Multi-Stage Catalyst Regeneration for Olefin Yield

Solution Overview

Problem

Existing fluid catalytic cracking (FCC) processes face limitations in maximizing olefin production, particularly propylene, due to high catalyst deactivation and restricted catalyst circulation, especially when processing heavier feedstocks, as they require high regenerator temperatures that limit catalyst circulation and impact product yields.

Innovation Solution

A multi-stage catalyst regeneration process is implemented, with independent control over catalyst circulation, utilizing a partial burn zone and a full burn zone in series to adjust regenerator temperatures and optimize catalyst circulation, allowing for flexible processing of various feedstocks and maximizing olefin production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If high regenerator temperatures are used to process heavier feedstocks, then cracking capability is improved, but catalyst circulation is limited and catalyst deactivation increases

Engineering Contradiction:

Improvecracking capabilityVSAvoidcatalyst deactivation

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The regenerator is divided into multiple stages with different temperature zones. The first stage operates at lower temperature to minimize catalyst deactivation, while the second stage operates at higher temperature to provide sufficient cracking capability for heavier feedstocks. This segmentation allows each zone to optimize for its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the regenerator are assigned different thermal characteristics. The lower stage maintains cooler conditions suitable for catalyst preservation, while the upper stage provides hotter conditions for effective cracking. This local differentiation of thermal quality enables simultaneous optimization of catalyst stability and cracking performance.

Inventive Principle:

Principle #3Local quality

2Productivity

If high regenerator temperatures are used to process heavier feedstocks, then cracking capability is improved, but catalyst circulation is limited

Engineering Contradiction:

Improvecracking capabilityVSAvoidcatalyst circulation

Core Design Contradiction:

ProductivityVSSpeed

Solution Approach 1:

The regenerator is divided into multiple stages with different temperature zones. The first stage operates at lower temperature to minimize catalyst deactivation, while the second stage operates at higher temperature to provide sufficient cracking capability for heavier feedstocks. This segmentation allows each zone to optimize for its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The temperature parameter is varied across different stages of the regenerator rather than maintaining a uniform high temperature. This parameter change allows the system to achieve high cracking capability in the second stage while maintaining conditions in the first stage that promote faster catalyst circulation and reduce deactivation.

Inventive Principle:

Principle #35Parameter changes

3Device complexity

If single-stage regeneration is used, then equipment complexity is reduced, but flexibility in controlling catalyst circulation and optimizing olefin production is limited

Engineering Contradiction:

Improveregeneration process simplicityVSAvoidcatalyst circulation control flexibility

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The regenerator is divided into multiple stages with different temperature zones. The first stage operates at lower temperature to minimize catalyst deactivation, while the second stage operates at higher temperature to provide sufficient cracking capability for heavier feedstocks. This segmentation allows each zone to optimize for its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The multi-stage regenerator enables dynamic control of catalyst circulation by independently adjusting operating parameters in each stage. This allows the system to adapt to different feedstocks and product requirements, providing versatility while maintaining manageable complexity through modular design.

Inventive Principle:

Principle #15Dynamics

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 olefin production by achieving the highest possible catalyst-to-oil ratio, reducing catalyst deactivation, and increasing propylene yields, while also reducing equipment costs and operational complexity.

Implementation Method 1

the vaporized hydrocarbon feed upon contact with hot fully regenerated catalyst undergoes a catalytic cracking

Methodology Applied

Scientific EffectCatalytic cracking: Catalysis

Implementation Method 2

In the regenerator, the coked catalyst is combined with an oxygen containing gas, e.g., air, whereby coke is burned off the catalyst and the catalyst is both reactivated and heated

Methodology Applied

Scientific EffectCombustion: Combustion

Data Source

PatentUS20250002793A1Maximum olefins production utilizing multi-stage catalyst reaction and regeneration

Publication Date: 2025.01.02 TECHNIP ENERGIES FRANCE SAS

AI summary

A method and system for increasing olefin production and quality from a hydrocarbon feed comprising a fully integrated multi-stage catalyst regeneration zones with multi-stage reaction zones in series and/or parallel. The multi-stage regeneration with at least one partial and one full burn zone provides an independent control to achieve the lowest possible regenerated catalyst temperature, resulting in highest possible catalyst to oil ratio required to maximize olefins yields through increased catalytic cracking in a multi stage FCC riser/risers.