FCC Regenerator Plastic Combustion for Temperature Control
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Solution Overview
Problem
Fluid catalytic cracking (FCC) units face challenges in optimizing regenerator temperature and reducing delta coke, leading to constraints on refinery profitability due to limitations in incorporating alternative feedstocks, which are often contaminated with sulfur and other impurities.
Innovation Solution
Introducing recycled plastic as an additive to the FCC regenerator, which is combusted with coke to increase temperature and regenerate the catalyst, thereby optimizing hydrocarbon processing while reducing energy consumption and plastic waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If severe hydroprocessing of FCC feedstock is used to meet gasoline sulfur specifications, then sulfur compliance is improved, but regenerator temperature decreases and delta coke formation increases
Solution Approach 1:
The patent introduces plastic waste as a fuel source in the regenerator, converting a harmful waste product into a beneficial energy source. The plastic combusts with the coke on the catalyst to generate heat, raising regenerator temperature while simultaneously addressing waste disposal issues and maintaining sulfur compliance through the hydroprocessed feedstock.
2Productivity
If alternative feedstocks are incorporated to optimize refinery operations, then productivity is improved, but contamination with sulfur and other impurities increases
Solution Approach 1:
The patent uses plastic waste as an intermediary fuel source that bridges the gap between alternative feedstock incorporation and contaminant control. By combusting plastic in the regenerator, the system can utilize alternative feedstocks for productivity enhancement while the plastic combustion provides the energy needed to maintain operation quality despite sulfur constraints.
3Temperature
If traditional refinery streams are used to ameliorate low regenerator temperature, then temperature is improved, but sulfur and contaminant content increases
Solution Approach 1:
The patent changes the fuel parameter from traditional high-sulfur refinery streams to plastic waste. This parameter change allows temperature amelioration without the sulfur and contaminant penalties associated with traditional refinery streams, as plastic waste combustion provides heat while the system maintains sulfur control through the hydroprocessed feedstock configuration.
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 introduction of plastic allows for controlled temperature increases in the regenerator, maintaining sulfur specifications of FCC products and enhancing refinery profitability by debottlenecking FCC constraints and reducing waste disposal issues.
Implementation Method 1
Oxygen and/or air and plastic may be introduced into the regenerator to facilitate the combustion of the plastic and coke from the coked FCC catalyst
Implementation Method 2
The plastic and coke are oxidized by the oxygen (and/or, in some embodiments, oxygen in supplied air), and the catalyst is thus regenerated
Implementation Method 3
A catalytic FCC unit has two main components—a reactor and a regenerator
Data Source
AI summary
Systems and methods are disclosed for enhancing the processing of hydrocarbons in a FCC unit by introduction of fluidized plastic at one or more locations of the FCC unit. In an embodiment, the method may include passing a coked FCC catalyst from a cyclone of the FCC unit to a regenerator. The method may include introducing at least oxygen and a fluidized plastic into the regenerator. The method may include combusting a combination of the fluidized plastic and a coke from the coked FCC catalyst in the regenerator, thereby to oxidize via the oxygen and produce a regenerated FCC catalyst and a flue gas. The method may include supplying the regenerated FCC catalyst from the regenerator to a riser of the FCC unit to crack the gas oil supplied to the riser of the FCC unit.