Integrated Hydroconversion Catalyst Regeneration With Continuous Transfer

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Solution Overview

Problem

There is no effective process for regenerating a spent hydroconversion catalyst in situ, requiring ex situ transportation and separate regeneration, which is inefficient and costly.

Innovation Solution

A process for in situ regeneration of hydroconversion catalysts using a regeneration device that allows for continuous catalyst transfer and regeneration without stopping the hydrocarbon conversion process, utilizing moving or fluidized bed technologies to optimize catalyst distribution and combustion, eliminating secondary combustion zones.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If ex situ regeneration is used, then catalyst can be regenerated, but transportation cost and process complexity increase

Engineering Contradiction:

Improvecatalyst regeneration capabilityVSAvoidprocess complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The invention combines the hydroconversion reactor and catalyst regenerator into a single integrated system where the reactor serves dual functions: hydroconversion of feedstock and regeneration of spent catalyst. This eliminates the need for separate transportation and external regeneration facilities, directly resolving the contradiction between achieving catalyst regeneration and reducing process complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The system enables self-service regeneration where the hydroconversion reactor itself performs the regeneration function by circulating catalyst between reaction and regeneration zones. The catalyst is continuously regenerated within the same vessel that performs hydroconversion, eliminating dependency on external regeneration services and reducing overall system complexity.

Inventive Principle:

Principle #25Self-service

2Reliability

If ex situ regeneration is used, then catalyst can be regenerated, but transportation time and productivity decrease

Engineering Contradiction:

Improvecatalyst regeneration capabilityVSAvoidprocess efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The integrated system maintains continuous operation by simultaneously performing hydroconversion and catalyst regeneration within the same reactor. Catalyst circulates continuously between reaction and regeneration zones without removing the reactor from service, eliminating downtime associated with ex situ regeneration and maintaining continuous productivity.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

By merging the regeneration function into the hydroconversion reactor, the system eliminates the time required for catalyst transportation to and from external regeneration facilities. The regeneration process occurs in-place, directly improving productivity by eliminating non-productive time intervals.

Inventive Principle:

Principle #5Merging (Combining)

3Manufacturing precision

If multiple combustion zones are used, then regeneration quality improves, but device complexity increases

Engineering Contradiction:

Improveregeneration qualityVSAvoidregenerator structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The regenerator is divided into multiple functional zones (first combustion zone for coke oxidation, second combustion zone for sulfur compound oxidation, and cooling zone) arranged in sequence. This segmentation allows different combustion functions to be performed in distinct zones within a single integrated regenerator structure, achieving high regeneration quality without requiring multiple separate units.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple combustion zones and functional regions are merged into a single integrated regenerator vessel that is part of the hydroconversion reactor system. This consolidation achieves the regeneration quality of multiple zones while avoiding the complexity of multiple separate devices, as all zones operate within one unified structure.

Inventive Principle:

Principle #5Merging (Combining)

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

Enables continuous catalyst regeneration within the hydrocarbon conversion process, reducing fresh catalyst consumption and improving regeneration quality by controlling gas distribution, thus maintaining process efficiency.

Implementation Method 1

combustion of the coke and of the sulfur compounds deposited on the catalyst

Methodology Applied

Scientific EffectCombustion: Combustion

Implementation Method 2

charging the regeneration device with the spent catalyst is carried out in the form of a fluidized bed with the aid of a fluidization liquid

Methodology Applied

Scientific EffectFluidization: Fluidisation

Data Source

PatentUS20250325973A1Device making possible the regeneration of a hydroconversion catalyst and associated processes

Publication Date: 2025.10.23 AXENS SA

AI summary

The present invention relates to a process for the in situ regeneration of a hydroconversion catalyst. The invention also relates to a hydroconversion process comprising said regeneration process. The invention also relates to a system comprising a reaction section (40) comprising a hydroconversion reactor operating as an ebullating bed or as a moving bed; a regeneration section comprising a regeneration device (100); means for transfer of the hydroconversion catalyst between said reaction section (40) and said regeneration section comprising at least one fluidic connection; means for charging said regeneration device (100) as a fluidized bed or as a moving bed.