Regenerator Baffle for Catalyst Flow Distribution
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Deep catalyst beds in regenerator vessels suffer from flow distribution issues, leading to incomplete regeneration due to downward annular catalyst flow along the walls, resulting in insufficient contact with regeneration gas, which reduces catalyst activity and feed conversion yields.
Innovation Solution
Installation of deflector baffles on the regenerator vessel walls to push catalyst away from the walls and into the main section, ensuring thorough mixing with regeneration gas for complete combustion of coke.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If deep catalyst beds are used in regenerator vessels, then catalyst residence time is increased allowing complete coke combustion, but downward annular catalyst flow along the walls occurs causing flow distribution issues and incomplete regeneration
Solution Approach 1:
The harmful downward annular flow along the walls is extracted and eliminated by introducing upward gas flow through wall-mounted nozzles. This counteracts the gravitational downward flow and redistributes catalyst uniformly throughout the bed, preventing flow distribution issues while maintaining adequate residence time for complete coke combustion
Solution Approach 2:
The local gas velocity parameter is changed by introducing regeneration gas through wall nozzles at controlled rates. This creates upward gas flow that counteracts downward catalyst flow, transforming the flow distribution from annular to uniform radial patterns, thereby improving flow stability without reducing residence time
2Productivity
If catalyst flows down the walls of the regenerator, then catalyst bypasses the main regeneration zone, but this reduces exposure to regeneration gas and combustion efficiency
Solution Approach 1:
Regeneration gas introduced through wall nozzles acts as an intermediary that redirects catalyst flow from the walls into the main regeneration zone. The gas flow mediates between gravity-driven downward flow and the desired uniform distribution, ensuring catalyst particles are pushed into regions with sufficient oxygen for complete combustion while maintaining high regeneration efficiency
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
Prevents downward catalyst flow, enhancing catalyst regeneration and overall Fluid Catalytic Cracking (FCC) performance by ensuring sufficient exposure to regeneration gas, thereby improving product yield and minimizing operating costs.
Implementation Method 1
A baffle on the wall pushes catalyst away from the wall
Implementation Method 2
Regeneration gas is delivered to the regenerator vessel for combusting coke from the catalyst
Implementation Method 3
A high temperature regeneration operation within a regenerator zone combusts coke from the catalyst
Implementation Method 4
In a bubbling bed regenerator, fluidizing regeneration gas forms bubbles that ascend through a discernible top interface of a dense catalyst bed
Implementation Method 5
fluidizing regeneration gas forms bubbles that ascend through a discernible top interface
Implementation Method 6
Cyclone separators remove catalyst entrained in the flue gas before the gas exits the regenerator vessel
Data Source
AI summary
A baffle is installed on the wall of a regenerator vessel to push catalyst away from the wall to ensure adequate exposure to regeneration gas and complete combustion of coke from the catalyst. We have found that in deep beds, catalyst can flow down the walls and escape sufficient exposure to regeneration gas and undergo too little regeneration.