Slumped-Bed Slurry Reactor Fines Removal via Centrifugal Separation
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Solution Overview
Problem
Three-phase slurry processes, such as Fischer-Tropsch hydrocarbon synthesis, face challenges in maintaining filter efficiency due to catalyst fines accumulation, leading to filter plugging and deactivation, necessitating frequent backwashing and replacement, and there is a need for effective separation of catalyst particles from liquid products without relying on filters.
Innovation Solution
Operating the slurry process in a slumped-bed mode with a solids concentration less than 20 wt% in the upper region, degassing the slurry, and using liquid-solid separation devices other than filters to separate bulk catalyst particles and fines, allowing for the elimination of internal filters and improved separation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If filters are used to separate catalyst particles from liquid products, then separation is achieved, but filter efficiency decreases over time due to fines accumulation requiring frequent backwashing and replacement
Solution Approach 1:
The invention extracts and removes catalyst fines from the slurry liquid before the liquid reaches the filter. By using a centrifugal separator to remove fines from the liquid product stream, the filter is protected from fines accumulation, maintaining filter efficiency and reducing maintenance requirements.
Solution Approach 2:
The invention introduces a centrifugal separator as an intermediary device between the slurry reactor and the filter. This intermediary removes fines from the liquid stream before it reaches the filter, acting as a protective barrier that prevents filter plugging and extends filter life.
2Reliability
If filters are used to separate catalyst particles from liquid products, then separation is achieved, but the filter media plugs due to fines accumulation
Solution Approach 1:
The invention extracts and removes catalyst fines from the slurry liquid before the liquid product reaches the filter. By using a centrifugal separator to remove fines from the liquid product stream, the filter is protected from fines accumulation, maintaining filter efficiency and reducing maintenance requirements.
Solution Approach 2:
The invention introduces a centrifugal separator as an intermediary device between the slurry reactor and the filter. This intermediary removes fines from the liquid stream before it reaches the filter, acting as a protective barrier that prevents filter plugging and extends filter life.
3Productivity
If catalyst fines are present in the slurry liquid, then liquid product can be removed, but excessive filter backwashing and fouling occurs
Solution Approach 1:
The invention extracts and removes catalyst fines from the slurry liquid before the liquid product reaches the filter. By using a centrifugal separator to remove fines from the liquid product stream, the filter is protected from fines accumulation, maintaining filter efficiency and reducing maintenance requirements.
4Reliability
If internal filters are used in the slurry bed, then catalyst separation is achieved, but device complexity increases
Solution Approach 1:
The invention extracts and removes catalyst fines from the slurry liquid before the liquid product reaches the filter. By using a centrifugal separator to remove fines from the liquid product stream, the filter is protected from fines accumulation, maintaining filter efficiency and reducing maintenance requirements.
Solution Approach 2:
The invention introduces a centrifugal separator as an intermediary device between the slurry reactor and the filter. This intermediary removes fines from the liquid stream before it reaches the filter, acting as a protective barrier that prevents filter plugging and extends filter life.
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 the separation of catalyst particles from liquid products, reduces the need for frequent filter maintenance, and enables efficient removal of liquid products without filter usage, thereby improving process efficiency and extending filter lifespan.
Implementation Method 1
the settling tendency of the catalyst particles is opposed by dispersion forces created by the rising gas bubbles
Implementation Method 2
the settling tendency of the catalyst particles is opposed by dispersion forces created by the rising gas bubbles
Data Source
AI summary
The present invention provides methods and means for separating slurry liquid from catalyst in a three-phase slurry process. The embodiments of the invention are characterized by conducting the three-phase process under conditions to provide an upper region in the slurry that contains a catalyst concentration of about 20 wt % or less and a lower region with a catalyst concentration higher than about 20 wt %. A portion of the slurry in this upper region is degassed and passed to liquid-solid separation devices for recovery of liquid product.