Coke deposition process

Understanding of coke deposition process can be improved from Ar experiments (77 K and 87 K) at low carbon content coke deposition occurs predominantly on micropore walls leading to the formation of smaller micropores. Then, coke progressively plugs the micropore entrances in such a way that the number of pore decreases while the diameter of open micropores remains constant. 

Chloride salts, 25 Chrome steel, 416 Claus plant, 112, 124-125, 132 CO2 recovery (minimizing), 107 Coke cutting (coking cycle), 61-63 Coke deposition (process heaters), 333-334... 

The visbreaking process thermally cracks atmospheric or vacuum residues. Conversion is limited by specifications for marine or Industrial fuel-oil stability and by the formation of coke deposits in equipment such as heaters and exchangers. 

This was a Hquid-phase process which used what was described as siUceous zeoUtic catalysts. Hydrogen was not required in the process. Reactor pressure was 4.5 MPa and WHSV of 0.68 kg oil/h kg catalyst. The initial reactor temperature was 127°C and was raised as the catalyst deactivated to maintain toluene conversion. The catalyst was regenerated after the temperature reached about 315°C. Regeneration consisted of conventional controlled burning of the coke deposit. The catalyst life was reported to be at least 1.5 yr. 

Catalysts in this service can deactivate by several different mechanisms, but deactivation is ordinarily and primarily the result of deposition of carbonaceous materials onto the catalyst surface during hydrocarbon charge-stock processing at elevated temperature. This deposit of highly dehydrogenated polymers or polynuclear-condensed ring aromatics is called coke. The deposition of coke on the catalyst results in substantial deterioration in catalyst performance. The catalyst activity, or its abiUty to convert reactants, is adversely affected by this coke deposition, and the catalyst is referred to as spent. The coke deposits on spent reforming catalyst may exceed 20 wt %. 

The specific rate is expected to have an Arrhenius dependence on temperature. Deactivation by coke deposition in cracking processes apparently has this kind of correlation. 

The separation of n-alkanes from a kerosene or gas oil fraction by a molecular sieve can be performed in a liquid phase or in a gas phase process. In the gas phase processes there are no problems of cleaning the loaded molecular sieve from adherent branched and cyclic hydrocarbons. However, the high reaction temperature of the gas phase processes leads to the development of coke-contaminated sieves, which have to be regenerated from time to time by a careful burning off of the coke deposits. 

Figure 9.10. Scheme of an FCC Unit. Cracking ofthe heavy hydrocarbon feed occurs in an entrained bed, in which the catalyst spends only a few seconds and becomes largely deactivated by coke deposition. Coke combustion in the regenerator is an exothermic process that generates heat for the regeneration and for the endothermic cracking process. 

The major disadvantage of the alkylation process is that acid is consumed in considerable quantities (up to 100 kg of acid per ton of product). Hence, solid acids have been explored extensively as alternatives. In particular, solid super acids such sulfated zirconia SO/ IZr02) show excellent activities for alkylation, but only for a short time, because the catalyst suffers from coke deposition due to oligomerization of alkenes. These catalysts are also extremely sensitive to water. 

Coke formation on these catalysts occurs mainly via methane decomposition. Deactivation as a function of coke content (see Fig. 3 for Pt/ y-AljO,) seems to involve two processes, i e, a slow initial one caused by coke formed from methane on Pt that is non reactive towards CO2 (see Table 3) In parallel, carbon also accumulates on the support and given the ratio between the support surface and metal surface area at a certain level begins to physically block Pt deactivating the catalyst rapidly. The coke deposited on the support very close to the Pt- support interface could be playing an important role in this process. 

The enthalpy of the depositional process described by Equation 10 is obtained by dividing the measured heat produced at 155°C by the mass of bitumen converted to coke, yielding AHD = -2 kJ g. ... 

As practiced today, FCC is a fluidized-bed process with continuous catalyst regeneration which reUes on short contact in a riser reactor between the feed and catalyst, fluidized with an inert gas, followed by disengagement and catalyst regeneration to burn off coke deposits and return the catalyst to near-fresh activity. 

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