Moving Bed Catalyst Regenerator with Segmented Zones
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Solution Overview
Problem
Current catalytic reforming processes using a single type of catalyst are inefficient as they cannot effectively manage the varying reactions of dehydrogenation and dehydrocyclization of naphthenes and paraffins, leading to catalyst deactivation and variable selectivity.
Innovation Solution
A regenerator capable of simultaneously and separately regenerating multiple types of catalysts, each optimized for specific reactions, with distinct zones for combustion, oxychlorination, and calcination, allowing for tailored treatment of catalysts with different compositions and gas flows.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single type of catalyst is used for catalytic reforming, then the device complexity is reduced, but the productivity and selectivity deteriorate due to inability to effectively manage varying reactions of dehydrogenation and dehydrocyclization
Solution Approach 1:
The regenerator is divided into multiple separate regeneration zones (first regeneration zone for dehydrogenation catalyst, second regeneration zone for dehydrocyclization catalyst), each equipped with independent combustion sections, oxychlorination sections, and calcination sections. This segmentation allows simultaneous separate treatment of different catalyst types with tailored gas flows and operational parameters, resolving the contradiction between handling multiple catalysts and maintaining device simplicity.
Solution Approach 2:
The regenerator is designed as a multi-functional device that can simultaneously perform combustion, oxychlorination, and calcination operations for different catalyst types in separate zones. Each regeneration zone contains all necessary functional sections (combustion, oxychlorination, calcination) to handle the complete regeneration cycle for its specific catalyst type, enabling the single regenerator to serve multiple catalyst regeneration purposes concurrently.
2Reliability
If catalyst regeneration is performed frequently to maintain activity, then the catalyst activity is preserved, but the production continuity is interrupted due to reactor shutdowns
Solution Approach 1:
Multiple regeneration zones for different catalyst types are merged into a single integrated regenerator device, allowing simultaneous regeneration of dehydrogenation and dehydrocyclization catalysts. This consolidation enables continuous operation of the catalytic reforming process by maintaining both catalyst types active through concurrent regeneration, eliminating production interruptions that would occur with sequential regeneration in separate devices.
Solution Approach 2:
The regenerator enables continuous catalyst regeneration through simultaneous operation of multiple regeneration zones. While one catalyst type is being regenerated in one zone, another catalyst type is being regenerated in another zone, ensuring that catalyst activity is continuously maintained across the entire catalytic reforming process without shutdowns or interruptions to production.
3Manufacturing precision
If separate regeneration zones for different catalysts are implemented, then the manufacturing precision of catalyst treatment is improved, but the device complexity increases
Solution Approach 1:
The regenerator is segmented into distinct regeneration zones with separate combustion sections, oxychlorination sections, and calcination sections for each catalyst type. This segmentation enables precise control of gas flows, temperatures, and chemical environments tailored to each catalyst's specific regeneration requirements, achieving high manufacturing precision while organizing complexity into manageable modular zones.
Solution Approach 2:
Each regeneration zone is equipped with local quality features including dedicated gas distribution systems, temperature control mechanisms, and flow regulation devices specific to the catalyst type being treated. The first regeneration zone has optimized parameters for dehydrogenation catalyst while the second zone has tailored parameters for dehydrocyclization catalyst, allowing precise localized treatment without compromising the overall device structure.
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 enhances the efficiency of catalytic reforming by maintaining catalyst activity and optimizing reaction yields, allowing continuous operation without interrupting production, and reducing the need for frequent reactor shutdowns.
Implementation Method 1
a combustion section; an oxychlorination section disposed below the combustion section
Implementation Method 2
combustion section
Implementation Method 3
an oxychlorination section disposed below the combustion section and comprising means for bringing catalyst from the combustion section into the oxychlorination section
Implementation Method 4
a calcination section disposed below the oxychlorination section
Implementation Method 5
catalyst particles circulate by gravity
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The present invention relates to a moving bed catalyst regenerator (1), comprising a chamber (2) extending in a vertical direction, said chamber being divided into at least two regeneration zones extending along the vertical height of said chamber, in which catalyst particles circulate by gravity, the regenerator being configured so that each regeneration zone is capable of separately regenerating a catalyst of different composition and in which each zone comprises successively and in the order of circulation of the catalysts: a) a combustion section (CO); b) an oxychlorination section (O) disposed below the combustion section and comprising means for bringing the catalyst from the combustion section (CO) into the oxychlorination section (O); c) a calcination section (CA) disposed below the oxychlorination section.