Fluidized catalytic cracking unit system with integrated reformer-electrolyzer-purifier
A fluidized catalytic cracking unit system includes: a fluidized catalytic cracking unit assembly including a first catalyst regenerator and a cracking unit, the cracking unit configured to output spent catalyst to the first catalyst regenerator; and a reformer-electrolyzer-purifier assembly comprising a reformer-electrolyzer-purifier cell, the reformer-electrolyzer-purifier cell comprising an anode section and a cathode section.
1 . A fluidized catalytic cracking unit system comprising:
a fluidized catalytic cracking unit assembly comprising a first catalyst regenerator and a cracking unit, the cracking unit configured to output spent catalyst to the first catalyst regenerator; and
a reformer-electrolyzer-purifier assembly comprising a reformer-electrolyzer-purifier cell, the reformer-electrolyzer-purifier cell comprising an anode section and a cathode section;
wherein the anode section of the reformer-electrolyzer-purifier assembly is configured to receive an anode input stream comprising hydrocarbon gases and water;
wherein the cathode section of the reformer-electrolyzer-purifier assembly is configured to produce a cathode exhaust stream comprising oxygen and carbon dioxide;
wherein the first catalyst regenerator is configured to:
receive the cathode exhaust stream;
regenerate the spent catalyst and form carbon dioxide by burning carbon on the spent catalyst using the oxygen in the cathode exhaust stream; and
generate a flue gas comprising the carbon dioxide from the cathode exhaust stream, carbon dioxide formed from regenerating the spent catalyst, and residual oxygen from the cathode exhaust stream; and
wherein the fluidized catalytic cracking unit system further comprises a carbon capture assembly configured to cool the flue gas to condense carbon dioxide in the flue gas.
2 . The system of claim 1 , further comprising a condenser configured to remove water from the flue gas and output a dried flue gas stream that comprises at least 90 mole % carbon dioxide.
3 . The system of claim 1 , wherein the carbon capture assembly is configured to produce a stream that comprises at least 90 mole % carbon dioxide.
4 . The system of claim 1 , wherein:
the cracking unit of the fluidized catalytic cracking unit assembly comprises a riser and a catalyst separation unit;
the riser is configured to receive catalyst from the first catalyst regenerator, to receive steam and hydrocarbon feedstock, to crack the hydrocarbon feedstock into smaller molecules using the catalyst, and to provide cracked hydrocarbons and spent catalyst to the catalyst separation unit; and
the catalyst separation unit is configured to separate the cracked hydrocarbons from spent catalyst, to output a cracked hydrocarbon stream, and to output the spent catalyst to the first catalyst regenerator.
5 . The system of claim 4 , further comprising a fractionation assembly that is configured to receive the cracked hydrocarbon stream from the catalyst separation unit and output a light ends stream.
6 . The system of claim 5 , wherein the anode section of the reformer-electrolyzer-purifier assembly is configured to receive the light ends stream produced by the fractionation assembly as the anode input stream.
7 . The system of claim 1 , wherein:
the fluidized catalytic cracking unit assembly further comprises a second catalyst regenerator unit; and
the second catalyst regenerator unit is configured to receive any excess catalyst from the cracking unit that is not needed to minimize excess oxygen output by the first catalyst regenerator, and to regenerate the excess catalyst using air.
8 . The system of claim 1 , wherein the cathode section of the reformer-electrolyzer-purifier assembly is configured to produce a stream that comprises oxygen in a range of 25 to 40 mole % and carbon dioxide in a range of 60 to 75 mole % as the cathode exhaust stream.
9 . The system of claim 1 , wherein the anode section is configured to produce an anode exhaust stream comprising primarily water and hydrogen.
10 . The system of claim 9 , further comprising a cooling and condensation system configured to cool and condense the anode exhaust stream, to remove the water contained in the anode exhaust stream, and to produce a hydrogen stream.
11 . The system of claim 10 , wherein the hydrogen stream comprises at least 95 mole % hydrogen.
12 . The system of claim 1 , wherein the reformer-electrolyzer-purifier cell is a molten carbonate electrolysis cell.
13 . The system of claim 1 , wherein the cathode exhaust stream is the only source of oxygen to the first catalyst regenerator.
14 . A fluidized catalytic cracking unit system comprising:
a fluidized catalytic cracking unit assembly comprising a first catalyst regenerator, a second catalyst regenerator, and a cracking unit, the cracking unit configured to output spent catalyst to the first catalyst regenerator; and
a reformer-electrolyzer-purifier assembly comprising a reformer-electrolyzer-purifier cell, the reformer-electrolyzer-purifier cell comprising an anode section and a cathode section;
wherein the anode section of the reformer-electrolyzer-purifier assembly is configured to receive an anode input stream comprising hydrocarbon gases and water;
wherein the cathode section of the reformer-electrolyzer-purifier assembly is configured to produce a cathode exhaust stream comprising oxygen and carbon dioxide;
wherein the first catalyst regenerator is configured to:
receive the cathode exhaust stream;
partially regenerate the spent catalyst and form carbon dioxide by burning carbon on the spent catalyst using the oxygen in the cathode exhaust stream;
generate a flue gas comprising the carbon dioxide from the cathode exhaust stream, carbon dioxide formed from regenerating the spent catalyst, and residual oxygen from the cathode exhaust stream;
wherein the second catalyst regenerator is configured to receive the partially regenerated spent catalyst from the first catalyst regenerator and finish regenerating the partially regenerated spent catalyst by reacting the partially regenerated spent catalyst with air; and
wherein the fluidized catalytic cracking unit system further comprises a carbon capture assembly configured to cool the flue gas to condense carbon dioxide in the flue gas.
15 . The system of claim 1 , wherein the first catalyst regenerator is configured to receive an entirety of the cathode exhaust stream.