Hydro pyrolysis catalyst coke management for olefin yield
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Solution Overview
Problem
Current fluidized catalytic cracking (FCC) processes face issues with catalyst deactivation due to rapid coke formation, which decreases catalyst efficiency and adversely impacts the yield of light olefins and aromatics.
Innovation Solution
The process involves contacting a hydrocarbon feed stream with a catalyst and hydrogen source to reduce coke formation, followed by contacting the used catalyst with a coke precursor to deposit coke, thereby maintaining catalyst activity and enhancing heat management and yield of high-value chemicals like olefins and aromatics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If fluidized catalytic cracking is used to produce olefins and aromatics, then high value chemicals can be obtained, but catalyst deactivation occurs due to rapid coke formation
Solution Approach 1:
The patent introduces a hydrogen source before the cracking reaction to prevent coke formation on the catalyst surface in advance. This preliminary action of hydrogen saturation protects the catalyst from deactivation during the cracking process, maintaining catalyst activity while enabling continuous production of olefins and aromatics.
Solution Approach 2:
The patent uses a hydrogen source as an intermediary substance that mediates between the hydrocarbon feed and the catalyst. The hydrogen acts as a protective intermediary that prevents direct coke formation on the catalyst surface, allowing the cracking reaction to proceed without rapid catalyst deactivation.
2Reliability
If coke formation is reduced on the catalyst, then catalyst efficiency is maintained, but heat management becomes challenging
Solution Approach 1:
The patent extracts the heat generation function from the catalyst regeneration process and separates it from the cracking process. By introducing a dedicated coke precursor feed that deposits coke in a controlled manner, the system can manage heat generation independently while maintaining catalyst efficiency in the cracking zone.
Solution Approach 2:
The patent changes the parameters of coke formation by introducing a specific coke precursor feed with controlled composition and flow rate. This allows precise control over the amount and location of coke deposition, enabling optimized heat management while maintaining catalyst performance.
3Reliability
If a hydrogen source is added to reduce coke formation, then catalyst activity is maintained, but process complexity increases
Solution Approach 1:
The patent uses a hydrogen source that serves multiple functions: it prevents coke formation on the catalyst, participates in the cracking reaction to enhance olefin production, and contributes to heat balance. This multi-functionality reduces the need for separate systems and simplifies the overall process despite the additional hydrogen feed requirement.
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 approach increases the yield of olefins and aromatics by managing catalyst activity and heat management, reducing coke formation, and allowing for more efficient regeneration of the catalyst, leading to higher production of light olefins and aromatics.
Implementation Method 1
contacting a first hydrocarbon feed stream with a catalyst and a hydrogen source under conditions sufficient to produce a used catalyst and an intermediate stream comprising olefins and aromatics
Implementation Method 2
contacting the used catalyst with the intermediate stream and a coke precursor feed to produce a spent coked catalyst
Implementation Method 3
fluidized catalytic cracking of petroleum based feed stocks
Implementation Method 4
coke burnt in catalyst regenerator
Data Source
AI summary
Systems and processes for producing olefins and aromatics. A process can include contacting a first hydrocarbon feed with a catalyst and a hydrogen source under conditions sufficient to produce a used catalyst and an intermediate stream containing olefins and aromatics, and contacting the used catalyst with the intermediate stream and a coke precursor feed to produce a spent coked catalyst and a products stream comprising additional olefins and aromatics.