Catalyst Settler for FCC Regenerator Gas Separation
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Solution Overview
Problem
Conventional fluid catalytic cracking (FCC) units face challenges in separating regenerated catalyst from entrained gases, leading to increased material burden and corrosion in reactor vessels due to the presence of inert and corrosive gases like nitrogen, carbon monoxide, and carbon dioxide.
Innovation Solution
Incorporating a catalyst settler within the regeneration vessel, physically separated from the catalyst bed, which separates entrained gases from the regenerated catalyst through mechanical agitation with baffles and/or packing, and/or contact with an injected inert gas, before the catalyst is transferred to another vessel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional processing feeds regenerated catalyst with entrained gases to the reactor vessel, then the catalyst is readily transferred, but the reactor vessel processes increased amounts of material and suffers corrosion from corrosive gases
Solution Approach 1:
The patent extracts and removes entrained gases (including corrosive gases like CO2, CO, and inert gases like nitrogen) from the regenerated catalyst stream before the catalyst enters the reactor vessel. This is achieved through a gas-catalyst separation section that physically separates the gas phase from the catalyst particles, thereby eliminating the harmful effects of these gases on the reactor while maintaining easy catalyst transfer.
Solution Approach 2:
The patent introduces an intermediary separation section between the regenerator and reactor vessel. This intermediary component (the gas-catalyst separation section) acts as a mediator that processes the catalyst-gas mixture, removing harmful gases before the catalyst reaches the reactor, thus protecting the reactor from corrosion and excess material burden while maintaining operational simplicity.
2Object-affected harmful factors
If a catalyst settler is added to separate entrained gases from regenerated catalyst, then corrosion and material burden are reduced, but the device complexity increases
Solution Approach 1:
The patent merges the gas-catalyst separation function directly into the existing regenerator structure. The gas-catalyst separation section is integrated with the regenerator vessel, combining multiple functions (regeneration and gas-catalyst separation) into a single unified apparatus. This integration reduces overall device complexity while achieving the benefit of removing corrosive gases and reducing material burden on the reactor.
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 solution effectively reduces the material burden on gas concentration units and minimizes corrosion and wear on reactor equipment by removing corrosive gases from the regenerated catalyst before it is fed to the reactor vessel, enhancing operational reliability and reducing the need for amine in sulfur removal processes.
Implementation Method 1
a catalyst settler located in the regeneration vessel and configured to separate entrained gas from the regenerated catalyst
Implementation Method 2
the carbonized catalyst is introduced into a fluidized bed at the base of the regenerator, and oxygen-containing combustion air is passed upwardly through the bed
Implementation Method 3
Regeneration occurs by oxidation of the carbonaceous deposits to carbon oxides and water
Data Source
AI summary
Apparatuses and methods for separating regenerated catalyst are provided. In one embodiment, an apparatus for separating regenerated catalyst includes a regeneration vessel including a catalyst bed section. The apparatus includes a catalyst settler physically separated from the catalyst bed section by a wall extending within the regeneration vessel. The catalyst overflowing the catalyst bed section flows over the wall and enters the catalyst settler. The apparatus further includes a pipe in fluid communication with the catalyst settler and configured to deliver regenerated catalyst from the regeneration vessel to another vessel.