Systems and methods for regenerating a spent catalyst
View Patent ↗Systems and methods for regenerating a spent catalyst are provided. The method can include heating a hydrocarbon and a coke precursor in the presence of catalyst particles to provide a cracked hydrocarbon product and coked catalyst particles. The cracked hydrocarbon product and the coked catalyst particles can be selectively separated to provide a hydrocarbon product and coked catalyst particles. The coked catalyst particles can be mixed with a carrier fluid to provide a mixture. The mixture can be introduced to an upper surface of a dense phase catalyst zone disposed within a regenerator. A gas can be introduced to a lower zone of the dense phase catalyst zone. At least a portion of the carbon deposited on the coked catalyst particles can be combusted to provide a flue gas, heat, and a regenerated catalyst.
1. A method for regenerating coked catalyst particles, comprising:
heating a hydrocarbon and a coke precursor in the presence of catalyst particles to provide a cracked hydrocarbon and coked catalyst particles, wherein the coked catalyst particles include carbon deposited on at least a portion thereof;
selectively separating the cracked hydrocarbon and the coked catalyst particles to provide a hydrocarbon product and coked catalyst particles;
mixing the coked catalyst particles with a carrier fluid to provide a mixture;
introducing the mixture to a dilute phase catalyst zone disposed within a regenerator;
distributing the mixture of the dilute phase catalyst zone onto an upper surface of a dense phase catalyst zone disposed within the regenerator;
introducing a gas to a lower zone of the dense phase catalyst zone; and
combusting at least a portion of the carbon deposited on the coked catalyst particles to provide a flue gas, heat, and a regenerated catalyst.
2. The method of claim 1 , wherein the carrier fluid comprises from about 10% to about 90% of the total amount of gas introduced to the regenerator, and wherein the carrier fluid comprises from about 5% to about 90% of the total amount of oxygen introduced to the regenerator.
3. The method of claim 1 , wherein the carrier fluid comprises from about 20% to about 50% of the total amount of gas introduced to the regenerator, and wherein the carrier fluid comprises from about 5% to about 50% of the total amount of oxygen introduced to the regenerator.
4. The method of claim 3 , further comprising introducing an oxygen containing gas to the regenerator above the upper surface of the dense phase catalyst zone.
5. The method of claim 1 , further comprising distributing the mixture above the upper surface of the dense phase catalyst zone.
6. The method of claim 1 , wherein the gas comprises an oxygen-lean gas, air, or oxygen-rich gas.
7. The method of claim 1 , wherein the carbon deposited on the spent catalyst ranges from about 0.7% wt to about 1.3% wt.
8. The method of claim 1 , further comprising introducing a carbon monoxide combustion promoter to the regenerator.
9. A method for regenerating coked catalyst particles, comprising:
heating a hydrocarbon and a coke precursor in the presence of catalyst particles to provide a cracked hydrocarbon and coked catalyst particles, wherein the coked catalyst particles include carbon deposited on at least a portion thereof;
selectively separating the cracked hydrocarbon and the coked catalyst particles to provide a hydrocarbon product and coked catalyst particles;
mixing the coked catalyst particles with a carrier fluid to provide a mixture;
introducing the mixture to a dilute phase catalyst zone disposed above a dense phase catalyst zone in a regenerator;
distributing the mixture of the dilute phase catalyst zone onto an upper surface of the dense phase catalyst zone;
introducing a gas to a lower portion of the dense phase catalyst zone;
combusting at least a portion of the carbon deposited on the coked catalyst particles to provide a flue gas, heat, and a regenerated catalyst; and
recycling at least a portion of the regenerated catalyst to provide at least a portion of the catalyst particles.
10. The method of claim 9 , further comprising distributing the mixture above the upper surface of the dense phase catalyst zone.
11. The method of claim 9 , wherein the carrier fluid comprises from about 10% to about 90% of a total amount of gas introduced to the regenerator, and wherein the carrier fluid comprises from about 40% to about 90% of the total amount of oxygen introduced to the regenerator.
12. The method of claim 9 , wherein the carrier fluid comprises from about 10% to about 50% of a total amount of gas introduced to the regenerator, and wherein the carrier fluid comprises from about 20% to about 50% of the total amount of oxygen introduced to the regenerator.
13. The method of claim 9 , wherein the flue gas comprises less than about 150 ppm nitrogen oxides.
14. The method of claim 9 , further comprising introducing air, an oxygen-rich gas, or a combination thereof to the dilute phase catalyst zone.
15. The method of claim 9 , further comprising introducing a carbon monoxide combustion promoter to the regenerator.
16. A method for regenerating coked catalyst particles, comprising:
heating a hydrocarbon in the presence of catalyst particles to provide a cracked hydrocarbon and coked catalyst particles, wherein the coked catalyst particles include carbon deposited on at least a portion thereof;
selectively separating the cracked hydrocarbon and the coked catalyst particles to provide a hydrocarbon product and coked catalyst particles;
mixing the coked catalyst particles with a carrier fluid to provide a mixture;
introducing the mixture to a dilute phase catalyst zone disposed above a dense phase catalyst zone in the regenerator, wherein the carrier fluid comprises from 5% to about 90% of the total amount of oxygen introduced to the regenerator;
distributing the mixture of the dilute phase catalyst zone onto an upper surface of the dense phase catalyst zone;
introducing a gas to a lower zone of the dense phase catalyst zone;
introducing a coke precursor to the dense phase catalyst zone, the dilute phase catalyst zone, the upper surface of the dense phase catalyst zone, the mixture, or any combination thereof;
combusting at least a portion of the carbon deposited on the catalyst and at least a portion of the coke precursor to provide a flue gas, heat, and a regenerated catalyst; and
recycling at least a portion of the regenerated catalyst to provide at least a portion of the catalyst particles.
17. The method of claim 16 , wherein the carrier fluid comprises from about 10% to about 90% of a total amount of gas introduced to the regenerator, and wherein the carrier fluid comprises from about 60% to about 90% of the total amount of oxygen introduced to the regenerator.
18. The method of claim 16 , wherein the carrier fluid comprises from about 10% to about 50% of a total amount of gas introduced to the regenerator, and wherein the carrier fluid comprises from about 30% to about 50% of the total amount of oxygen introduced to the regenerator.
19. The method of claim 16 , further comprising introducing a carbon monoxide combustion promoter to the regenerator.
20. The method of claim 16 , wherein the carbon deposited on the coked catalyst particles ranges from about 0.05% wt to about 0.3% wt.
21. The method of claim 1 , wherein the carrier fluid comprises air, oxygen-rich gas, ozone, or any combination thereof.
22. The method of claim 1 , wherein a total amount of gas introduced to the regenerator is from a low of about 80% to a high of about 115% of the stoichiometric oxygen required to oxidize a total amount of coke and carbon monoxide present within the regenerator.
23. The method of claim 1 , wherein the flue gas comprises less than about 40 ppm nitrogen oxides.
24. The method of claim 1 , wherein the flue gas comprises less than about 0.1 mol % carbon monoxide.
25. The method of claim 16 , further comprising distributing the mixture above the upper surface of the dense phase catalyst zone.
26. The method of claim 16 , wherein the dilute phase catalyst zone has a catalyst concentration from about 50 kg/m 3 to about 160 kg/m 3 .
27. The method of claim 1 , wherein the carrier fluid comprises from about 10% to about 90% of the total amount of gas introduced to the regenerator, and wherein the carrier fluid comprises from about 40% to about 90% of the total amount of oxygen introduced to the regenerator.
28. The method of claim 9 , wherein the carrier fluid comprises from about 10% to about 90% of the total amount of gas introduced to the regenerator, and wherein the carrier fluid comprises from about 60% to about 90% of the total amount of oxygen introduced to the regenerator.
29. The method of claim 16 , wherein a total amount of gas introduced to the regenerator comprises from about 90% to about 105% of the stoichiometric oxygen required to oxidize a total amount of coke and carbon monoxide present within the regenerator.