Preheated Particle Feed Line Heating for High-Temperature Reactions
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Solution Overview
Problem
Existing processes for carrying out reactions on preheated particles are limited by the maximum temperature that can be achieved in a buffer container, which is insufficient for high-temperature reactions, and require additional heating methods to maintain uniform temperature distribution, especially in reactions where coke generation is insufficient or not applicable.
Innovation Solution
A process where particles are heated in a feed line to temperatures above those achievable in a buffer container, using combustible and oxidant combustion or other heating means, allowing for efficient transfer to a reactor while enabling catalyst regeneration at lower temperatures, and ensuring uniform heat distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If particles are preheated in a buffer container, then particles can be stored and regenerated at lower temperatures, but the maximum temperature is limited by buffer container and valve materials
Solution Approach 1:
The particles are preheated to reaction temperature in the feed line before entering the reactor, rather than storing them at high temperature in the buffer container. This preliminary heating action in the feed line allows the buffer container to operate at lower, material-compatible temperatures while still achieving the required high particle temperature for reaction
Solution Approach 2:
The heating function is segmented between two locations: the buffer container maintains particles at lower temperatures for storage and regeneration, while the feed line provides additional heating to achieve the final high reaction temperature. This segmentation allows each component to operate within its material temperature limits
2Temperature
If particles are heated to higher temperatures for reactions like pyrolysis, then reaction temperature requirements are met, but the particles cannot be handled in a regenerator at such high temperatures
Solution Approach 1:
The particles receive their final temperature increase in the feed line just before entering the reactor, rather than being maintained at high temperature throughout the system. This allows the regenerator to operate at lower, safer temperatures for particle handling while the feed line provides the necessary high temperature for the reaction
Solution Approach 2:
High temperature is applied locally only in the feed line where needed for reaction initiation, while the buffer container and regenerator operate at lower temperatures for safe particle handling. This localized heating approach meets reaction temperature requirements without compromising operational safety
3Temperature
If additional heat is supplied between regenerator and reactor, then particle temperature can be increased, but process complexity increases
Solution Approach 1:
The feed line serves dual functions: it transports particles from the buffer container to the reactor and simultaneously provides heating to increase particle temperature. By merging the transport and heating functions into a single component, the system avoids the need for separate heating equipment, thereby reducing overall process complexity
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
Enables the achievement of higher reaction temperatures necessary for processes like fluid catalytic cracking and pyrolysis, maintains catalyst efficiency by avoiding coke deposition, and allows for the reuse of particles by recycling them through a buffer container for regeneration.
Implementation Method 1
using combustible and oxidant combustion or other heating means
Implementation Method 2
ensuring uniform heat distribution
Data Source
AI summary
The invention relates to a process for carrying out reactions on preheated particles, comprising: (a) providing particles in a buffer container; (b) feeding the particles from the buffer container into a reactor via a feed line; (c) withdrawing the particles from the reactor, wherein the particles are heated in the feed line.