Magnetic Separation of Sulfided Sorbent from Zeolite Catalyst
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Solution Overview
Problem
Existing methods for upgrading straight run naphtha to octane-rich gasoline in petroleum refining are inefficient due to the simultaneous deactivation of zeolite additives and sorbent-based diluents, leading to wasteful replacement of both components when only one is spent, as they deactivate at different rates and mechanisms.
Innovation Solution
A method involving a reactor system with a solid particulate mixture of a nickel-containing sorbent and a zeolite catalyst, where magnetic separation is used to distinguish between sulfided and non-sulfided sorbents, allowing for independent processing and recycling of each component, thereby enabling selective replacement and regeneration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a combination of zeolite additive and sorbent based diluent is used in a fluidized bed, then octane rich gasoline is produced with sulfur removal, but both components deactivate at different rates and mechanisms requiring simultaneous replacement even when only one is spent
Solution Approach 1:
The patent applies segmentation by dividing the previously combined zeolite and sorbent into separate functional components with distinct magnetic properties. The sorbent is designed to become magnetic when sulfided, enabling it to be separated from the non-magnetic zeolite catalyst. This allows independent replacement of each component based on its specific deactivation state, preventing waste of still-active materials.
Solution Approach 2:
The patent introduces magnetic properties as an intermediary characteristic that enables selective separation. By making the sorbent magnetic upon sulfur adsorption (while the zeolite remains non-magnetic), a magnetic separator can act as an intermediary device to divide the two components, facilitating independent processing and replacement decisions.
2Ease of operation
If the sorbent is made magnetic upon sulfuration, then magnetic separation enables selective removal of spent sorbent while retaining active zeolite catalyst, but requires modification of sorbent properties
Solution Approach 1:
The patent applies parameter changes by modifying the magnetic property parameter of the sorbent material. The sorbent is formulated to transition from non-magnetic to magnetic state upon sulfur adsorption, creating a controllable parameter change that enables easy separation. This parameter change occurs naturally during the sorbent's functional operation, requiring no additional complexity in the separation process.
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 cost-effective and efficient processing by separating and recycling the sorbent and catalyst independently, reducing unnecessary replacements and maintaining optimal zeolite activity, thus enhancing octane levels in the gasoline stream while minimizing waste.
Implementation Method 1
The sorbent includes a nickel-containing material and adsorbs sulfur from the hydrocarbon-containing feed stream
Implementation Method 2
Separating the sorbent from the catalyst within the removed portion occurs by magnetic separation. Magnetism of the sorbent depends on sulfur content of the sorbent.
Data Source
AI summary
Methods and apparatus relate to processing of petroleum with a bed having a sorbent based diluent that the petroleum contacts upon passing through the bed. Magnetic properties of the sorbent and any other material, such as zeolite, used in the bed enable separation of such bed constituents based on a sulfided form of the sorbent being magnetic in contrast to a non-sulfided form of the sorbent being non-magnetic. Dividing the bed constituents into first and second portions by magnetic separation facilitates in selective replacing and/or regenerating the first portion independent of the second portion.