Slurry Separator Moving Blade for LCO Recovery
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Solution Overview
Problem
The existing FCC process struggles to efficiently remove catalyst fines from slurry oil, leading to suboptimal recovery of Light Cycle Oil (LCO) and resulting in reduced product value, as conventional methods like settling tanks, mechanical filtration, and electrostatic filtration have demonstrated less than ideal performance.
Innovation Solution
A slurry separator with a moving blade that wipes slurry oil onto its wall, generating a thin film for efficient separation of a recovered oil stream from a concentrated residue stream, effectively removing catalyst fines and coke particles, thereby maximizing the recovery of solids-free oil.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods (settling tanks, mechanical filtration, electrostatic filtration) are used to remove catalyst fines, then some separation is achieved, but the recovery of LCO is suboptimal and product value is reduced
Solution Approach 1:
The patent replaces conventional mechanical filtration systems (settling tanks, filters, electrostatic separators) with a thermal field-based separation system. The slurry oil is heated to vaporize the catalyst fines and coke particles, which are then removed from the oil stream, enabling both effective separation and high LCO recovery simultaneously
Solution Approach 2:
The invention utilizes phase transition of the catalyst fines and coke particles from solid/liquid suspension to vapor phase through heating. The slurry oil is heated to a temperature that vaporizes the lighter catalyst fines and coke particles, allowing them to be separated from the liquid oil phase, thus achieving both separation quality and productivity improvement
2Reliability
If LCO is left in the slurry oil to control bottom temperature, then process reliability is maintained, but total product value is reduced
Solution Approach 1:
The patent replaces temperature-based process control with a separation-based approach. Instead of controlling bottom temperature to manage LCO content, the system uses thermal vaporization to physically separate LCO from catalyst fines and coke particles, allowing independent optimization of both process reliability and product value
Solution Approach 2:
The invention extracts and removes catalyst fines and coke particles from the slurry oil through vaporization and separation. This extraction allows the LCO to be recovered in a purified form, maximizing product value while maintaining process reliability through the separation mechanism rather than temperature control
3Device complexity
If catalyst fines are not removed, then processing is simpler, but product value is reduced due to presence of solids
Solution Approach 1:
The patent employs a simple thermal vaporization process that leverages the difference in volatility between the slurry oil components. By heating the slurry oil, the catalyst fines and coke particles vaporize and are easily separated from the liquid oil, achieving effective removal without complex separation equipment or multi-stage processing
Solution Approach 2:
The invention substitutes complex mechanical separation systems with a simple thermal field-based process. The heating element creates a thermal field that vaporizes catalyst fines and coke particles, which are then removed from the oil stream, achieving both simplicity and effectiveness in catalyst fine removal
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 enables higher production of higher value, solids-free oil by effectively removing catalyst fines and coke particles, enhancing the overall efficiency and product value of the FCC process.
Implementation Method 1
A slurry separator with a moving blade that wipes slurry oil onto its wall, generating a thin film for efficient separation
Implementation Method 2
separating a recovered oil stream from a concentrated residue stream, effectively removing catalyst fines and coke particles
Data Source
AI summary
A slurry separator comprising a moving blade that wipes slurry oil onto a wall of the slurry separator for separating a recovered oil stream from a concentrated residue stream has the capability of maximizing recovery of the LCO from slurry oil as well as removing both the catalyst fines as well as coke particles suspended in the slurry oil. The slurry separator can be fed directly from the main column bottoms. Advantageously, the process and apparatus can enable the FCC unit to achieve higher production of LCO and higher value clarified slurry oil more efficiently.