Lipid Conversion Reactor Cycling Downflow and Upflow Regeneration

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Solution Overview

Problem

Existing reactor systems face challenges with plugging and non-uniform fluid flows due to coke and impurity accumulation, which degrade performance in processing lipid feedstocks for hydrocarbon production.

Innovation Solution

A reactor system that alternates between a downflow reaction mode and an upflow regeneration mode, using a metal oxide catalyst to treat lipid feedstocks, where the downflow mode minimizes plugging and channeling, and the upflow mode regenerates the catalyst by combusting impurities, maintaining uniform fluid distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a fixed bed reactor operates continuously in reaction mode, then productivity is maintained, but plugging and channeling occur due to coke and impurity accumulation

Engineering Contradiction:

Improvecontinuous reaction mode operationVSAvoidreactor performance degradation from plugging and channeling

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The reactor system alternates between reaction mode and regeneration mode in periodic cycles. During reaction mode, the reactor processes lipid feedstock continuously. When coke and impurities accumulate to problematic levels, the system switches to regeneration mode to burn off deposits, then returns to reaction mode. This periodic switching prevents permanent plugging and channeling while maintaining overall productivity.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The harmful coke and impurity accumulation that causes plugging is converted into a beneficial regeneration process. By introducing air during regeneration mode, the accumulated coke combusts to regenerate the catalyst, transforming the harmful deposition into a useful cleaning mechanism that restores reactor performance.

Inventive Principle:

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

2Reliability

If air is introduced to regenerate the catalyst, then coke and impurities are combusted, but non-uniform flow and channeling may occur

Engineering Contradiction:

Improvecatalyst regenerationVSAvoiduniformity of fluid flow distribution

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The patent inverts the conventional fixed bed configuration by allowing the bed to move downward during regeneration mode, opposite to the upward movement during reaction mode. This inversion, combined with air introduction from the bottom, creates upward flow that prevents channeling and ensures uniform distribution throughout the catalyst bed, eliminating the non-uniform flow problem.

Inventive Principle:

Principle #13The other way round (Inversion)

3Productivity

If the reactor operates at high pressure to improve reaction efficiency, then productivity increases, but the risk of plugging from impurity accumulation increases

Engineering Contradiction:

Improvereaction efficiencyVSAvoidplugging risk from impurity accumulation

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system operates at high pressure during reaction mode to maximize reaction efficiency and productivity. When plugging becomes a risk due to impurity accumulation, the system periodically switches to regeneration mode where pressure is reduced and air is introduced to burn off deposits. This periodic pressure variation allows the system to maintain high productivity while preventing permanent plugging.

Inventive Principle:

Principle #19Periodic action

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 alternating mode operation effectively inhibits plugging and channeling, ensuring consistent reactor performance and producing a treated stream with reduced oxygen and impurities, suitable for refining into biofuels.

Implementation Method 1

treating the lipid feedstock to produce a treated stream that comprises a condensable oil fraction having a lower content of oxygen and impurities than the lipid feedstock

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 2

providing an input of air optionally diluted with steam or inert gas into a bottom portion of the reactor such that the air flows upward through the catalyst particles; maintaining a temperature of 400° C. to 800° C., thereby causing combustion of combustible solids on the catalyst particles and thereby regenerating the catalyst particles

Methodology Applied

Scientific EffectCombustion: Combustion

Data Source

PatentUS20260008023A1Downflow lipid conversion with upflow catalyst regeneration

Publication Date: 2026.01.08 CHEVRON USA INC

AI summary

A reactor system includes a reactor that treats a lipid feedstock using a metal oxide catalyst to produce a treated stream comprising a bio-oil. The reactor system includes a catalyst zone in which the metal oxide catalyst reacts with the lipid feedstock to produce the treated stream. The reactor system operates in a reaction mode, during which the lipid feedstock flows in a downward direction through the metal oxide catalyst to produce the treated stream. Alternately, the reactor also operates in a regeneration mode, during which coke is burned from the metal oxide catalyst thereby regenerating the metal oxide catalyst. In one aspect, a regeneration mode pressure is less than a reaction mode pressure within the reactor to fluidize the catalyst.