Recessed FCC Riser Feed Distributor with Shielded Nozzles
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Solution Overview
Problem
In fluid catalytic cracking (FCC) processes, existing methods face challenges in efficiently distributing gaseous hydrocarbon feeds to the reactor, particularly when recycling product cuts like naphtha, which can affect the production of light olefins and catalyst efficiency.
Innovation Solution
A feed distributor with a tubular header and array of nozzles is positioned in a recess within the riser wall, spraying gaseous hydrocarbons from behind an imaginary line extending between the top and bottom intersections of the recess, ensuring effective contact with catalysts and optimizing the cracking process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If gaseous hydrocarbon feed is introduced into the FCC reactor, then the cracking reaction can proceed, but the distribution of feed to catalyst may be insufficient leading to poor contact efficiency
Solution Approach 1:
The feed distributor is segmented into multiple nozzles arranged in arrays on the tubular header, with nozzles positioned at different locations (front, side, rear) to distribute gaseous feed across different zones of the riser, ensuring comprehensive contact with catalyst particles
Solution Approach 2:
The feed distribution is extended from a single-point injection to a three-dimensional distribution pattern using nozzles positioned at front, side, and rear locations, creating multi-directional spray patterns that enhance feed-catalyst contact throughout the riser cross-section
2Productivity
If product cuts like naphtha are recycled to increase light olefin production, then light olefin yield increases, but the feed distribution system becomes more complex
Solution Approach 1:
The tubular header feed distributor with its array of nozzles serves multiple functions: distributing recycled naphtha, distributing fresh hydrocarbon feed, and accommodating different feed rates and compositions, making it a universal distribution system for various feed streams
Solution Approach 2:
Multiple feed distribution functions are merged into a single integrated tubular header structure with arrays of nozzles, combining what would traditionally require separate distribution systems into one unified device that handles both recycled and fresh feeds
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 enhances the distribution of gaseous hydrocarbons, improving the cracking efficiency and increasing the production of light olefins, such as propylene and ethylene, by ensuring uniform and efficient contact with the catalysts, thereby enhancing the overall FCC process performance.
Implementation Method 1
gaseous feed is sprayed from nozzles in the header into contact with the catalyst
Data Source
AI summary
An FCC process may include a distributor disposed in a recess in a wall of the riser for distributing gaseous hydrocarbon feed to a riser. The distributor may be shielded from upwardly flowing catalyst by a shield. An array of nozzles from the distributor may extend through openings in the shield.