Chemical Looping FCC Catalyst Regeneration for Syngas Production
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Solution Overview
Problem
The Fluid Catalytic Cracking (FCC) process generates significant CO2 emissions due to the combustion of catalyst coke, and there is a need to convert this coke into synthesis gas for downstream applications while reducing environmental impact.
Innovation Solution
A chemical looping process utilizing a system with a reducer/regenerator reactor, an oxidizer reactor, and a combustor reactor, where catalyst coke and metal oxide particles are processed to produce synthesis gas, hydrogen, and heat, with iron oxide as an oxygen carrier, converting coke into CO and H2 streams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If catalyst coke is combusted in the FCC regenerator to regenerate the catalyst, then the catalyst activity is restored, but CO2 emissions are generated
Solution Approach 1:
The patent converts the harmful CO2 emissions from coke combustion into beneficial synthesis gas (CO and H2) by using metal oxide particles as oxygen carriers in a chemical looping process. The metal oxide reduces with coke to produce CO and H2 instead of CO2, transforming the harmful combustion product into a useful fuel gas that can be used for power generation or chemical production.
Solution Approach 2:
The patent introduces metal oxide particles as an intermediary substance that mediates between the coke and the atmosphere. The metal oxide acts as an oxygen carrier that transfers oxygen to the coke in a controlled manner, enabling partial oxidation to produce synthesis gas rather than complete combustion to CO2. This intermediary allows the process to avoid direct CO2 emissions while still regenerating the catalyst.
2Object-generated harmful factors
If catalyst coke is converted into synthesis gas instead of combusted, then CO2 emissions are reduced, but the process complexity increases
Solution Approach 1:
The patent merges the coke combustion process with the catalyst regeneration process into a single integrated chemical looping system. The metal oxide particles serve dual purposes: they act as oxygen carriers to convert coke to synthesis gas while also facilitating catalyst regeneration. This merging of functions reduces the need for separate processes and minimizes overall system complexity despite the advanced chemistry involved.
3Productivity
If metal oxide particles are used to convert coke to synthesis gas, then synthesis gas production is achieved, but additional reactor equipment is required
Solution Approach 1:
The patent designs the chemical looping system with reactors that perform multiple functions. The metal oxide particles circulate through different zones (reduction zone, oxidation zone, combustion zone) where they perform different functions sequentially. This multi-functionality allows a single reactor system to produce synthesis gas, regenerate catalyst, and generate heat, reducing the need for multiple separate pieces of equipment.
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 process effectively reduces CO2 emissions by converting catalyst coke into high-concentration synthesis gas, which can be used in applications like alcohol production and hydrogen generation, while recovering heat as a valuable byproduct.
Implementation Method 1
The reduction of the metal oxide particles with a carbon-based fuel typically generates streams of carbon monoxide, hydrogen, carbon dioxide, water vapor and reduced metal oxide particles
Implementation Method 2
The reduced metal oxide particles are usually then oxidized with air to produce heat and/or oxidized with steam to produce hydrogen
Implementation Method 3
The reduced metal oxide particles are usually then oxidized with air to produce heat and/or oxidized with steam to produce hydrogen
Data Source
AI summary
Provided is a process capable of converting the cokes on spent catalysts in a fluid catalytic cracking (FCC) process into synthesis gas. The produced synthesis gas contains high concentrations of CO and H2 and may be utilized in many downstream applications such as syngas fermentation for alcohol production, hydrogen production and synthesis of chemical intermediates. A reducer/regenerator reactor for a fluid catalytic process comprising a chemical looping system to produce synthesis gas is also described.