Inert Gas Heat Exchange for Catalyst Regeneration
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Solution Overview
Problem
Catalytic reforming processes face challenges in efficiently managing heat during catalyst regeneration, leading to inefficiencies and potential damage from steam leaks, especially in achieving high octane ratings for gasoline without lead-containing additives.
Innovation Solution
The method involves heating an inert gas stream for indirect heat exchange with hydrogen or organic chloride-containing streams to lift and chlorinate the catalyst, and using nitrogen gas for preheating, which improves heat management and reduces the need for steam, thereby enhancing the regeneration process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If steam is used for heating during catalyst regeneration, then heat supply is achieved, but steam leaks may occur that contact the catalyst and cause detrimental effects
Solution Approach 1:
The patent introduces nitrogen gas as an intermediary heating medium between the heat source and the catalyst. Instead of using steam directly for heating, the system heats nitrogen gas and then uses this heated inert gas to transfer heat to the catalyst and process streams. This intermediary approach eliminates the harmful effects of steam leaks while maintaining effective heat supply for catalyst regeneration, chlorination, and lifting operations.
2Temperature
If multiple heat sources are introduced at various points into the regeneration system, then heating requirements are met, but system complexity and potential for harmful leaks increase
Solution Approach 1:
The patent makes the nitrogen gas heating system universal by using a single heated inert gas stream that serves multiple functions throughout the regeneration process. The same heated nitrogen gas is used for lifting catalyst, chlorinating catalyst, and heating various process streams at different points in the system. This multi-functional approach replaces multiple separate heat sources with one versatile heating system, reducing complexity while maintaining comprehensive heating capability.
3Productivity
If steam is used for catalyst lifting and chlorination, then process requirements are met, but efficiency is reduced due to steam's detrimental effects
Solution Approach 1:
The patent changes the physical and chemical parameters of the heating medium from steam (water-based, reactive) to nitrogen gas (inert, non-condensing). This parameter change eliminates the efficiency losses associated with steam condensation and the harmful chemical interactions with catalyst. The nitrogen gas system provides more efficient heat transfer for catalyst lifting and chlorination operations while avoiding the energy waste and detrimental effects of steam exposure.
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 allows for more efficient heat distribution and reduced steam usage, improving catalyst regeneration efficiency and maintaining catalyst effectiveness without detrimental steam exposure, while also eliminating the need for steam heating, thus optimizing the catalytic reforming process.
Implementation Method 1
a combustion zone configured to combust coke disposed on the catalyst in the presence of an oxygen-containing gas to form a heated combustion zone gas
Implementation Method 2
One or more heat exchangers are disposed along the fluid circuit and are configured for indirect heat exchange between the heated combustion zone gas and the inert gas
Data Source
AI summary
Embodiments of methods and apparatuses for catalytic reforming of hydrocarbons including regeneration of catalyst are provided. In one example, a method comprises heating an inert gas to form a heated inert gas stream. A first portion of the heated inert gas stream is indirect heat exchanged with hydrogen gas to form a first partially heated inert gas stream and a heated hydrogen gas stream that is for lifting the catalyst; and/or a second portion of the heated inert gas stream is indirect heat exchanged with an organic chloride-containing stream to form a second partially heated inert gas stream and a heated organic chloride-containing stream that is for chlorinating the catalyst; and/or the catalyst is preheated using at least a third portion of the heated inert gas stream for indirect heat exchange with a nitrogen gas stream or using the first and/or second partially heated inert gas streams.