Integrated Regenerator Drying Catalyst for Propane Dehydrogenation
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Solution Overview
Problem
In catalytic hydrocarbon processing, particularly in fluidized bed reactor-regenerator systems, catalyst deactivation due to coke accumulation and sensitivity to water and gases like oxygen and carbon monoxide poses challenges in maintaining long-term process viability, with existing regeneration methods being insufficient to fully restore catalyst activity.
Innovation Solution
An integrated regenerator design that includes a combustion chamber, a drying chamber, and a stripping chamber, where the spent catalyst is regenerated, dried, and stripped of residual gases and water, using a drying gas to achieve over 90% water removal and subsequent stripping to remove residual oxygen, thereby improving catalyst activity without the need for additional drying equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional regenerator design is used, then catalyst regeneration is achieved, but water removal efficiency is insufficient and additional drying equipment is required
Solution Approach 1:
The patent combines the regenerator and dryer into a single integrated unit. The regenerator's combustion chamber serves dual purposes: regenerating the catalyst and drying it by removing adsorbed water through the combustion process and hot gas contact. This eliminates the need for separate drying equipment while achieving over 90% water removal efficiency.
Solution Approach 2:
The regenerator is designed to perform multiple functions simultaneously: catalyst regeneration through coke combustion, water removal through hot gas contact and evaporation, and catalyst heating. This multi-functionality eliminates the need for dedicated drying equipment while improving overall process efficiency.
2Device complexity
If catalyst is exposed to water during regeneration, then regeneration process is simplified, but catalyst activity is reduced due to water sensitivity
Solution Approach 1:
The patent implements preliminary drying action within the regenerator before the regenerated catalyst leaves the unit. The combustion process and hot gas contact occur first, removing the majority of adsorbed water, and only then does the catalyst proceed to the dryer for final moisture reduction. This preliminary water removal protects water-sensitive catalysts while maintaining process simplicity.
3Manufacturing precision
If separate drying equipment is added, then water removal efficiency is improved, but capital costs increase
Solution Approach 1:
The patent merges the regenerator and dryer into one integrated piece of equipment. The regenerator's combustion chamber and associated gas handling systems are used for both regeneration and drying functions, eliminating the need for separate drying equipment and the capital investment it would require.
Solution Approach 2:
The regenerator is designed to perform multiple functions including catalyst regeneration, water removal through evaporation, and catalyst heating. This multi-functionality eliminates the need for dedicated drying equipment while achieving over 90% water removal efficiency, thereby reducing capital costs.
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 effectively regenerates catalysts by removing adsorbed water and gases, enhancing catalyst performance and reducing capital costs by eliminating the need for separate drying systems, ensuring efficient recirculation and reuse of catalysts in continuous processes.
Implementation Method 1
the catalyst is passed to the regenerator, where the coke is burned off, and the catalyst is regenerated
Implementation Method 2
the combustion of coke on the catalyst
Implementation Method 3
A drying gas is passed to the drying chamber to remove water from the catalyst
Implementation Method 4
the regeneration process produces some moisture that can be adsorbed onto the regenerated catalyst
Implementation Method 5
The stripping chamber has a stripping gas inlet, and the stripping gas after contacting the catalyst
Data Source
AI summary
An apparatus and process are presented for drying a catalyst in a reactor-regenerator system. The process includes a continuous operating system with catalyst circulating between a reactor and regenerator, and the catalyst is dried before returning the catalyst to the reactor. The process uses air that is split between the drying stage and the combustion stage without adding equipment outside of the regenerator, minimizing energy, capital cost, and space requirements.