Structured Packing for FCC Strippers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional gas-solid contacting systems in FCC strippers face issues such as catalyst maldistribution, gas bypassing, and flooding, which reduce mass transfer efficiency and increase the likelihood of inactive volumes and dead zones.
Innovation Solution
The implementation of a gas-solid contacting system with structured packing, featuring a gas header, vertically aligned tubes with radial gas distribution, and structured packing elements with twisted plates and holes, creates a 3D flow path for catalysts and controls gas bubble size, enhancing radial distribution and mass transfer efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional gas-solid contacting systems are used in FCC strippers, then the system structure is simple, but catalyst maldistribution, gas bypassing, and flooding occur which reduce mass transfer efficiency
Solution Approach 1:
The packing is divided into multiple structured packing elements arranged in parallel rows, each element consisting of segmented plates with specific geometries. This segmentation creates multiple flow paths that distribute catalyst and steam uniformly, preventing maldistribution and flooding while maintaining efficient mass transfer
Solution Approach 2:
The invention transitions from conventional two-dimensional contact patterns to three-dimensional flow paths through vertically stacked structured packing elements. The 3D arrangement with plates at different heights and angles creates complex flow patterns that enhance gas-solid contact efficiency while preventing bypassing
2Productivity
If conventional packing is used, then the device complexity is low, but inactive volumes and dead zones are formed which reduce productivity
Solution Approach 1:
The structured packing elements incorporate curved and angled plate surfaces that guide flow patterns smoothly through the packing. The non-linear flow paths created by inclined plates and curved surfaces prevent stagnant zones and dead volumes, ensuring all catalyst particles are actively contacted by steam for maximum hydrocarbon recovery
Solution Approach 2:
Different regions of the structured packing elements have different plate angles, openings, and geometries optimized for local flow conditions. This local customization ensures uniform distribution of catalyst and steam throughout the entire packing volume, eliminating inactive zones and maximizing productivity
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 solution improves catalyst distribution, reduces inactive volumes, and prevents dead zones, thereby enhancing mass transfer efficiency and hydrocarbon recovery in FCC strippers.
Implementation Method 1
The vertically aligned tubes include openings at different heights of the tubes to distribute the gas received from the gas header in radial direction
Implementation Method 2
The plurality of vertically aligned tubes and the structured packing elements arranged on the vertically aligned tubes create a 3D flow path for the catalyst
Implementation Method 3
creates a 3D flow path for catalysts and controls gas bubble size, enhancing radial distribution and mass transfer efficiency
Data Source
AI summary
A gas-solid contacting system (100) with structured packing (108) is disclosed. The structured packing (108) comprises a gas header (102) with an inlet to receive a gas. A plurality of vertically aligned tubes (104) is fluidically connected to the gas header (102), wherein each vertically aligned tube (104) comprises openings (180) to distribute the gas at different heights in a radial direction. A structured packing element (106) is arranged on each vertically aligned tube (104), wherein the structured packing element (106) comprises one or more plates attached to the vertically aligned tube (104) to create a convoluted 3-dimensional flow path for smooth flow and radial distribution of a solid particulate stream.