Multiphase Separator for Catalyst Stripping in Hydrocarbon Conversion

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Solution Overview

Problem

Current processes for converting oxygenates and olefins to hydrocarbons face challenges with catalyst deactivation and the need for effective multiphase separation of gases, liquids, and solids, particularly in methanol conversion reactions, where irreversible deactivation and reduced product yield occur due to inadequate stripping of process fluids from catalysts.

Innovation Solution

A multiphase separator system comprising an inlet chamber, a stripping chamber with perforations, and a collection chamber, where a stripping fluid enters the inlet chamber and flows through perforations into the stripping chamber and collection chamber, effectively stripping process fluids from catalysts, thereby extending catalyst life and improving product yield.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Duration of action of moving object

If a moving catalyst bed reactor is used to reduce irreversible catalyst deactivation, then catalyst cycle life and product yield are improved, but effective stripping of process fluid from solid catalyst becomes critical and difficult to achieve

Engineering Contradiction:

Improvecatalyst cycle lifeVSAvoidstripping of process fluid from catalyst

Core Design Contradiction:

Duration of action of moving objectVSEase of operation

Solution Approach 1:

The separator is divided into multiple chambers (inlet chamber, stripping chamber, collection chamber) with distinct functions. The stripping chamber contains perforated plates that segment the flow path, allowing systematic separation of catalyst particles from process fluid through controlled fluid flow zones.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A stripping fluid is introduced as an intermediary substance to facilitate the separation process. The stripping fluid flows through the perforated plates and catalyst bed, carrying process fluids away from the catalyst particles while allowing catalyst particles to be collected and returned to the reactor.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If multiphase separation of process fluid from solids is achieved, then catalyst activity retention and product yield are enhanced, but the system complexity increases with multiple chambers and perforations

Engineering Contradiction:

Improveproduct yieldVSAvoidseparator structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

Multiple separation functions (gas-liquid separation, solid-liquid separation, catalyst collection) are merged into a single integrated separator unit with interconnected chambers. This consolidation achieves multiphase separation without requiring multiple separate equipment pieces, reducing overall system complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Perforated plates with controlled pore sizes are used as separation media. The perforations allow selective passage of fluids while retaining catalyst particles, providing efficient separation functionality through simple geometric structures rather than complex mechanisms.

Inventive Principle:

Principle #31Porous materials

3Reliability

If catalyst regeneration is performed to restore activity, then some catalyst activity is recovered, but irreversible deactivation occurs leading to shorter cycle life

Engineering Contradiction:

Improvecatalyst activityVSAvoidcatalyst cycle life

Core Design Contradiction:

ReliabilityVSDuration of action of moving object

Solution Approach 1:

The separator performs preliminary action by completely stripping process fluids from catalyst particles before they enter the regeneration system. This pre-cleaning prevents irreversible deactivation during regeneration by ensuring catalyst particles are free of process fluids that could cause damage during the regeneration process.

Inventive Principle:

Principle #10Preliminary 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 system enhances catalyst activity retention and product yield by efficiently separating process fluids from catalysts, reducing irreversible deactivation and prolonging catalyst cycle life, while allowing for the production of valuable hydrocarbon products.

Implementation Method 1

the stripping fluid enters the at least one inlet chamber and flows through the perforations into the at least one stripping chamber and into the at least one collection chamber

Methodology Applied

Scientific EffectFluid flow: