Separator-Reactor Vessel for Catalytic Cracking
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Catalytic cracking of heavy residues in refineries is hindered by contaminants like carbon residue, metal impurities, and sulfur compounds, which reduce catalyst activity and require costly secondary processes for separation and regeneration.
Innovation Solution
An apparatus and method involving a separator-reactor vessel with distinct channels for adsorbent and catalyst separation, where an adsorbent removes contaminants from the feedstock before it contacts the catalyst, allowing for separate regeneration and independent selection of physical properties, reducing catalyst contamination and operational costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contaminant separation techniques (residue hydro-demetallation, residue desulphurization, metal passivation) are used to protect the catalyst, then catalyst activity is maintained, but processing cost increases due to additional secondary processes
Solution Approach 1:
A magnetic adsorbent material is introduced as an intermediary between the heavy residue feedstock and the catalyst. This adsorbent selectively removes contaminants (metal impurities, sulfur compounds, nitrogen compounds) from the feedstock through adsorption, protecting the catalyst from deactivation while avoiding the need for complex secondary separation processes. The magnetic properties enable easy separation of the adsorbent from the cracked products.
2Reliability
If contaminant adsorption techniques using physical mixtures of catalyst and adsorbent are used, then contaminants are removed from the catalyst, but the technique is limited by physical properties (particle size, density) and becomes economically unviable
Solution Approach 1:
The patent uses a magnetic adsorbent as an intermediary that can be easily separated from both the feedstock and catalyst using magnetic fields. This eliminates the need for complex physical separation techniques based on particle size or density differences, making the process economically viable while maintaining effective contaminant removal.
Solution Approach 2:
The patent replaces mechanical separation methods (based on particle size, density, or magnetic properties of catalyst and adsorbent) with magnetic field-based separation of the magnetic adsorbent. This substitution simplifies the separation process and removes limitations associated with physical property matching between catalyst and adsorbent particles.
3Reliability
If metal passivation technique is used to protect the catalyst, then catalyst deactivation is reduced, but operating conditions must be frequently changed rendering the apparatus ineffective
Solution Approach 1:
The magnetic adsorbent performs preliminary removal of contaminants (including metal impurities) from the heavy residue feedstock before the feedstock contacts the catalyst. This preliminary action prevents catalyst deactivation without requiring frequent changes in operating conditions, maintaining continuous and stable operation of the catalytic cracking apparatus.
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 enhances catalyst performance and life, reduces catalyst addition rates, and lowers operational costs by minimizing contaminant exposure and enabling independent selection of adsorbent and catalyst properties.
Implementation Method 1
A feedstock is treated with an adsorbent in the first channel to produce a treated intermediate
Implementation Method 2
The treated intermediate is contacted with a catalyst in the second channel. On contact with the catalyst, the treated intermediate is converted to a cracking yield
Data Source
AI summary
An apparatus for catalytic cracking of feedstock includes a first channel in which a feedstock is treated with an adsorbent to obtain a treated intermediate. The apparatus further comprises a separator-reactor vessel. The separator-reactor vessel includes an adsorbent separating region to remove the adsorbent from the treated intermediate. The separator-reactor vessel further includes a second channel connected to the adsorbent separating region. The treated intermediate is contacted with a catalyst in the second channel to produce a cracking yield. The second channel terminates in a catalyst separating region of the separator-reactor vessel. The catalyst is removed from the cracking yield in the catalyst separating region. The separator-reactor vessel further includes a physical partition disposed between the adsorbent separating region and the catalyst separating region to separate the two regions.