Regenerator components

The evolution and improvement of the above-mentioned topics set the background for providing FCC design parameters. The following sections present the latest commercially-proven process and mechanical design recommendations for FCC reactor-regenerator components. 

Improving mechanical reliability of the FCC reactor-regenerator components. 

TSA and PSA processes are, by virtue of the distinct adsorption and regeneration components of the cycle, not continuous processes, although a continuous flow of product may be achieved by careful design and bed utilization. Moving bed and simulated moving bed processes are, however, by their very nature truly continuous. Examples of these are given in Chapter 7, but here it suffices to say that a number of continuous commercial processes for the separation of aromatic mixtures, the separation of n-parafhns from branched and cycloalkanes, the production of olefins from olefin and paraffin mixtures and the isolation of fructose from corn syrup, have been in operation since the early 1980s. 

Ergonovine (100, R = NHCH(CH3)CH2 0H) was found to yield lysergic acid (100, R = OH) and (+)-2-aminopropanol on alkaline hydrolysis during the early analysis of its stmcture (66) and these two components can be recombined to regenerate the alkaloid. Salts of ergonovine with, for example, malic acid are apparently the dmgs of choice in the control and treatment of postpartum hemorrhage. 

A process development known as NOXSO (DuPont) (165,166) uses sodium to purify power plant combustion flue gas for removal of nitrogen oxide, NO, and sulfur, SO compounds. This technology reHes on sodium metal generated in situ via thermal reduction of sodium compound-coated media contained within a flue-gas purification device, and subsequent flue-gas component reactions with sodium. The process also includes downstream separation and regeneration of spent media for recoating and circulation back to the gas purification device. A full-scale commercial demonstration project was under constmction in 1995. 

Dehydrogenation of /i-Butane. Dehydrogenation of / -butane [106-97-8] via the Houdry process is carried out under partial vacuum, 35—75 kPa (5—11 psi), at about 535—650°C with a fixed-bed catalyst. The catalyst consists of aluminum oxide and chromium oxide as the principal components. The reaction is endothermic and the cycle life of the catalyst is about 10 minutes because of coke buildup. Several parallel reactors are needed in the plant to allow for continuous operation with catalyst regeneration. Thermodynamics limits the conversion to about 30—40% and the ultimate yield is 60—65 wt % (233). 

Reclamation, Disposal, and Toxicity. Removal of poisons and inorganic deposits from used catalysts is typically difficult and usually uneconomical. Thus some catalysts are used without regeneration, although they may be processed to reclaim expensive metal components. Used precious metal catalysts, including automobile exhaust conversion catalysts, are treated (often by the suppHers) to extract the metals, and recovery efficiencies are high. Some spent hydroprocessing catalysts may be used as sources of molybdenum and other valuable metals. 

The hterature consists of patents, books, journals, and trade Hterature. The examples in patents may be especially valuable. The primary Hterature provides much catalyst performance data, but there is a lack of quantitative results characterizing the performance of industrial catalysts under industrially reaHstic conditions. Characterizations of industrial catalysts are often restricted to physical characterizations and perhaps activity measurements with pure component feeds, but it is extremely rare to find data characterizing long-term catalyst performance with impure, multicomponent industrial feedstocks. Catalyst regeneration procedures are scarcely reported. Those who have proprietary technology are normally reluctant to make it known. Readers should be critical in assessing published work that claims a relevance to technology. 

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