Hydrogen-Rich Supplemental Fuel for Catalyst Regeneration

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Solution Overview

Problem

Existing reactor systems for producing light olefins face challenges in maintaining catalyst activity and conversion efficiency due to the deactivation caused by combustion of supplemental fuels rich in hydrocarbons, leading to increased operating costs and reduced productivity.

Innovation Solution

The use of a supplemental fuel with a high concentration of hydrogen (molar ratio of hydrogen to other combustible fuels of at least 1:1) in the combustor of a catalyst processing portion, followed by an oxygen treatment to reactivate the catalyst, enhances catalyst activity and extends catalyst lifetime, allowing for increased conversion and reduced catalyst inventory.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If supplemental fuel rich in hydrocarbons (e.g., methane) is combusted during catalyst regeneration, then heat input for endothermic reactions is increased, but catalyst activity is reduced due to deactivation

Engineering Contradiction:

Improveheat inputVSAvoidcatalyst activity

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

The patent changes the compositional parameter of the supplemental fuel from hydrocarbon-rich (e.g., methane) to hydrogen-rich (at least 50 mol% hydrogen). This parameter change allows the fuel to provide necessary heat input while avoiding catalyst deactivation, as hydrogen combustion does not produce the harmful effects associated with hydrocarbon combustion on these catalysts.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If the amount of active metal (e.g., platinum, gallium) in the catalyst is increased to maintain productivity, then reactor system capacity is maintained, but operating costs increase

Engineering Contradiction:

Improvereactor system capacityVSAvoidactive metal content

Core Design Contradiction:

ProductivityVSQuantity of substance

Solution Approach 1:

The patent effectively replaces expensive active metals with a cheaper alternative approach: using hydrogen-rich supplemental fuel during catalyst regeneration. This allows the catalyst to maintain its activity without requiring large amounts of precious metals like platinum or gallium, thereby reducing operating costs while maintaining productivity.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Productivity

If catalyst inventory is increased to compensate for deactivation, then conversion efficiency is maintained, but catalyst bulk inventory increases

Engineering Contradiction:

Improveconversion efficiencyVSAvoidcatalyst bulk inventory

Core Design Contradiction:

ProductivityVSQuantity of substance

Solution Approach 1:

The patent converts the previously harmful effect of supplemental fuel combustion into a beneficial process by using hydrogen-rich fuel. This allows catalyst regeneration to occur without deactivation, meaning the catalyst maintains its conversion efficiency without requiring increased bulk inventory to compensate for activity loss.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 catalyst activity and conversion efficiency, enabling the reactor system to operate with less active metal and achieving target conversions with reduced catalyst bulk inventory, while maintaining or improving reactor system capacity.

Implementation Method 1

combusting a supplemental fuel in the combustor to heat the catalyst

Methodology Applied

Scientific EffectCombustion: Combustion

Implementation Method 2

heat the catalyst

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 3

treating the heated catalyst with an oxygen-containing gas to produce a reactivated catalyst

Methodology Applied

Scientific EffectOxidation: Oxidation

Data Source

PatentUS11643377B2Chemical processing utilizing hydrogen containing supplemental fuel for catalyst processing

Publication Date: 2023.05.09 DOW GLOBAL TECHNOLOGIES LLC

AI summary

A method for processing a chemical stream includes contacting a feed stream with a catalyst in a reactor portion of a reactor system that includes a reactor portion and a catalyst processing portion. The catalyst includes platinum, gallium, or both and contacting the feed stream with the catalyst causes a reaction which forms an effluent stream. The method includes separating the effluent stream from the catalyst, passing the catalyst to the catalyst processing portion, and processing the catalyst in the catalyst processing portion. Processing the catalyst includes passing the catalyst to a combustor, combusting a supplemental fuel in the combustor to heat the catalyst, treating the heated catalyst with an oxygen-containing gas to produce a reactivated catalyst, and passing the reactivated catalyst from the catalyst processing portion to the reactor portion. The supplemental fuel may include a molar ratio of hydrogen to other combustible fuels of at least 1:1.