Integrated Reaction-Regeneration System for Olefin Production
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Solution Overview
Problem
Catalyst fouling in hydrocarbon processing leads to frequent regeneration needs, increasing operating and capital costs due to the requirement for multiple equipment systems and inefficient heat management in catalytic cracking processes for producing light olefins like ethylene and propylene.
Innovation Solution
Integration of a staggered reaction/regeneration cycle using multiple fixed bed reactors with an integrated regeneration gas system that recovers and reheats regeneration gas for both preheating the hydrocarbon feed and regenerating the catalyst, eliminating the need for separate heating systems and optimizing heat recovery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fixed bed reactor systems with separate regeneration equipment are used, then catalyst regeneration is achieved, but device complexity and capital expenditures increase due to multiple separate equipment systems
Solution Approach 1:
The patent combines the reaction and regeneration functions into a single fixed bed reactor system. The reactor is designed to alternately perform cracking reactions and catalyst regeneration within the same vessel, eliminating the need for separate regeneration equipment and reducing overall device complexity while maintaining reliable catalyst regeneration
Solution Approach 2:
The fixed bed reactor is designed as a multi-functional unit that can perform both cracking reactions and catalyst regeneration. By making the reactor universal, the system eliminates dedicated regeneration equipment, thereby reducing capital expenditures and equipment count while ensuring catalyst regeneration capability
2Temperature
If separate heating systems are used for feed preheating and regeneration, then heating requirements are met, but device complexity and operating costs increase
Solution Approach 1:
The patent merges the heating functions for feed preheating and catalyst regeneration into a single heating system. The same heater used for regenerating the catalyst also preheats the hydrocarbon feed, eliminating redundant heating equipment and reducing both device complexity and operating costs while meeting all temperature requirements
Solution Approach 2:
The heating system is designed as a multi-functional unit that serves dual purposes: regenerating the catalyst and preheating the feed. This universal heating approach reduces the number of heating equipment pieces and lowers both capital expenditures and operating costs while maintaining adequate temperature control for both processes
3Loss of energy
If heat recovery from regeneration gas is not implemented, then process simplicity is maintained, but energy efficiency decreases and operating costs increase
Solution Approach 1:
The patent converts the hot regeneration gas, which would otherwise be waste heat, into a useful resource for preheating the feed. By utilizing the thermal energy from the regeneration gas, the system recovers energy that would be lost, improving overall energy efficiency and reducing operating costs
Solution Approach 2:
The system recovers thermal energy from the regeneration gas that would otherwise be discarded. The hot regeneration gas is passed through a heat exchanger to preheat the feed, thereby recovering valuable energy and improving process efficiency while adding minimal complexity to the system
4Reliability
If frequent catalyst regeneration is performed, then catalyst activity is maintained, but productivity decreases due to more frequent shutdowns
Solution Approach 1:
The patent implements a periodic operation mode where the fixed bed reactor alternates between cracking reactions and catalyst regeneration in regular cycles. This periodic action allows the catalyst to be regenerated frequently to maintain activity while the reactor remains a single unit, avoiding the productivity losses associated with multiple reactor shutdowns and transitions
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 reduces operating costs and capital expenditures by minimizing equipment count, stabilizing reactor performance, and maintaining consistent product composition through efficient heat management and catalyst regeneration.
Implementation Method 1
the catalyst loses activity in a time frame measured in minutes to hours depending upon conditions. In order to re-establish the activity of the catalyst, the coke produced in the reaction, which reduces the activity of the catalyst, must be removed under controlled conditions
Implementation Method 2
the catalyst loses activity in a time frame measured in minutes to hours depending upon conditions. In order to re-establish the activity of the catalyst, the coke produced in the reaction, which reduces the activity of the catalyst, must be removed under controlled conditions
Implementation Method 3
separate heaters are required. In these cases additional equipment is required
Data Source
AI summary
Disclosed is a process for the production of C2 to C3 olefins via the catalytic cracking of feedstocks including C4 and heavier olefins in an integrated reaction/regeneration system.