Spent Catalyst Distributor for Uniform Regenerator Distribution
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Solution Overview
Problem
Existing spent catalyst distributors in the Fluidized Catalytic Cracking (FCC) process fail to achieve uniform distribution of spent catalyst in the regenerator, leading to inefficient coke burning, hotspots, and localized catalyst deactivation, resulting in suboptimal regeneration and increased NOx and SOx emissions.
Innovation Solution
A spent catalyst distributor design featuring a conduit with multiple orifices and a distal opening that projects spent catalyst horizontally and/or downwardly across the regenerator vessel, ensuring even distribution and minimizing hotspots, combined with optional aeration to enhance fluidization and distribution efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If spent catalyst is distributed using conventional distributors (standpipes with radial slots, deflector plates, or single-point injection), then the structure is simple and ease of manufacture is good, but uniform distribution of catalyst is not achieved, leading to hotspots and inefficient regeneration
Solution Approach 1:
The spent catalyst distributor is segmented into multiple injection points arranged around the regenerator perimeter, with each point having multiple nozzles oriented at different angles. This segmentation allows the catalyst flow to be divided into multiple streams that distribute more uniformly across the catalyst bed, eliminating the single-point injection limitation of conventional designs.
Solution Approach 2:
The invention transitions from conventional single-point or radial injection to a multi-dimensional distribution system. The nozzles are arranged in three dimensions with varying orientations (horizontal, downward, and angled), creating a spatial distribution pattern that achieves uniform catalyst dispersion throughout the regenerator volume rather than concentrating it in specific zones.
2Productivity
If spent catalyst is not uniformly distributed, then device complexity remains low, but coke burning efficiency decreases and hotspots occur
Solution Approach 1:
Each nozzle in the distributed injection system is locally optimized with specific orientation and positioning to address the local requirements of different regions in the regenerator. The varying nozzle angles (horizontal, downward, angled) are selected based on the specific distribution needs of each zone, ensuring that catalyst is delivered where it is most needed for efficient coke combustion.
Solution Approach 2:
The multi-point injection system ensures continuous and uniform catalyst distribution throughout the regenerator, eliminating the intermittent and localized injection patterns of conventional systems. This continuous distribution maintains optimal conditions for coke burning across the entire catalyst bed, preventing temperature spikes and ensuring consistent regeneration performance.
3Reliability
If conventional distribution methods are used, then installation is simple, but regeneration quality is suboptimal with increased NOx and SOx emissions
Solution Approach 1:
The spent catalyst distributor is designed as a universal system that can be adapted to different regenerator configurations and catalyst flow rates. The modular nozzle arrangement and adjustable injection parameters allow the same basic design to achieve optimal distribution across various operating conditions, improving regeneration quality while maintaining installation flexibility.
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
The solution achieves improved coke burning and catalyst regeneration, reducing hotspots and deactivation, while maintaining a cleaner regenerated catalyst with reduced NOx and SOx emissions, and ensuring uniform particle distribution and negligible pressure buildup.
Implementation Method 1
combined with optional aeration to enhance fluidization and distribution efficiency
Data Source
Figure 1(a)
Figure 1(b)
Figure 2
AI summary
A spent catalyst distributor for distributing spent catalyst in a catalyst regenerator vessel (102, 202, 302, 402) housing a dense phase catalyst bed (108a) and a dilute phase catalyst bed (108b) is disclosed. The spent catalyst distributor comprises a conduit (110, 206, 306, 406) comprising a proximal end (112a, 208a, 308a, 408a) and a distal end (112b, 208b, 308b, 408b). The conduit (110, 206, 306, 406) projects horizontally or horizontally and downwardly into the regenerator vessel (102, 202, 302, 402) and includes an opening (114, 210, 310, 410) located at the distal end (112b, 208b, 308b, 408b). The conduit (110, 206, 306, 406) further includes a plurality of orifices (116, 212, 312, 412) located along a length of the conduit (110, 206, 306, 406) between the distal end (112b, 208b, 308b, 408b) and an inner wall (106a, 214, 314, 414) of the regenerator vessel (102, 202, 302, 402).