Shared Regenerator Partition for Fluid Catalytic Cracking
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Solution Overview
Problem
Conventional Fluid Catalytic Cracking (FCC) processes face challenges with catalyst deactivation due to varying coke content in spent catalysts from multiple reactors, leading to inefficient regeneration and increased operational costs with separate regenerators for each reactor.
Innovation Solution
A regenerator assembly with a partition divides the vessel into subunits to regenerate spent catalysts from multiple reactors to different degrees, using controlled air flow to manage coke combustion and prevent unwanted deactivation, shared by multiple reactors to reduce costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate regenerators are used for each reactor, then each catalyst can be regenerated independently, but device complexity and operational costs increase
Solution Approach 1:
The shared regenerator is divided into multiple compartments or zones that can independently receive and process spent catalyst from different reactors. Each compartment can be optimized for specific catalyst types or coke levels while maintaining overall system integration.
Solution Approach 2:
A single regenerator unit is designed to handle spent catalyst from multiple reactors with varying coke content, making the system multi-functional. The regenerator can process different catalyst loads and types through controlled air flow and residence time management.
2Device complexity
If spent catalyst with varying coke content is regenerated together, then device complexity is reduced, but manufacturing precision of regeneration control deteriorates
Solution Approach 1:
Different zones within the shared regenerator are designed with distinct characteristics (temperature, air flow rate, residence time) to match the specific regeneration needs of catalyst from different reactors. High coke content catalyst receives intensive treatment in one zone while low coke catalyst is processed in another.
Solution Approach 2:
The system dynamically adjusts air flow rates, temperature profiles, and residence times based on the coke content and operational status of different reactors. This dynamic control enables precise regeneration management despite varying catalyst conditions.
3Reliability
If longer residence time is used in regenerator, then coke combustion is more complete, but thermal deactivation of catalyst increases
Solution Approach 1:
The system optimizes the balance between residence time and temperature by adjusting operational parameters dynamically. Different catalyst batches experience different residence time-temperature profiles to achieve complete coke combustion without excessive thermal deactivation.
Solution Approach 2:
The regenerator operates with periodic air supply cycles that alternate between high air flow (for complete combustion) and reduced air flow (to prevent overheating). This periodic action allows complete coke removal while controlling thermal stress on the catalyst.
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 spent catalysts to desired levels, reducing catalyst deactivation and operational costs while maintaining product yield and quality, by allowing separate regeneration of catalysts with varying coke content.
Implementation Method 1
The regeneration of the spent catalyst generates sufficient heat and increases the temperature of the catalyst
Implementation Method 2
a hydrocarbon feedstock of a high boiling point range is pre-heated and then brought into contact with a hot cracking catalyst in a catalytic cracking reactor
Implementation Method 3
The hot catalyst that is thus regenerated is directed back to the catalytic cracking reactor for the cracking process and is utilized to carry out the endothermic catalytic cracking
Data Source
AI summary
Methods and apparatus for fluid catalytic cracking (FCC) of a hydrocarbon feedstock includes a first reactor (1), a second reactor (2), and a regenerator assembly (3) shared and connected with the two reactors. The regenerator assembly (3) includes a regenerator vessel which has a partition (17) dividing the regenerator vessel into a first subunit (18) and a second subunit (19); a plurality of regenerator inlets for receiving a first spent catalyst and second spent catalyst by the first subunit (18) and the second subunit (19); a plurality of regenerator inlet for receiving a first spent catalyst and a second spent catalyst by the first subunit (18) and the second subunit (10) respectively; an air controller (15) to allow for has flow to an air distributor (16) for supply of the gas to the first subunit (18) and the second subunit (19) to combust coke deposited on the first and the second spent catalyst, separately, to a desired degree to generate a fully and a partially regenerated catalyst.