon dioxide recovery methods are costly and complex.

Innovation Solution

Introduce biomass-derived charcoal fuel into the catalyst regeneration system for combustion, using oxygen-containing gases to maintain thermal balance and reduce carbon dioxide emissions from fossil energy sources.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-generated harmful factors

If fossil fuel-based regeneration methods are used, then energy supply for cracking unit is sufficient, but carbon dioxide emissions from fossil energy sources increase

Engineering Contradiction:

Improvecarbon dioxide emissions from fossil energyVSAvoidenergy supply for cracking unit

Core Design Contradiction:

Object-generated harmful factorsVSUse of energy by moving object

Solution Approach 1:

The invention changes the fuel source parameter from fossil-based to biomass-based. By using biomass charcoal instead of fossil fuel, the carbon cycle changes from depleting underground reserves to utilizing atmospheric carbon through plant growth, thereby reducing net carbon dioxide emissions while maintaining energy supply for the cracking unit

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention uses biomass charcoal, a renewable and relatively inexpensive fuel source, to replace expensive and environmentally harmful fossil fuels. The biomass can be sourced from agricultural waste, forestry residues, or dedicated energy crops, making it both economically viable and environmentally friendly

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Object-generated harmful factors

If carbon dioxide recovery and separation processes are implemented, then carbon emissions are reduced, but process complexity and cost increase

Engineering Contradiction:

Improvecarbon dioxide emissionsVSAvoidseparation process complexity

Core Design Contradiction:

Object-generated harmful factorsVSDevice complexity

Solution Approach 1:

The invention converts the harmful effect of carbon dioxide emissions into a beneficial outcome by using biomass as the fuel source. The carbon dioxide released during biomass combustion is part of the natural carbon cycle, having been recently absorbed from the atmosphere by growing plants, thus transforming a harmful emission into a neutral or even beneficial circular process

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The biomass fuel source essentially pays for its own combustion through photosynthesis during plant growth, absorbing carbon dioxide from the atmosphere. This self-service mechanism eliminates the need for complex and expensive external carbon capture and storage infrastructure

Inventive Principle:

Principle #25Self-service

3Use of energy by moving object

If fuel oil injection is used to increase regeneration temperature, then energy balance is improved, but carbon dioxide emissions from fossil energy increase

Engineering Contradiction:

Improveenergy balance of cracking unitVSAvoidcarbon dioxide emissions from fossil energy

Core Design Contradiction:

Use of energy by moving objectVSObject-generated harmful factors

Solution Approach 1:

The invention changes the thermal energy source parameter from fossil fuel combustion to biomass combustion. This parameter change maintains the necessary high temperatures for catalyst regeneration and cracking reactions while fundamentally altering the carbon emission profile from unsustainable fossil sources to renewable biomass sources

Inventive Principle:

Principle #35Parameter changes

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

Biomass charcoal provides a renewable energy source, reducing carbon dioxide emissions, improving energy efficiency, and enabling carbon-neutral operation by capturing and utilizing carbon dioxide, while simplifying the regeneration process.

Implementation Method 1

contacting the catalyst to be regenerated with the biomass charcoal and oxygen-containing gas in the catalyst regenerator for coke-burning regeneration

Methodology Applied

Scientific EffectCombustion: Combustion

Implementation Method 2

contacting the catalyst to be regenerated with the biomass charcoal and oxygen-containing gas in the catalyst regenerator for coke-burning regeneration

Methodology Applied

Scientific EffectOxidation: Oxidation

Data Source

PatentUS20250352993A1Method and system for regenerating a catalytic cracking catalyst using a biomass charcoal fuel

Publication Date: 2025.11.20 CHINA PETROLEUM & CHEMICAL CORP

AI summary

A catalyst regeneration method is suitable for a fluidized catalytic cracking unit has a catalytic cracking reactor and a catalyst regenerator. The regeneration method has the following steps: 1) providing a biomass-derived biomass charcoal; 2) feeding the biomass charcoal and the catalyst to be regenerated from the catalytic cracking reactor into the catalyst regenerator together or separately; 3) introducing an oxygen-containing gas into the catalyst regenerator, wherein the oxygen content of the oxygen-containing gas is 14-28% by volume; and 4) contacting the catalyst to be regenerated with the biomass charcoal and oxygen-containing gas in the catalyst regenerator for coke-burning regeneration. The method can significantly reduce carbon emissions from the catalytic cracking unit, realize the recycling of carbon elements, and provide energy for other process units.