FCC Reactor Cyclone Clusters for Compact Vessel Design
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Solution Overview
Problem
Large fluid catalytic cracking (FCC) reactors face inefficiencies due to excessive unused space within the reactor vessel caused by symmetrical cyclone layouts, leading to increased vessel diameters and wasted space, particularly in larger units.
Innovation Solution
The arrangement of cyclones in clusters with shared outlet piping and cross-over ducts allows for a more efficient packing of cyclones within the reactor vessel, reducing the vessel diameter by positioning cyclones at different radii and using various piping configurations to maintain even flow and minimize wasted space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If cyclones are arranged in a symmetrical layout on the same radius, then even flow distribution to all cyclones is achieved, but excessive unused space is created in large reactor units
Solution Approach 1:
The patent applies asymmetry by transitioning from a traditional symmetrical cyclone layout (all cyclones on the same radius) to an asymmetrical clustered arrangement. Cyclones are grouped in clusters of 3-5 units positioned at different radii within the reactor vessel, with each cluster served by a common primary outlet pipe. This asymmetrical configuration eliminates excessive unused space in large reactor units while maintaining operational effectiveness through the clustered organization that ensures proper flow distribution to each cyclone.
2Area of stationary object
If more cyclones are packed into the reactor vessel to reduce unused space, then space utilization improves, but flow distribution to individual cyclones becomes uneven
Solution Approach 1:
The patent applies segmentation by dividing the reactor vessel into multiple clusters, with each cluster containing 3-5 cyclones served by a dedicated primary outlet pipe. This segmentation allows for efficient space utilization by packing multiple clusters throughout the vessel volume while maintaining even flow distribution within each cluster. The cross-over ducts further segment and distribute flow appropriately to individual cyclones within their respective clusters, preventing flow imbalance even as cyclone density increases.
3Ease of manufacture
If a symmetrical cyclone layout is used, then the design and installation is simplified, but the vessel diameter increases leading to larger equipment footprint
Solution Approach 1:
The patent applies dimensional change by transitioning from a two-dimensional symmetrical arrangement (cyclones on a single circular radius) to a three-dimensional clustered configuration. Cyclone clusters are positioned at multiple radii and vertical levels within the reactor vessel, utilizing the third dimension (vertical space) to accommodate more cyclones without increasing the vessel diameter. This spatial reorganization reduces the equipment footprint while maintaining design and installation feasibility through modular cluster units.
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 a reduction in reactor vessel diameter by up to 15% while maintaining the same number of cyclones, resulting in a more compact and efficient use of space within the reactor vessel, applicable to both FCC and other types of reactors.
Implementation Method 1
separating the cracked product vapors from the spent catalyst by running the vapor through one or more catalyst separation devices, such as cyclones
Implementation Method 2
separate the catalyst particles from the hydrocarbon vapors through centrifugal force generated by rotating flow
Data Source
AI summary
A fluid catalytic cracking reactor including a vessel, a chamber housed within the vessel, and a plurality of cyclones housed within the vessel, but externally of the chamber. The plurality of cyclones are arranged in a plurality of cyclone clusters, where each of the cyclone clusters includes a grouping of at least two cyclones that share common outlet piping for communication with the chamber. Alternatively, a fluid catalytic cracking reactor including a vessel, a chamber housed within the vessel, and a plurality of catalytic separation devices housed within the vessel, but externally of the chamber. The catalytic separation devices are in communication with the chamber via outlet piping. Preferably, the catalytic separation devices of the reactor are also in communication with a plenum via separator gas outlet piping, and optionally at least one of the catalytic separation devices feeds an outlet vapor stream into at least two different separator gas outlet piping members.