Ventilated Annular Baffle for Catalyst Regeneration Fluidization
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Solution Overview
Problem
High gas velocity in catalyst regeneration units leads to catalyst attrition and clogging of vent gas lines due to excessive fluidization, which is not effectively addressed by existing technologies.
Innovation Solution
Modifying the bottom portion of the annular baffle in catalyst regeneration units by adding a ventilated screen or perforated plate to reduce gas velocity, increasing the surface area for gas escape and reducing fluidization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the gas velocity in the catalyst bed is increased to improve regeneration efficiency, then the regeneration process becomes more effective, but catalyst attrition and clogging of vent gas lines occur due to excessive fluidization
Solution Approach 1:
The annular baffle is segmented into a solid upper portion and a ventilated lower portion with openings. This segmentation allows the gas flow to be distributed differently across the baffle height, reducing excessive velocity at the catalyst bed interface while maintaining overall regeneration efficiency. The ventilated section specifically addresses the fluidization problem without compromising the regeneration process.
Solution Approach 2:
Different portions of the annular baffle are given different properties: the upper portion remains solid to maintain structural integrity and catalyst retention, while the lower portion is made ventilated with openings to reduce gas velocity and minimize catalyst attrition. This local differentiation of properties allows simultaneous optimization of both regeneration efficiency and catalyst stability.
2Stability of the object's composition
If a solid annular baffle is used to maintain catalyst bed structure, then catalyst retention is improved, but gas velocity becomes too high causing catalyst fluidization and attrition
Solution Approach 1:
The annular baffle is divided into two functional sections: a solid upper portion that provides structural support and catalyst retention, and a ventilated lower portion with openings that reduces gas velocity to prevent catalyst fluidization and attrition. This segmentation resolves the contradiction between maintaining bed structure and preventing harmful fluidization effects.
Solution Approach 2:
The baffle structure is modified by applying different local properties: the upper portion maintains solid construction for structural stability, while the lower portion incorporates ventilated openings to reduce gas velocity locally at the catalyst bed interface, thereby preventing attrition without compromising overall bed structure.
3Reliability
If the annular baffle is modified with a ventilated screen or perforated plate, then gas velocity is reduced and catalyst attrition decreases, but the device complexity increases
Solution Approach 1:
The lower portion of the annular baffle is constructed using a ventilated screen or perforated plate, which are standardized porous-like structures. These components are commercially available and can be directly installed, reducing the need for custom fabrication. The ventilated structure effectively reduces gas velocity and catalyst attrition while maintaining relatively simple construction using standard industrial components.
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 effectively reduces catalyst attrition and clogging by decreasing gas velocity, providing a 25-50% increase in gas escape surface area without altering the catalyst flow regime or requiring significant design changes, and offers a low-cost solution to the problem of fluidization.
Implementation Method 1
the addition of about a 6 to 25 cm ventilated screen or a perforated plate to the bottom of the annular baffle sufficiently solves the problem of excessive gas velocity of the combined reduction gas flow
Data Source
AI summary
The invention involves a process that reduces the potential for catalyst fluidization in a reduction vessel of a continuous catalyst regeneration system. The gas exit area from the catalyst reduction zone is increased by ventilating the cylindrical baffle of the upper reduction zone. This provides an increased exit cross-sectional area for the upper reduction gas to escape and reduce the overall exit velocity of the combined upper and lower reduction gases and reduces the potential for catalyst fluidization.