FCC Reactor Contacting Insert for Uniform Feed Mixing
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Solution Overview
Problem
Existing methods for dispersing hydrocarbon feed in fluidized catalyst beds in FCC processes result in non-uniform contact between feed and catalyst, leading to thermal cracking and reduced reaction product quality due to quiescent zones and nozzle erosion.
Innovation Solution
A contacting device is positioned upstream of the feed injectors in the reactor, diverting catalyst flow to enhance uniform dispersal and protect injectors from erosion, using a refractory material with a metal structure for durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If angled feed nozzles protrude into the reactor to inject feed towards the centre, then feed dispersal is improved, but nozzle erosion from high velocity catalyst particles worsens
Solution Approach 1:
A refractory insert is introduced as an intermediary component between the feed nozzles and the catalyst particle flow. The insert protrudes into the reactor upstream of the nozzles, serving as a protective barrier that deflects high-velocity catalyst particles away from the nozzle tips, thereby reducing erosion while maintaining the nozzles' protruding position for effective feed dispersal
Solution Approach 2:
The refractory insert is positioned upstream of the feed injection zone to preemptively deflect catalyst particles before they reach the nozzles. This preliminary protective action prevents erosion before it occurs, allowing the nozzles to maintain their optimal protruding position for feed injection
2Duration of action of stationary object
If feed nozzles are recessed completely into the wall to protect from erosion, then nozzle durability is improved, but feed injection coverage and dispersal effectiveness worsen
Solution Approach 1:
The refractory insert acts as a mediator that allows the nozzles to maintain their protruding position for effective feed injection while providing protective function. The insert absorbs the erosive impact, serving as a sacrificial protective element between the catalyst flow and the nozzles
3Object-affected harmful factors
If quiescent zones form around protruding nozzles, then nozzle protection from erosion is improved, but feed-catalyst contact uniformity worsens
Solution Approach 1:
The refractory insert is strategically positioned upstream of the nozzles rather than around them, creating a flow deflection pattern that protects nozzles from direct particle impact while minimizing disruption to the catalyst flow in the injection zone. This positioning reduces quiescent zone formation while maintaining nozzle protection
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
Improves the rapid and uniform distribution of hydrocarbon feed across the reactor cross-section, enhancing reaction efficiency and reducing thermal cracking while minimizing nozzle damage.
Implementation Method 1
a gaseous medium upwardly transports the catalyst in a fluidized state
Implementation Method 2
diverting catalyst flow to enhance uniform dispersal
Implementation Method 3
using a refractory material with a metal structure for durability
Data Source
AI summary
The present invention provides a catalytic cracking reactor comprising a conduit, configured to allow the passage of a flow of catalyst particles, and an injection zone comprising a ring of feed injectors extending inwardly from the wall of reactor and angled to inject feed into the flow of catalyst particles, characterised in that the reactor also comprises a contacting device protruding into the reactor from the inner wall of said reactor upstream of the injection zone.