Hydrogen Recovery from Catalyst Lock Hopper
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In continuous catalyst regeneration reformers, hydrogen-rich gas streams are often wasted as fuel, leading to inefficient operations and unstable pressures, which hampers the overall efficiency and cost-effectiveness of refining processes.
Innovation Solution
An apparatus and process that includes a pressurizing means, such as a compressor, and a surge drum with a feedforward and feedback controller system to raise and stabilize the pressure of hydrogen-rich gas streams from the catalyst lock hopper, allowing for efficient recovery and recycling of hydrogen while maintaining stable pressures within the system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If hydrogen-rich gas stream is routed to fuel gas drum, then pressure stability in fuel gas drum is maintained, but hydrogen is wasted and cannot be used at its chemical value
Solution Approach 1:
The patent extracts hydrogen-rich gas stream from the conventional fuel gas drum route and directs it to a dedicated hydrogen recovery system. The gas is pulled from the catalyst lock hopper and routed through a pressure control system to a hydrogen service drum, separating the hydrogen recovery function from the fuel gas system.
Solution Approach 2:
The patent creates a multi-functional system where the hydrogen recovery apparatus serves multiple purposes: recovering valuable hydrogen for chemical use, maintaining pressure stability in the reformer system, and providing flexible routing to different downstream locations including hydrogen service drums and reformer units.
2Productivity
If pressure control is implemented to recover hydrogen, then hydrogen can be recycled, but system complexity increases
Solution Approach 1:
The patent implements a feedback control system where pressure sensors monitor the hydrogen-rich gas stream and feed signals to a pressure control valve. The valve automatically adjusts to maintain desired pressure levels, creating a closed-loop control system that stabilizes pressure during hydrogen recovery operations.
Solution Approach 2:
The patent introduces a pressure control valve as an intermediary device between the hydrogen-rich gas stream source and the downstream hydrogen recovery system. This intermediary component mediates the pressure differential, allowing controlled flow and recovery while protecting the downstream system from pressure fluctuations.
3Quantity of substance
If hydrogen-rich gas stream flow is increased for recovery, then more hydrogen is recovered, but pressure fluctuations occur in the reformer system
Solution Approach 1:
The patent implements preliminary pressure control by positioning pressure control valves and surge drums upstream in the hydrogen recovery path. These devices pre-regulate the gas flow and pressure before it enters the recovery system, preventing pressure fluctuations from propagating back into the reformer system while still enabling high hydrogen recovery rates.
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 enables the efficient recovery and recycling of hydrogen, maintaining stable pressures and reducing the need for seal gas, thus enhancing the operational efficiency and reducing costs in refining processes.
Implementation Method 1
the pressure of a hydrogen-rich gas stream is raised so that the hydrogen gas is recovered
Implementation Method 2
a surge drum with a feedforward and feedback controller system to raise and stabilize the pressure of hydrogen-rich gas streams
Data Source
AI summary
An apparatus and method for recovering and recycling hydrogen from a reforming process raises the pressure of at least one hydrogen-rich gas stream from at least one catalyst lock hopper and delivers at least a portion of the pressurized hydrogen-rich gas stream to at least one predetermined downstream location. At least another portion of the pressurized hydrogen-rich gas is used to maintain the desired pressure within the hydrogen recovery and recycling process and apparatus.