Fluidized Bed Reactor Catalyst Distribution and CO2 Regeneration
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Solution Overview
Problem
Existing devices for producing low-carbon olefin face issues with uneven catalyst distribution, inefficient regeneration heat utilization, and low yield, leading to temperature fluctuations and environmental concerns due to the use of air for regeneration.
Innovation Solution
A fluidized bed reactor design with a raw material first distributor, a raw material second distributor, and a catalyst distributor arranged in sequence, forming a dense-phase zone and a catalyst distribution zone, allowing for uniform catalyst distribution and improved reaction efficiency by segmenting the flow field and optimizing catalyst contact with raw materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If air is used for catalyst regeneration, then the burning rate of carbon deposit increases, but the control of residual carbon amount becomes difficult and temperature flying occurs
Solution Approach 1:
The patent changes the composition parameter of the regeneration gas from pure air to a mixture containing CO2 (30-70 vol%) and O2 (20-50 vol%). This parameter change moderates the burning rate while maintaining regeneration effectiveness, preventing temperature flying and enabling better control of residual carbon content in the catalyst.
2Speed
If air is used for catalyst regeneration, then the burning rate of carbon deposit increases, but greenhouse gas CO2 emission increases
Solution Approach 1:
The patent converts CO2, which is normally a harmful greenhouse gas emission, into a beneficial regeneration gas component. By introducing CO2 into the regeneration system, it serves as a heat carrier and reaction medium that reduces the need for excessive air injection, thereby reducing overall CO2 emissions from complete combustion while still achieving effective carbon deposit removal.
3Productivity
If regenerated catalyst is directly introduced into the reaction zone, then the alkylation reaction is promoted, but uneven catalyst distribution occurs
Solution Approach 1:
The patent segments the catalyst introduction process by providing multiple catalyst distributors positioned at different locations and heights within the reaction zone. This segmentation ensures uniform catalyst distribution throughout the reactor while maintaining high alkylation reaction efficiency through optimized contact between catalyst and reactants.
4Stability of the object's composition
If multiple distributors are arranged in the reaction zone, then the uniformity of reactant concentration is improved, but the device complexity increases
Solution Approach 1:
The patent designs catalyst distributors that serve multiple functions: they distribute catalyst uniformly, provide structural support for reaction zones, and facilitate heat transfer. This multi-functionality reduces the need for separate components, thereby maintaining concentration uniformity while limiting the increase in device complexity.
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 solution achieves uniform catalyst distribution, enhances reaction efficiency, and increases the yield of low-carbon olefin while reducing environmental impact by utilizing CO2 for regeneration, thereby improving the overall performance and sustainability of the process.
Implementation Method 1
fluidized bed reactor
Implementation Method 2
the catalyst distributor main guide pipe passes through the raw material first distributor and the raw material second distributor from bottom to top
Implementation Method 3
the regeneration process mainly uses air as the regeneration gas... If air is used to burn carbon deposit to partially regenerate the catalyst
Data Source
AI summary
A fluidized bed reactor, a device for preparing low-carbon olefin, and a method for preparing low-carbon olefin are provided. The reaction zone of the fluidized bed reactor is sequentially, from bottom to top, provided with a raw material first distributor, a raw material second distributor and a catalyst distributor; the catalyst distributor is connected with the catalyst second feeding inlet; a dense-phase zone is formed between the raw material first distributor and the raw material second distributor, and the area where the catalyst distributor is located is formed as a catalyst distribution zone connected with the dense-phase zone; and at least one catalyst first feeding inlet(s) is provided on the side wall of reactor of the dense-phase zone. The distribution of the catalyst and the full contact of the catalyst with the raw materials can be achieved using the fluidized bed reactor and the device.