Fluid Distribution Device Radial Arms for FCC
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional mushroom-style fluid distribution devices in the fluid catalytic cracking process suffer from limited cross-sectional coverage, leading to inconsistent gas and catalyst distribution, which results in poor yields, temperature variations, and reduced operating flexibility due to mal-distribution and channeling issues.
Innovation Solution
The introduction of distribution arms extending radially from the mushroom cap, providing additional holes and increasing the surface area for gas and catalyst distribution, promotes uniform mixing and reduces the likelihood of gas channeling by enhancing cross-sectional coverage and bubble formation, thereby improving the interaction between vapors and the fluidized catalyst bed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If traditional mushroom cap distributors with discrete holes and weir notches are used, then gas and catalyst distribution is provided, but cross-sectional coverage is limited leading to mal-distribution and channeling
Solution Approach 1:
The distributor cap is segmented into multiple functional zones: a central region with first holes for gas-catalyst mixture distribution, and a peripheral region with second holes for additional distribution coverage. This segmentation allows each zone to contribute differently to overall distribution, expanding cross-sectional coverage while maintaining uniformity and preventing channeling.
Solution Approach 2:
The invention transitions from a single-plane distribution approach to a multi-dimensional strategy by positioning holes at different radial distances from the center. The first holes are arranged in a central pattern while second holes are arranged in a peripheral pattern, creating a two-zone radial distribution system that covers the entire cross-section more effectively and eliminates dead zones that cause mal-distribution.
2Reliability
If the number of holes on the mushroom cap is increased to improve distribution, then gas solid contacting is enhanced, but device complexity increases
Solution Approach 1:
Different regions of the distributor cap are assigned different hole characteristics. The central region contains first holes with specific spacing and size optimized for core gas-catalyst mixture distribution, while the peripheral region contains second holes optimized for edge coverage. This local differentiation allows each zone to perform its specific function effectively without requiring uniform complexity across the entire structure.
Solution Approach 2:
The distributor cap is designed to perform multiple functions simultaneously: the central holes handle primary gas-catalyst distribution while the peripheral holes provide secondary distribution and edge coverage. This multi-functionality allows a single distributor structure to achieve comprehensive coverage without requiring multiple separate components, thereby reducing overall device complexity while maintaining high gas-solid contacting efficiency.
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 design achieves improved gas flow uniformity, increased catalytic conversion, and uniform coke laydown, leading to enhanced regeneration performance and reduced bed depth requirements, resulting in higher propylene production and more consistent temperature profiles.
Implementation Method 1
The catalyst particulates are maintained in a fluidized state using gas or vapors as a fluidizing media allowing the catalyst to move between the reaction and regeneration zones
Implementation Method 2
The flow through the discrete holes 14 on the mushroom cap 12 promotes small bubble formation and increases gas solid contacting above the mushroom cap 12
Data Source
Figure 1A~1B
Figure 2
Figure 3A~3C
AI summary
A fluid distribution device includes a riser having a first end and a second end. A cap operatively connected to the second end of the riser. The cap includes an inner surface and an outer surface with a plurality of holes defined between the inner and outer surface. The device includes at least one distribution arm extending radially outward from the cap. The at least one distribution arm has an interior surface and an exterior surface. The at least one distribution arm includes a plurality of holes between the interior surface and the exterior surface. A processing assembly includes a vessel defining an interior space and the fluid distribution device including a riser mounted in the interior space of the vessel having a first end mounted to the vessel and a second end opposite from the first end.