Riser Feed Distributor Plate for FCC Catalyst Mixing
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Solution Overview
Problem
In the fluid catalytic cracking (FCC) process, distributing hydrocarbon feed evenly throughout the riser to ensure adequate mixing with catalyst is challenging, particularly due to the formation of a dense catalyst core and the difficulty in penetrating vaporous feeds into a flowing catalyst stream, which hampers efficient conversion of hydrocarbons.
Innovation Solution
A distributor system that feeds hydrocarbon and catalyst concurrently upwardly through a plate with multiple openings uniformly spread across the riser's cross-section, ensuring even distribution and contact within the reaction zone, enhancing mixing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If hydrocarbon feed is injected transversely into the riser, then feed distribution is simplified, but mixing efficiency deteriorates due to dense catalyst core formation
Solution Approach 1:
The distributor plate is segmented into multiple zones with different opening configurations. The plate includes a first region with openings for liquid feed and a second region with openings for vaporous feed, allowing segmented distribution strategies for different feed types to overcome the dense catalyst core problem while maintaining structural simplicity
Solution Approach 2:
Different regions of the distributor plate have different opening characteristics optimized for specific feed types. The first region has openings configured for liquid hydrocarbon feed while the second region has openings configured for vaporous recycled feed, enabling local optimization of feed distribution quality to improve mixing efficiency without increasing overall device complexity
2Productivity
If riser diameter is increased to handle higher throughput, then processing capacity improves, but feed penetration ability deteriorates
Solution Approach 1:
The distributor plate is divided into multiple regions with different opening patterns and densities. This segmentation allows the system to handle larger riser diameters and higher throughput while maintaining effective feed distribution across the entire cross-section, including better penetration to the center region where dense catalyst cores form
Solution Approach 2:
The distributor plate parameters (opening size, opening density, opening distribution) are optimized to change according to the riser diameter and feed type. This allows the system to maintain effective feed penetration ability across different riser sizes and throughput levels
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 solution allows for better contact between hydrocarbon feed and catalyst, improving the conversion efficiency of hydrocarbons and overcoming the limitations of traditional feed distribution methods by ensuring uniform distribution across the riser's cross-section.
Implementation Method 1
A distributor system that feeds hydrocarbon and catalyst concurrently upwardly through a plate with multiple openings uniformly spread across the riser's cross-section
Implementation Method 2
Hydrocarbon feed distributors spray dispersion steam and hydrocarbon feed into the riser typically transversely to a flowing stream of catalyst that is propelled upwardly by a fluidizing, lift gas
Data Source
AI summary
A process and apparatus for fluid catalytic cracking feeds catalyst to a chamber of a riser. The catalyst exits the chamber and passes through a plenum and into a reaction zone through a plurality of tubes which distribute the catalyst uniformly over a cross section of the reaction zone of the riser. A hydrocarbon feed is fed to the plenum. The hydrocarbon feed passes from the plenum into the reaction zone through a plate comprising a multiplicity of openings which distribute the hydrocarbon feed uniformly over a cross section of the reaction zone of the riser. The feed is contacted with the catalyst in a reaction zone of the riser.