Parallel Thermocompressors for Catalyst Regeneration Turndown

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Solution Overview

Problem

Continuous catalyst regeneration systems face challenges in maintaining operation under low coke conditions due to insufficient combustion air, which can lead to inadequate air heater and cooling zone requirements, affecting the efficiency and stability of the thermocompressor system.

Innovation Solution

A system utilizing two thermocompressors in parallel, where the first thermocompressor uses combustion air as a motive vapor and the second uses nitrogen, with valves to selectively direct a cooled stream to either compressor to produce a catalyst cooling stream, ensuring continuous operation by adjusting motive vapors based on operating conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a single thermocompressor utilizing combustion air as motive vapor is used, then the system can operate under normal coke conditions, but the system cannot maintain operation under low coke conditions due to insufficient combustion air flow

Engineering Contradiction:

Improvecatalyst regeneration throughputVSAvoidsystem operational continuity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The single thermocompressor is segmented into two parallel thermocompressors. The first thermocompressor handles normal operation with combustion air, while the second thermocompressor provides backup capability using nitrogen as motive vapor. This segmentation allows the system to maintain catalyst regeneration throughput under normal conditions while ensuring operational continuity under low coke conditions by switching to or combining with the second thermocompressor.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system changes the motive vapor parameter from solely combustion air to a flexible combination of combustion air and nitrogen. By adjusting the motive vapor composition and flow distribution between the two parallel thermocompressors, the system can adapt to varying coke conditions and maintain reliable operation across different throughput levels.

Inventive Principle:

Principle #35Parameter changes

2Loss of energy

If combustion air flow is reduced under low coke conditions, then oxygen consumption is minimized, but the air heater and cooling zone cannot meet minimum flow requirements

Engineering Contradiction:

Improveoxygen consumptionVSAvoidair heater and cooling zone operation

Core Design Contradiction:

Loss of energyVSEase of operation

Solution Approach 1:

Nitrogen serves as an intermediary motive vapor that can be introduced through the second thermocompressor when combustion air flow is insufficient. This intermediary allows the system to maintain the minimum flow requirements for the air heater and cooling zone without relying solely on combustion air, thereby ensuring ease of operation while controlling oxygen consumption under low coke conditions.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If the system switches to using nitrogen as motive vapor in the second thermocompressor, then operational stability is maintained under low coke conditions, but system complexity increases with parallel compressor configuration

Engineering Contradiction:

Improvesystem operational stabilityVSAvoidthermocompressor system configuration

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The parallel thermocompressor configuration provides multi-functionality: the first thermocompressor handles normal operation, the second thermocompressor provides backup and supplemental capacity, and both can operate simultaneously or independently based on conditions. This universality maintains operational stability across different coke levels while managing complexity through a modular, scalable architecture where each unit serves multiple potential functions.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 configuration maintains system operation during low coke conditions by providing sufficient air flow and pressure, ensuring efficient catalyst regeneration while maintaining appropriate oxygen concentrations in the regeneration zones, thus extending the system's operational stability and efficiency.

Implementation Method 1

a first thermocompressor, a second thermocompressor in parallel with the first thermocompressor... The first thermocompressor utilizes a first motive vapor. The second thermocompressor utilizes nitrogen as a motive vapor

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS8865608B2Turndown thermocompressor design for continuous catalyst recovery

Publication Date: 2014.10.21 UOP LLC

AI summary

Systems and processes for regenerating catalyst are provided herein that include a catalyst regeneration tower having a cooling zone that receives a catalyst cooling stream generated by a cooling gas loop. The systems and processes include a first thermocompressor that utilizes a first motive vapor and a second thermocompressor that utilizes a second motive vapor in order to provide the catalyst cooling stream to the regeneration tower. The second thermocompressor operates in parallel with the first thermocompressor. The first thermocompressor can utilize combustion air as the motive vapor. The second thermocompressor can utilize nitrogen as the motive vapor.