Parallel Reactor Trains for Continuous Catalyst Regeneration
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Solution Overview
Problem
Conventional catalyst regeneration processes in Fischer-Tropsch reactors disrupt plant facility operations, leading to reduced production capacity, increased emissions, and higher costs due to the need to flare feedstock or turn down upstream units.
Innovation Solution
A process and plant facility configuration that utilizes multiple parallel reactor trains with microchannel or microstructure reactors, allowing for continuous feed material flow through remaining online reactors during catalyst regeneration, thereby maintaining constant production levels and minimizing emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional catalyst regeneration processes are used in Fischer-Tropsch reactors, then the catalyst can be regenerated, but plant facility operations are disrupted, production capacity is reduced, and emissions increase
Solution Approach 1:
The plant facility is divided into multiple parallel reactor trains (e.g., Train 1, Train 2, Train 3). During catalyst regeneration, only one reactor train is isolated and taken offline while the other reactor trains continue to operate and process feed material. This segmentation allows catalyst regeneration to proceed without shutting down the entire plant, thereby maintaining production capacity.
Solution Approach 2:
The system ensures continuous processing of feed material by routing it through the online reactor trains even while one train undergoes catalyst regeneration. The feed material flow is continuously maintained at constant volume through the operating reactors, eliminating production interruptions and maintaining continuous useful action throughout the regeneration process.
2Reliability
If conventional catalyst regeneration processes are used, then catalyst regeneration is achieved, but feedstock must be flared or upstream units turned down, increasing emissions and costs
Solution Approach 1:
By maintaining continuous feed material flow through the online reactor trains during regeneration, the system eliminates the need to flare excess feedstock or turn down upstream gasification units. The continuous processing capability ensures that all feed material is productively utilized, preventing harmful emissions from flaring operations.
Solution Approach 2:
Instead of discarding feedstock through flaring, the system recovers and processes all feed material through the online reactor trains. The parallel reactor configuration ensures that feedstock continues to be converted into valuable products during regeneration, eliminating waste and associated emissions.
3Reliability
If conventional catalyst regeneration processes are used, then catalyst regeneration is performed, but plant efficiency decreases and operational costs increase
Solution Approach 1:
The plant is segmented into multiple independent reactor trains that can operate in parallel. This allows one train to undergo regeneration while others maintain full production, preventing overall plant shutdown and preserving operational efficiency. The segmented architecture enables maintenance and regeneration activities without compromising overall plant productivity.
Solution Approach 2:
The system maintains continuous and constant feed material flow through the online reactor trains during the entire regeneration process. This continuous operation eliminates production losses, maintains plant efficiency, and avoids the need for costly emergency shutdowns or production adjustments that would otherwise be required during catalyst regeneration.
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 maximizes operational efficiency and reduces environmental impact by maintaining near-constant production levels and minimizing emissions during catalyst regeneration, while also reducing capital expenditures associated with conventional methods.
Implementation Method 1
The Fischer-Tropsch (FT) process is widely used to generate fuels from carbon monoxide and hydrogen and can be represented by the equation: (2n+1)H2+nCO→CnH2n2+nH2O. This reaction is highly exothermic and is catalysed by a Fischer-Tropsch catalyst, typically a cobalt-based catalyst
Implementation Method 2
This reaction is highly exothermic and is catalysed by a Fischer-Tropsch catalyst
Implementation Method 3
The synthesis gas may be produced by gasifying a carbonaceous material at an elevated temperature, for example, about 700° C. or higher
Implementation Method 4
The synthesis gas may be produced by gasifying a carbonaceous material at an elevated temperature, for example, about 700° C. or higher. The carbonaceous material may comprise any carbon-containing material that can be gasified to produce synthesis gas
Data Source
AI summary
The present invention provides a process of conducting catalyst regeneration in a plant facility, comprising; providing a plant facility with a unit area operating within battery limits; wherein the battery limits of the unit area are configured to receive a feed material; receiving the feed material into the battery limits and flowing the feed material within the unit area of the plant facility through a plurality of parallel flow paths in a plurality of reactor trains wherein; each reactor train comprises at least one reactor; and at least one reactor in each reactor train is charged with a catalyst; isolating in at isolation step at least one, but not all, of the plurality of parallel flow paths to provide at least one isolated reactor train and remaining on-line reactor trains; regenerating in a regeneration step the catalyst in the at least one reactor in the at least one isolated reactor train; wherein during the regeneration step the feed material flows through the parallel flow paths supplied from the battery limits and accepted for processing in the plant facility is approximately constant before and during the isolation step.