Patent Description:
Embodiments described herein generally relate to chemical processing and, more specifically, to methods and systems for catalytic chemical conversion.

Many chemicals may be produced through processes employing particulate solids, such as solid particulate catalysts. During these processes, the particulate solids may become "spent" and have reduced activity in subsequent reactions. In addition, endothermic processes require heat and the "spent" catalyst must be reheated. Thus, spent particulate solids may be transferred to a regeneration unit to be reheated and regenerated, increasing the activity of the particulate solids for use in subsequent reactions. Following regeneration in the regeneration unit, the regenerated particulate solids may be transferred back to the reactor for use in subsequent reactions. <CIT> relates to chemical processing utilizing hydrogen containing supplemental fuel for catalyst processing.

There is a need for improved methods for regenerating, reactivating, or increasing the activity of particulate solids for use in the production of various chemicals, such as, but not limited to, light olefins. Many regenerator systems for regenerating particulate solids include a particulate solid treatment vessel positioned directly below a particulate solid separation section such that a riser extends from the particulate solid treatment vessel through the bottom of the particulate solid separation section. Such designs may negatively impact the flow of particulate solids through the particulate solid separation section by creating an annular space in the bottom of the particulate solid separation section where an outlet cannot be centered at the bottom of the particulate solid separation section.

One or more of the presently disclosed methods for regenerating particulate solids utilize systems that address this problem. In one or more embodiments, the riser does not enter the particulate solid separation section through the bottom of the particulate solid separation section. As such, the particulate solid outlet may be centered in the bottom of the particulate solid separation section, resulting in improved flow characteristics of particulate solids exiting the particulate solid separation section.

According to one aspect of the present invention, there is provided a method of regenerating a particulate solid, the method comprising regenerating the particulate solid in a particulate solid treatment vessel. The regenerating of the particulate solid comprises one or more of oxidizing the particulate solid by contact with an oxygen-containing gas; combusting coke present on the particulate solid; or combusting a supplemental fuel to heat the particulate solid. The method further comprises passing the particulate solid through a riser. The riser extends through a riser port of an outer shell of a particulate solid separation section such that the riser comprises an interior riser segment positioned in an interior region of the particulate solid separation section and an exterior riser segment positioned outside of an outer shell of the particulate solid separation section. The particulate solid separation section comprises at least the outer shell defining the interior region of the particulate solid separation section. The outer shell comprises a gas outlet port, a riser port, and a particulate solid outlet port. The outer shell houses a gas/solids separation device and a particulate solid collection area in the interior region of the particulate solid separation section. The riser port is positioned on a sidewall of the outer shell such that it is not located on a central vertical axis of the particulate solid separation section. The method further comprises separating the particulate solid from gases in the gas/solids separation device and passing the particulate solids, separated from the gasses, to the particulate solid collection area located proximate the central vertical axis of the particulate solid separation section.

It is to be understood that both the foregoing brief summary and the following detailed description present embodiments of the technology, and are intended to provide an overview or framework for understanding the nature and character of the technology as it is claimed. The accompanying drawings are included to provide a further understanding of the technology, and are incorporated into and constitute a part of this specification. The drawings illustrate various embodiments and, together with the description, serve to explain the principles and operations of the technology. Additionally, the drawings and descriptions are meant to be merely illustrative, and are not intended to limit the scope of the claims in any manner.

Additional features and advantages of the technology disclosed herein will be set forth in the detailed description that follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the technology as described herein, including the detailed description that follows, the claims, as well as the appended drawings.

It should be understood that the drawings are schematic in nature, and do not include some components of a fluid catalytic reactor system commonly employed in the art, such as, without limitation, temperature transmitters, pressure transmitters, flow meters, pumps, valves, and the like. It would be known that these components are within the scope of the present embodiments disclosed. However, operational components, such as those described in the present disclosure, may be added to the embodiments described in this disclosure.

As described herein, methods for regenerating particulate solids disclosed herein may be utilized to regenerate particulate solids from reactor systems for processing chemical streams. Such methods utilize systems which have particular features, such as a particular orientation of system parts. For example, according to the method of the present invention, the particulate solid treatment vessel is not directly below the particulate solid separation section. One particular embodiment, which is disclosed in detail herein, is depicted in <FIG>. However, it should be understood that the principles disclosed and taught herein may be applicable to other systems which utilize different system components oriented in different ways, or different reaction schemes utilizing various catalyst compositions.

Now referring to <FIG>, as may be understood with reference to the forgoing figures and description, feed chemical may be reacted by contact with the particulate solid, such as a catalyst, in a reactor section <NUM>. The particulate solid may be separated from the reaction products in the reactor section <NUM> and passed to the regeneration section <NUM>. In the regeneration section <NUM>, the particulate solid may be regenerated. Such regenerated particulate solid may be passed back to the reactor section <NUM> for subsequent cycles of the reaction.

While some embodiments are described herein in the context of a reactor system <NUM>, it should be understood that the methods and systems described herein may operate without the use of the reactor section <NUM>, or with alternative means for reacting a feed stream. As such, it should not be construed that the reactor section <NUM> is required or essential in all embodiments of the presently disclosed methods and systems.

In non-limiting examples, the reactor system <NUM> described herein may be utilized to produce light olefins from hydrocarbon feed streams. Light olefins may be produced from a variety of hydrocarbon feed streams by utilizing different reaction mechanisms. For example, light olefins may be produced by at least dehydrogenation reactions, cracking reactions, dehydration reactions, and methanol-to-olefin reactions. These reaction types may utilize different feed streams and different particulate solids to produce light olefins. It should be understood that when "catalysts" are referred to herein, they may equally refer to the particulate solid referenced with respect to the system of <FIG>.

According to one or more embodiments, the reaction may be a dehydrogenation reaction. According to such embodiments, the hydrocarbon feed stream may comprise one or more of ethylbenenze, ethane, propane, n-butane, and i-butane. In one or more embodiments, the hydrocarbon feed stream may comprise at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. % or even at least <NUM> wt. % of ethane. In additional embodiments, the hydrocarbon feed stream may comprise at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. % or even at least <NUM> wt. % of propane. In additional embodiments, the hydrocarbon feed stream may comprise at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. % or even at least <NUM> wt. % of n-butane. In additional embodiments, the hydrocarbon feed stream may comprise at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. % or even at least <NUM> wt. % of i-butane. In additional embodiments, the hydrocarbon feed stream may comprise at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. % or even at least <NUM> wt. % of the sum of ethane, propane, n-butane, and i-butane.

In one or more embodiments, the dehydrogenation reaction may utilize gallium and/or platinum particulate solids as a catalyst. In such embodiments, the particulate solids may comprise a gallium and/or platinum catalyst. As described herein, a gallium and/or platinum catalyst comprises gallium, platinum, or both. The gallium and/or platinum catalyst may be carried by an alumina or alumina silica support, and may optionally comprise potassium. Such gallium and/or platinum catalysts are disclosed in <CIT>. However, it should be understood that other suitable catalysts may be utilized to perform the dehydrogenation reaction.

In one or more embodiments, the reaction mechanism may be dehydrogenation followed by combustion (in the same chamber). In such embodiments, a dehydrogenation reaction may produce hydrogen as a byproduct, and an oxygen carrier material may contact the hydrogen and promote combustion of the hydrogen, forming water. Examples of such reaction mechanisms, which are contemplated as possible reactions mechanisms for the systems and methods described herein, are disclosed in <CIT>.

According to one or more embodiments, the reaction may be a cracking reaction. According to such embodiments, the hydrocarbon feed stream may comprise one or more of naphtha, n-butane, or i-butane. According to one or more embodiments, the hydrocarbon feed stream may comprise at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. % or even at least <NUM> wt. % of naphtha. In additional embodiments, the hydrocarbon feed stream may comprise at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. % or even at least <NUM> wt. % of n-butane. In additional embodiments, the hydrocarbon feed stream may comprise at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. % or even at least <NUM> wt. % of i-butane. In additional embodiments, the hydrocarbon feed stream may comprise at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. % or even at least <NUM> wt. % of the sum of naphtha, n-butane, and i-butane.

In one or more embodiments, the cracking reaction may utilize one or more zeolites as a catalyst. In such embodiments, the particulate solids may comprise one or more zeolites. In some embodiments, the one or more zeolites utilized in the cracking reaction may comprise a ZSM-<NUM> zeolite. However, it should be understood that other suitable catalysts may be utilized to perform the cracking reaction. For example, suitable catalysts that are commercially available may include Intercat Super Z Excel or Intercat Super Z Exceed. In additional embodiments, the cracking catalyst may comprise, in addition to a catalytically active material, platinum. For example, the cracking catalyst may include from <NUM> wt. % to <NUM> wt. % of platinum. The platinum may be sprayed on as platinum nitrate and calcined at an elevated temperature, such as around <NUM>. Without being bound by theory, it is believed that the addition of platinum to the catalyst may allow for easier combustion of supplemental fuels, such as methane.

According to one or more embodiments, the reaction may be a dehydration reaction. According to such embodiments, the hydrocarbon feed stream may comprise one or more of ethanol, propanol, or butanol. According to one or more embodiments, the hydrocarbon feed stream may comprise at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. % or even at least <NUM> wt. % of ethanol. In additional embodiments, the hydrocarbon feed stream may comprise at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. % or even at least <NUM> wt. % of propanol. In additional embodiments, the hydrocarbon feed stream may comprise at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. % or even at least <NUM> wt. % of butanol. In additional embodiments, the hydrocarbon feed stream or may comprise at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. % or even at least <NUM> wt. % of the sum of ethanol, propanol, and butanol.

In one or more embodiments, the dehydration reaction may utilize one or more acid catalysts. In such embodiments, the particulate solids may comprise one or more acid catalysts. In some embodiments, the one or more acid catalysts utilized in the dehydration reaction may comprise a zeolite (such as ZSM-<NUM> zeolite), alumina, amorphous aluminosilicate, acid clay, or combinations thereof. For example, commercially available alumina catalysts which may be suitable, according to one or more embodiments, include SynDol (available from Scientific Design Company), V200 (available from UOP), or P200 (available from Sasol). Commercially available zeolite catalysts which may be suitable include CBV <NUM>, CBV <NUM> (each available from Zeolyst). Commercially available amorphous aluminosilicate catalysts which may be suitable include silica-alumina catalyst support, grade <NUM> (available from Sigma Aldrich). However, it should be understood that other suitable catalysts may be utilized to perform the dehydration reaction.

According to one or more embodiments, the reaction may be a methanol-to-olefin reaction. According to such embodiments, the hydrocarbon feed stream may comprise methanol. According to one or more embodiments, the hydrocarbon feed stream may comprise at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. % or even at least <NUM> wt. % of methanol.

In one or more embodiments, the methanol-to-olefin reaction may utilize one or more zeolites as a catalyst. In such embodiments, the particulate solids may comprise one or more zeolites. In some embodiments, the one or more zeolites utilized in the methanol-to-olefin reaction may comprise a one or more of a ZSM-<NUM> zeolite or a SAPO-<NUM> zeolite. However, it should be understood that other suitable catalysts may be utilized to perform the methanol-to-olefin reaction.

In one or more embodiments, the operating of chemical process may include passing the product stream out of the reactor. The product stream may comprise light olefins. As described herein, "light olefins" refers to one or more of ethylene, propylene, or butene. As described herein, butene many include any isomer of butene, such as a-butylene, cis-<NUM>-butylene, trans-β-butylene, and isobutylene. In one embodiment, the product stream may comprise at least <NUM> wt. % light olefins. For example, the product stream may comprise at least <NUM> wt. % light olefins, at least <NUM> wt. % light olefins, at least <NUM> wt. % light olefins, at least <NUM> wt. % light olefins, at least <NUM> wt. % light olefins, or even at least <NUM> wt. % light olefins.

Still referring to <FIG>, the reactor system <NUM> generally comprises multiple system components, such as a reactor section <NUM> and a regeneration section <NUM>. As used herein in the context of <FIG>, a reactor section <NUM> generally refers to the portion of a reactor system <NUM> in which the major process reaction takes place, and the particulate solids are separated from the olefin-containing product stream of the reaction. In one or more embodiments, the particulate solids may be spent, meaning that they are at least partially deactivated. Also, as used herein, a regeneration section <NUM> generally refers to the portion of a fluid catalytic reactor system where the particulate solids are regenerated, such as through combustion, and the regenerated particulate solids are separated from the other process material, such as evolved gasses from the combusted material previously on the spent particulate solids or from supplemental fuel. The reactor section <NUM> generally includes a reaction vessel <NUM>, a riser <NUM> including an exterior riser segment <NUM> and an interior riser segment <NUM>, and a particulate solid separation section <NUM>. The regeneration section <NUM> generally includes a particulate solid treatment vessel <NUM>, a riser <NUM> including an exterior riser segment <NUM> and an interior riser segment <NUM>, and a particulate solid separation section <NUM>. Generally, the particulate solid separation section <NUM> may be in fluid communication with the particulate solid treatment vessel <NUM>, for example, by standpipe <NUM>, and the particulate solid separation section <NUM> may be in fluid communication with the reaction vessel <NUM>, for example, by standpipe <NUM> and transport riser <NUM>.

Generally, the reactor system <NUM> may be operated by feeding a hydrocarbon feed and fluidized particulate solids into the reaction vessel <NUM>, and reacting the hydrocarbon feed by contact with fluidized particulate solids to produce an olefin-containing product in the reaction vessel <NUM> of the reactor section <NUM>. The olefin-containing product and the particulate solids may be passed out of the reaction vessel <NUM> and through the riser <NUM> to a gas/solids separation device <NUM> in the particulate solid separation section <NUM>, where the particulate solids are separated from the olefin-containing product. The particulate solids may be transported out of the particulate solid separation section <NUM> to the particulate solid treatment vessel <NUM>. In the particulate solid treatment vessel <NUM>, the particulate solids may be regenerated by various processes. For example, the spent particulate solids are regenerated by one or more of oxidizing the particulate solid by contact with an oxygen containing gas, combusting coke present on the particulate solid, and combusting a supplemental fuel to heat the particulate solid. The particulate solid is then passed out of the particulate solid treatment vessel <NUM> and through the riser <NUM> to a riser termination device <NUM>, where the gas and particulate solids from the riser <NUM> are partially separated. The gas and remaining particulate solids from the riser <NUM> are transported to secondary separation device <NUM> in the particulate solid separation section <NUM> where the remaining particulate solids are separated from the gasses from the regeneration reaction. The particulate solids, separated from the gasses, are passed to a particulate solid collection area <NUM>. The separated particulate solids are then passed from the particulate solid collection area <NUM> to the reaction vessel <NUM>, where they are further utilized. Thus, the particulate solids may cycle between the reactor section <NUM> and the regeneration section <NUM>.

In one or more embodiments, the reactor system <NUM> may include either a reactor section <NUM> or a regeneration section <NUM>, and not both. In further embodiments, the reactor system <NUM> may include a single regeneration section <NUM> and multiple reactor sections <NUM>.

Additionally, as described herein, the structural features of the reactor section <NUM> and regeneration section <NUM> may be similar or identical in some respects. For example, each of the reactor section <NUM> and regeneration section <NUM> include a reaction vessel (i.e., reaction vessel <NUM> of the reactor section <NUM> and particulate solid treatment vessel <NUM> of the regeneration section <NUM>), a riser (i.e., riser <NUM> of the reactor section <NUM> and riser <NUM> of the regeneration section <NUM>), and a particulate solid separation section (i.e., particulate solid separation section <NUM> of the reactor section <NUM> and particulate solid separation section <NUM> of the regeneration section <NUM>). It should be appreciated that since many of the structural features of the reactor section <NUM> and the regeneration section <NUM> may be similar or identical in some respects, similar or identical portions of the reactor section <NUM> and the regeneration section <NUM> have been provided reference numbers throughout this disclosure with the same final two digits, and disclosures related to one portion of the reactor section <NUM> may be applicable to the similar or identical portion of the regeneration section <NUM>, and vice versa.

As depicted in <FIG>, the reaction vessel <NUM> may include a reaction vessel particulate solid inlet port <NUM> defining the connection of transport riser <NUM> to the reaction vessel <NUM>. The reaction vessel <NUM> may additionally include a reaction vessel outlet port <NUM> in fluid communication with, or directly connected to, the exterior riser segment <NUM> of the riser <NUM>. As described herein, a "reaction vessel" refers to a drum, barrel, vat, or other container suitable for a given chemical reaction. A reaction vessel may be generally cylindrical in shape (i.e., having a substantially circular diameter), or may alternately be non-cylindrically shaped, such as prism shaped with cross-sectional shaped of triangles, rectangles, pentagons, hexagons, octagons, ovals, or other polygons or curved closed shapes, or combinations thereof. Reaction vessels, as used throughout this disclosure, may generally include a metallic frame, and may additionally include refractory linings or other materials utilized to protect the metallic frame and/or control process conditions.

Generally, "inlet ports" and "outlet ports" of any system unit of the fluid catalytic reactor system <NUM> described herein refer to openings, holes, channels, apertures, gaps, or other like mechanical features in the system unit. For example, inlet ports allow for the entrance of materials to the particular system unit and outlet ports allow for the exit of materials from the particular system unit. Generally, an outlet port or inlet port will define the area of a system unit of the fluid catalytic reactor system <NUM> to which a pipe, conduit, tube, hose, transport line, or like mechanical feature is attached, or to a portion of the system unit to which another system unit is directly attached. While inlet ports and outlet ports may sometimes be described herein functionally in operation, they may have similar or identical physical characteristics, and their respective functions in an operational system should not be construed as limiting on their physical structures. Other ports, such as the riser port <NUM>, may comprise an opening in the given system unit where other system units are directly attached, such as where the riser <NUM> extends into the particulate solid separation section <NUM> at the riser port <NUM>.

The reaction vessel <NUM> may be connected to a transport riser <NUM>, which in operation, may provide regenerated particulate solids and chemical feed to the reactor section <NUM>. The particulate solids entering the reaction vessel <NUM> via transport riser <NUM> may be passed through standpipe <NUM> to a transport riser <NUM>, thus arriving from the regeneration section <NUM>. In some embodiments, particulate solids may come directly from the particulate solid separation section <NUM> via standpipe <NUM> and into a transport riser <NUM>, where they enter the reaction vessel <NUM>. These particulate solids may be slightly deactivated, but may still, in some embodiments, be suitable for use in the reaction vessel <NUM>.

As depicted in <FIG>, the reaction vessel <NUM> may be directly connected to the exterior riser segment <NUM>. In one embodiment, the reaction vessel <NUM> may include a reaction vessel body section <NUM> and a reaction vessel transition section <NUM> positioned between the reaction vessel body section <NUM> and the exterior riser segment <NUM>. The reaction vessel body section <NUM> may generally comprise a greater diameter than the reaction vessel transition section <NUM>, and the reaction vessel transition section <NUM> may be tapered from the size of the diameter of the reaction vessel body section <NUM> to the size of the diameter of the riser <NUM> such that the reaction vessel transition section <NUM> projects inwardly from the reaction vessel body section <NUM> to the exterior riser segment <NUM>. It should be understood that, as used herein, the diameter of a portion of a system unit refers to its general width, as shown in the horizontal direction in <FIG>.

In one or more embodiments, the reaction vessel <NUM> may have a maximum cross sectional area that is at least <NUM> times the maximum cross sectional area of the riser <NUM>. For example, the reaction vessel <NUM> may have a maximum cross sectional area that is at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, or even at least <NUM> times the maximum cross sectional area of the riser <NUM>. As described herein, unless otherwise explicitly stated, the "cross sectional area" refers to the area of the cross section of a portion of a system component in a plane substantially orthogonal to the direction of general flow of reactants and/or products.

Still referring to <FIG>, the reactor section <NUM> may comprise a riser <NUM>, which acts to transport reactants, products, and/or particulate solids from the reaction vessel <NUM> to the particulate solid separation section <NUM>. In one or more embodiments, the riser <NUM> may be generally cylindrical in shape (i.e., having a substantially circular cross-sectional shape), or may alternately be non-cylindrically shaped, such as prism shaped with cross-sectional shape of triangles, rectangles, pentagons, hexagons, octagons, ovals, or other polygons or curved closed shapes, or combinations thereof. The riser <NUM>, as used throughout this disclosure, may generally include a metallic frame, and may additionally include refractory linings or other materials utilized to protect the metallic frame and/or control process conditions.

The riser <NUM> includes an exterior riser segment <NUM> and an interior riser segment <NUM>. As used herein, an "exterior riser segment" refers to the portion of the riser that is outside of the particulate solid separation section, and an "interior riser segment" refers to the portion of the riser that is within the particulate solid separation section. For example, in the embodiment depicted in <FIG>, the interior riser segment <NUM> of the reactor section <NUM> is positioned within the particulate solid separation section <NUM>, while the exterior riser segment <NUM> is positioned outside of the particulate solid separation section <NUM>.

The particulate solid separation section <NUM> comprises an outer shell <NUM> where the outer shell <NUM> defines an interior region <NUM> of the particulate solid separation section <NUM>. The outer shell <NUM> comprises a gas outlet port <NUM>, a riser port <NUM>, and a particulate solid outlet port <NUM>. Furthermore, the outer shell <NUM> houses a gas/solids separation device <NUM> and a particulate solid collection area <NUM> in the interior region <NUM> of the particulate solid separation section <NUM>.

In one or more embodiments, the outer shell <NUM> of the particulate solid separation section <NUM> may define an upper segment <NUM>, a middle segment <NUM>, and a lower segment <NUM> of the particulate solid separation section <NUM>. Generally, the upper segment <NUM> may have a substantially constant cross sectional area, such that the cross sectional area does not vary by more than <NUM>% in the upper segment <NUM>. Additionally, in one or more embodiments, the lower segment <NUM> of the particulate solid separation section <NUM> may have a substantially constant cross sectional area, such that the cross sectional area does not vary by more than <NUM>% in the lower segment <NUM>. The cross sectional area of the lower segment <NUM> may be larger than the maximum cross sectional area of the riser <NUM> and smaller than the maximum cross sectional area of the upper segment <NUM>. The middle segment <NUM> may be shaped as a frustum where the cross sectional area of the middle segment <NUM> is not constant and the cross sectional area of the middle segment <NUM> transitions from the cross sectional area of the upper segment <NUM> to the cross sectional area of the lower segment <NUM> throughout the middle segment <NUM>.

As depicted in <FIG>, the interior riser segment <NUM> of the riser <NUM> extends through the riser port <NUM> of an outer shell of the particulate solid separation section <NUM>. The riser port <NUM> may be any opening in the particulate solid separation section <NUM> through which at least the interior riser segment <NUM> of the riser <NUM> protrudes into the interior region <NUM> of the particulate solid separation section <NUM>. In one or more embodiments, the interior riser segment <NUM> enters the particulate solid separation section <NUM> in the middle segment <NUM> or the upper segment <NUM>, and does not pass through the lower segment <NUM>.

At the upper segment <NUM> of the particulate solid separation section <NUM>, the interior riser segment <NUM> may be in fluid communication with the gas/solids separation device <NUM>. The gas/solids separation device <NUM> may be any mechanical or chemical separation device that may be operable to separate particulate solids from gas or liquid phases, such as a cyclone or a plurality of cyclones.

The particulate solids may move upward through the riser <NUM> from the reaction vessel <NUM> and into the gas/solids separation device <NUM>. The gas/solids separation device <NUM>, may be operable to deposit separated particulate solids into the bottom of the upper segment <NUM> or into the middle segment <NUM> or lower segment <NUM>. The separated vapors may be removed from the fluid catalytic reactor system <NUM> via a pipe <NUM> at a gas outlet port <NUM> of the particulate solid separation section <NUM>.

In one or more embodiments, the lower segment <NUM> of the particulate solid separation section <NUM> may comprise a particulate solid collection area <NUM>. In one or more embodiments, the particulate solid collection area <NUM> may allow for accumulation of particulate solids within the particulate solid separation section <NUM>. The particulate solid collection area <NUM> may comprise a stripping section. The stripping section may be utilized to remove product vapors from the particulate solids prior to sending them to the regeneration section <NUM>. As product vapors transported to the regeneration section <NUM> will be combusted, it is desirable to remove those product vapors with the stripper, which utilizes less expensive gases for combustion than product gases.

The particulate solid collection area <NUM> in the lower segment <NUM> may comprise a particulate solid outlet port <NUM>. Standpipe <NUM> may be connected to the particulate solid separation section <NUM> at particulate solid outlet port <NUM>, and the particulate solids may be transferred out of the reactor section <NUM> via standpipe <NUM> and into the regeneration section <NUM>. Optionally, the particulate solids may also be transferred directly back into the reaction vessel <NUM> via standpipe <NUM>. Alternatively, the particulate solids may be premixed with regenerated particulate solids in the transport riser <NUM>.

After separation in the particulate solid separation section <NUM>, the spent particulate solids are transferred to the regeneration section <NUM>. The regeneration section <NUM>, as described herein, may share many structural similarities with the reactor section <NUM>. As such, the reference numbers assigned to the portions of the regeneration section <NUM> are analogous to those used with reference to the reactor section <NUM>, where if the final two digits of the reference number are the same the given portions of the reactor section <NUM> and regeneration section <NUM> may serve similar functions and have similar physical structure. Thus, many of the present disclosures related to the regeneration section <NUM> may be equally applied to the reactor section <NUM>.

Referring now to the regeneration section <NUM>, as depicted in <FIG> and <FIG>, the particulate solid treatment vessel <NUM> of the regeneration section <NUM> may include one or more reactor vessel inlet ports <NUM> and a reactor vessel outlet port <NUM> in fluid communication with, or even directly connected to, the exterior riser segment <NUM> of the riser <NUM>. The particulate solid treatment vessel <NUM> may be in fluid communication with the particulate solid separation section <NUM> via standpipe <NUM>, which may supply spent particulate solids from the reactor section <NUM> to the regeneration section <NUM> for regeneration. The particulate solid treatment vessel <NUM> may include an additional reactor vessel inlet port <NUM> where inlet <NUM> connects to the particulate solid treatment vessel <NUM>. The inlet <NUM> may supply reactive fluids, such as supplemental fuels in liquid or gaseous form and oxygen containing gasses, including air, enriched air, and even pure oxygen, which may be used to at least partially regenerate the particulate solids. In one or more embodiments, the particulate solid treatment vessel <NUM> may comprise multiple additional reactor vessel inlet ports, and each additional reactor inlet port may supply a different reactive fluid to the particulate solid treatment vessel <NUM>. For example, the particulate solids may be coked following the reactions in the reaction vessel <NUM>, and the coke may be removed from the particulate solids by a combustion reaction. In alternative examples, oxygen containing gasses, such as air, may be fed into the particulate solid treatment vessel <NUM> via the inlet <NUM> to oxidize the particulate solids, or supplemental fuel may be fed into the particulate solid treatment vessel <NUM> and combusted to heat the particulate solids.

As depicted in <FIG> and <FIG>, the particulate solid treatment vessel <NUM> may be directly connected to the exterior riser segment <NUM> of the riser <NUM>. In one embodiment, the particulate solid treatment vessel <NUM> may include a particulate solid treatment vessel body section <NUM> and a particulate solid treatment vessel transition section <NUM>. The particulate solid treatment vessel body section <NUM> may generally comprise a greater diameter than the particulate solid treatment vessel transition section <NUM>, and the particulate solid treatment vessel transition section <NUM> may be tapered from the size of the diameter of the particulate solid treatment vessel body section <NUM> to the size of the diameter of the exterior riser segment <NUM> such that the particulate solid treatment vessel transition section <NUM> projects inwardly from the particulate solid treatment vessel body section <NUM> to the exterior riser segment <NUM>.

In one or more embodiments, the particulate solid treatment vessel <NUM> may have a maximum cross sectional area that is at least <NUM> times the maximum cross sectional area of the riser <NUM>. For example, the particulate solid treatment vessel <NUM> may have a maximum cross sectional area that is at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, or even at least <NUM> times the maximum cross sectional area of the riser <NUM>.

Additionally, the particulate solid treatment vessel body section <NUM> may generally comprise a height, where the height of the particulate solid treatment vessel body section <NUM> is measured from the reactor vessel inlet port <NUM> to the particulate solid treatment vessel transition section <NUM>. In one or more embodiments, the diameter of the particulate solid treatment vessel body section <NUM> may be greater than the height of the particulate solid treatment vessel body section <NUM>. In one or more embodiments, the ratio of the diameter to the height of the particulate solid treatment vessel body section <NUM> may be from <NUM>:<NUM> to <NUM>:<NUM>. For example, the ratio of the diameter to the height of the particulate solid treatment vessel body section <NUM> may be from <NUM>:<NUM> to <NUM>:<NUM>, from <NUM>:<NUM> to <NUM>:<NUM>, from <NUM>:<NUM> to <NUM>:<NUM>, from <NUM>:<NUM> to <NUM>:<NUM>, from <NUM>:<NUM> to <NUM>:<NUM>, from <NUM>:<NUM> to <NUM>:<NUM>, from <NUM>:<NUM> to <NUM>:<NUM>, from <NUM>:<NUM> to <NUM>:<NUM>, from <NUM>:<NUM> to <NUM>:<NUM>, from <NUM>:<NUM> to <NUM>:<NUM>, from <NUM>:<NUM> to <NUM>:<NUM>, from <NUM>:<NUM> to <NUM>:<NUM>, from <NUM>:<NUM> to <NUM>:<NUM>, form <NUM>:<NUM> to <NUM>:<NUM>, from <NUM>:<NUM> to <NUM>:<NUM>, or any combination or sub-combination of these ranges.

Referring to <FIG> and <FIG>, the particulate solid separation section <NUM> includes an outer shell <NUM> defining an interior region <NUM> of the particulate solid separation section <NUM>. The outer shell <NUM> comprises a gas outlet port <NUM>, a riser port <NUM>, and a particulate solid outlet port <NUM>. Furthermore, the outer shell <NUM> may house a secondary separation device <NUM> and a particulate solid collection area <NUM> in the interior region <NUM> of the particulate solid separation section <NUM>.

In one or more embodiments, the outer shell <NUM> of the particulate solid separation section <NUM> may define an upper segment <NUM>, a middle segment <NUM>, and a lower segment <NUM> of the particulate solid separation section <NUM>. Generally, the upper segment <NUM> may have a substantially constant cross sectional area, such that the cross sectional area does not vary by more than <NUM>% in the upper segment <NUM>. In one or more embodiments, the cross sectional area of the upper segment <NUM> may be at least three times the maximum cross sectional area of the riser <NUM>. For example, the cross sectional area of the upper segment <NUM> may be at least <NUM> times, at least <NUM> times, at least <NUM> times, at least <NUM> times, at least <NUM> times, at least <NUM> times, at least <NUM> times, at least <NUM> times, at least <NUM> times, at least <NUM> times, or even at least <NUM> times the maximum cross sectional area of the riser <NUM>, such as from <NUM> times to <NUM> times. In further embodiments, the maximum cross sectional area of the upper segment <NUM> may be from <NUM> to <NUM> times the maximum cross sectional area of the riser <NUM>. For example, the maximum cross sectional area of the upper segment <NUM> may be from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, or even from <NUM> to <NUM> times the maximum cross sectional area of the riser <NUM>.

Additionally, in one or more embodiments, the lower segment <NUM> of the particulate solid separation section <NUM> may have a substantially constant cross sectional area, such that the cross sectional area does not vary by more than <NUM>% in the lower segment <NUM>. The cross sectional area of the lower segment <NUM> may be larger than the maximum cross sectional area of the riser <NUM> and smaller than the maximum cross sectional area of the upper segment <NUM>. The middle segment <NUM> may be shaped as a frustum where the cross sectional area of the middle segment <NUM> is not constant and the cross sectional area of the middle segment <NUM> transitions from the cross sectional area of the upper segment <NUM> to the cross sectional area of the lower segment <NUM> throughout the middle segment <NUM>.

Referring again to <FIG>, the particulate solid separation section <NUM> may comprise a central vertical axis <NUM>. The central vertical axis may extend through the top of the particulate solid separation section <NUM> and the bottom of the particulate solid separation section <NUM>, such that the central vertical axis <NUM> passes through the upper segment <NUM>, the middle segment <NUM>, and the lower segment <NUM> of the particulate solid separation section <NUM>. In one or more embodiments, the upper segment <NUM>, the middle segment <NUM>, and the lower segment <NUM> of the particulate solid separation section <NUM> may be centered on the central vertical axis <NUM>. For example, in embodiments where the upper segment <NUM> and the lower segment <NUM> are substantially cylindrical, the central vertical axis <NUM> may pass through the midpoint of a diameter of the upper segment <NUM> and a midpoint of a diameter of the lower segment <NUM>.

As depicted in <FIG> and <FIG>, the interior riser segment <NUM> of the riser <NUM> extends through the riser port <NUM> of the particulate solid separation section <NUM>. The riser port <NUM> may be any opening in the outer shell <NUM> of particulate solid separation section <NUM> through which at least the interior riser segment <NUM> of the riser <NUM> protrudes into the interior region <NUM> of the particulate solid separation section <NUM>. The riser port <NUM> is not located on the central vertical axis <NUM> of the particulate solid separation section <NUM>. The riser port <NUM> is located on a sidewall of the outer shell <NUM> such that the riser port <NUM> is not located on the central vertical axis <NUM>. In some embodiments, the riser port <NUM> is oriented so that the riser <NUM> does not extend into the particulate solid separation section <NUM> in a direction substantially parallel to the central vertical axis <NUM>.

In one or more embodiments, the interior riser segment <NUM> enters the particulate solid separation section <NUM> in the middle segment <NUM> of the particulate solid separation section <NUM>. In such embodiments, the interior riser segment <NUM> passes through at least a portion of the middle segment <NUM> and through at least a portion of the upper segment <NUM>. In such embodiments, the interior riser segment <NUM> does not pass through the lower segment <NUM> of the particulate solid separation section <NUM>. In further embodiments, the interior riser segment <NUM> may enter the particulate solid separation section <NUM> in the upper segment <NUM> and the interior riser segment <NUM> may pass through at least a portion of the upper segment <NUM>. In such embodiments, the interior riser segment <NUM> does not pass through the lower segment <NUM> or the middle segment <NUM>.

Referring now to <FIG>, the interior riser segment <NUM> may comprise a vertical portion <NUM>, a non-vertical portion <NUM>, and a non-linear portion <NUM>. As described herein, a "non-linear portion" may refer to a portion or a riser segment comprising a curve or a mitered junction. The non-linear portion <NUM> may be positioned between the vertical portion <NUM> and the non-vertical portion <NUM> and may connect the vertical portion <NUM> and the non-vertical portion <NUM>. Additionally, the non-vertical portion <NUM> of the interior riser segment <NUM> may be proximate to the riser port <NUM>. In one or more embodiments, the non-vertical portion <NUM> of the interior riser segment <NUM> may be adjacent or directly connected to the riser port <NUM>. As such, the riser <NUM> may extend through the riser port <NUM> in a non-vertical direction.

Referring again to <FIG>, the exterior riser segment <NUM> may comprise a vertical portion <NUM>, a non-vertical portion <NUM>, and a non-linear portion <NUM>. The non-linear portion <NUM> may be positioned between the vertical portion <NUM> and the non-vertical portion <NUM> and may connect the vertical portion <NUM> and the non-vertical portion <NUM>. The non-vertical portion <NUM> of the exterior riser segment <NUM> may be proximate to the riser port <NUM>. In one or more embodiments, the non-vertical portion <NUM> of the exterior riser segment <NUM> may be adjacent or directly connected to the riser port <NUM>. Furthermore, the vertical portion <NUM> of the exterior riser segment <NUM> may be proximate to the particulate solid treatment vessel <NUM>. In such embodiments, an expansion joint <NUM>, described in further detail herein, may be positioned between the vertical portion <NUM> of the exterior riser segment <NUM> and the particulate solid treatment vessel <NUM>.

In one or more embodiments, the riser <NUM> may extend through the riser port <NUM> in a diagonal direction where the diagonal direction is <NUM> to <NUM> degrees from vertical. For example, the diagonal direction may be from <NUM> to <NUM> degrees from vertical, from <NUM> to <NUM> degrees from vertical, from <NUM> to <NUM> degrees from vertical, from <NUM> to <NUM> degrees from vertical, from <NUM> to <NUM> degrees from vertical, from <NUM> to <NUM> degrees from vertical, from <NUM> to <NUM> degrees from vertical, from <NUM> to <NUM> degrees from vertical, from <NUM> to <NUM> degrees from vertical, from <NUM> to <NUM> degrees from vertical, from <NUM> to <NUM> degrees from vertical, from <NUM> to <NUM> degrees from vertical, from <NUM> to <NUM> degrees from vertical, from <NUM> to <NUM> degrees from vertical, from <NUM> to <NUM> degrees from vertical, from <NUM> to <NUM> degrees from vertical, from <NUM> to <NUM> degrees from vertical, from <NUM> to <NUM> degrees from vertical, from <NUM> to <NUM> degrees from vertical, from <NUM> to <NUM> degrees from vertical, from <NUM> to <NUM> degrees from vertical, from <NUM> to <NUM> degrees from vertical, from <NUM> to <NUM> degrees from vertical, or any combination or sub-combination of these ranges. In one or more alternative embodiments, the riser <NUM> may pass through the riser port <NUM> is a substantially horizontal direction. As described herein, a "substantially horizontal" direction may be within <NUM> degrees of horizontal, within <NUM> degrees of horizontal, or even within <NUM> degrees of horizontal.

Referring to <FIG>, the outer shell <NUM> may further house a riser termination device <NUM>. The riser termination device <NUM> may be positioned proximate to the interior riser segment <NUM>. In one or more embodiments, the riser termination device <NUM> may be directly connected to the vertical portion <NUM> of the interior riser segment <NUM>. The gas and particulate solids passing through the riser <NUM> may be at least partially separated by riser termination device <NUM>. The gas and remaining particulate solids may be transported to a secondary separation device <NUM> in the particulate solid separation section <NUM>. The secondary separation device <NUM> may be any mechanical or chemical separation device that may be operable to separate particulate solids from gas or liquid phases, such as a cyclone or a plurality of cyclones.

According to one or more embodiments, the secondary separation device <NUM> may be a cyclonic separation system, which may include two or more stages of cyclonic separation. In embodiments where the secondary separation device <NUM> comprises more than one cyclonic separation stages, the first separation device into which the fluidized stream enters is referred to a primary cyclonic separation device. The fluidized effluent from the primary cyclonic separation device may enter into a secondary cyclonic separation device for further separation. Primary cyclonic separation devices may include, for example, primary cyclones, and systems commercially available under the names VSS (commercially available from UOP), LD2 (commercially available from Stone and Webster), and RS2 (commercially available from Stone and Webster). Primary cyclones are described, for example, in <CIT>; <CIT>; and <CIT>. In some separation systems utilizing primary cyclones as the primary cyclonic separation device, one or more set of additional cyclones, e.g. secondary cyclones and tertiary cyclones, are employed for further separation of the particulate solids from the product gas. It should be understood that any primary cyclonic separation device may be used in embodiments disclosed herein.

The secondary separation device <NUM> may deposit separated particulate solids into the bottom of the upper segment <NUM>, the middle segment <NUM> or the lower segment <NUM> of the particulate solid separation section <NUM>. As such, the particulate solids may flow by gravity from the bottom of the upper segment <NUM> or the middle segment <NUM> to the lower segment <NUM>. The separated vapors may be removed from the fluid catalytic reactor system <NUM> via a pipe <NUM> at a gas outlet port <NUM> of the particulate solid separation section <NUM>.

Referring to <FIG> and <FIG>, the lower segment <NUM> of the particulate solid separation section <NUM> may comprise a particulate solid collection area <NUM>, which may allow for the accumulation of particulate solids in the particulate solid separation section <NUM>. In one or more embodiments, the particulate solid collection area <NUM> may comprise one or more of an oxygen soak zone, an oxygen stripping zone, and a reduction zone.

As described herein, an "oxygen soak zone" may refer to a portion of the particulate solid collection area <NUM> where the particulate solids are exposed to a flow of oxygen containing gas. In one or more embodiments, the particulate solids may generally flow downward and the oxygen containing gas may generally flow upward. The particulate solids may have an average residence time of more than <NUM> minutes in the oxygen soak zone, and preferably have a residence time from <NUM> to <NUM> minutes. The particulate solids may become oxygen-containing particulate solids within the oxygen soak zone, and thus, may have increased activity for one or more reactions occurring in the reactor section <NUM>, including but not limited to dehydrogenation reactions.

The particulate solid collection area <NUM> may comprise an oxygen stripping zone. As described herein, an "oxygen stripping zone" refers to a zone of the particulate solid collection area <NUM> where the particulate solids are stripped of oxygen containing gas molecules. Oxygen containing gas molecules may be stripped from the particulate solids by contacting the particulate solids with a gas that does not contain more than <NUM> mol. Generally, the particulate solids move downward and the gas moves upwards through the oxygen stripping zone. As such, excess oxygen-containing gas may not be passed to the reactor section <NUM> with the particulate solids.

As described herein, a "reduction zone" may refer to a zone where a reducing agent such as hydrogen or methane is fed in a catalyst stream fluidized by a non-participating gas such as nitrogen or steam. The reducing agent removes oxygen from the particle; thereby increasing the effectiveness of particle for reaction.

Referring again to <FIG> and <FIG>, the particulate solid collection area <NUM> may comprise a particulate solid outlet port <NUM>. In one or more embodiments, the particulate solid outlet port <NUM> may be located proximate to, or even on, the central vertical axis <NUM>. According to one or more embodiments, the bottom of the particulate solid collection area <NUM> may be curved such that the particulate solid outlet port <NUM> is located at the lowest portion of the particulate solid collection area <NUM>. Standpipe <NUM> may be connected to the particulate solid separation section <NUM> at particulate solid outlet port <NUM>, and the particulate solids may be transferred out of the regeneration section <NUM> via standpipe <NUM> and into the reactor section <NUM>. As such, the particulate solids may be continuously recirculated through the reactor system <NUM>.

Without wishing to be bound by theory, it is believed that when the riser <NUM> does not pass through the particulate solid collection area <NUM> and when the particulate solid outlet port <NUM> is located on the central vertical axis <NUM>, then the flow of particulate solids through the particulate solid collection area <NUM> may be improved relative to designs in which the riser <NUM> does pass through the particulate solid collection area <NUM>. When the riser <NUM> does not pass through the particulate solid collection area <NUM>, the particulate solid outlet port <NUM> may be located on the central vertical axis <NUM>, and the particulate solids may move through the particulate solid collection area <NUM> in manner more closely resembling plug flow. This may lead to an increased minimum residence time of the particulate solids within the particulate solid collection area <NUM>, which may be beneficial when stripping, oxygen soaking, or other contemplated processes occur within the particulate solid collection area <NUM>.

As described herein, portions of system units such as reaction vessel walls, separation section walls, or riser walls, may comprise a metallic material, such as carbon or stainless steel. In addition, the walls of various system units may have portions which are attached with other portions of the same system unit or to another system unit. Sometimes, the points of attachment or connection are referred to herein as "attachment points" and may incorporate any known bonding medium such as, without limitation, a weld, an adhesive, a solder, etc. It should be understood that components of the system may be "directly connected" at an attachment point, such as a weld.

To mitigate damage caused by hot particulate solids and gasses, refractory materials may be used as internal linings of various system components. Refractory materials may be included on the riser <NUM> as well as the particulate solid separation section <NUM>. It should be understood that while embodiments are provided of specific refractory material arrangements and materials, they should not be considered limiting regarding the physical structure of the disclosed system. For example, refractory liner may extend in the riser <NUM> along an interior surface of the riser <NUM> and along interior surfaces of the middle segment <NUM> and upper segment <NUM> of the particulate solid separation section <NUM>. The refractory liner may include hex mesh or other suitable refractory materials.

Mechanical loads applied onto the particulate solid treatment vessel <NUM> from the weight of the particulate solids, thermal stresses from differential growth of the various parts and other parts of the regeneration section <NUM> may be high, and in cases where expansion joints are not utilized springs may be utilized to allow movement of the particulate solid treatment vessel <NUM> while controlling nozzle forces within limits at the <NUM> junction. For example, the particulate solid treatment vessel <NUM> may be hung from springs, or springs may be positioned below the particulate solid treatment vessel <NUM> to support its weight and all or a portion of the expected catalyst weight. For example, <FIG> depicts spring supports <NUM> mechanically attached to the regeneration section <NUM> at the particulate solid treatment vessel <NUM>, wherein the regeneration section <NUM> is suspended from a support structure by the spring supports <NUM>.

Additionally, the particulate solid treatment vessel <NUM> and riser <NUM> may undergo thermal expansion. As such, hanging the particulate solid treatment vessel <NUM> from spring supports <NUM> or supporting the particulate solid treatment vessel <NUM> with spring supports <NUM> may relieve tension between the particulate solid treatment vessel <NUM> and the exterior riser segment <NUM>. In cases where springs are used, generally expansion joints are not employed. Referring now to <FIG>, an expansion joint <NUM> may be positioned between the particulate solid treatment vessel <NUM> and the exterior riser segment <NUM>. As described herein, an "expansion joint" may refer to a bellows made of metal or other suitable material, which reduces the stress between the system components joined by the expansion joint. For example, expansion joints may be used to reduce stress between system components due to thermal expansion and contraction. In cases where an expansion joint is used, generally the particulate solid treatment vessel <NUM> will be supported via a fixed support (no springs) either by rod hangers or a skirt. In one or more embodiments, an expansion joint <NUM> may be used in combination with spring supports to mitigate stress caused by thermal expansion between the particulate solid treatment vessel <NUM> and the exterior riser segment <NUM>.

The following examples illustrate features of the present disclosure but are not intended to limit the scope of the disclosure. The following examples discuss the performance of particulate solid collection areas according to one or more embodiments disclosed herein.

Flow of particulate solids through two particulate solid collection areas was modeled. The first particulate solid collection area <NUM> is depicted in <FIG>, and had an annular shape with a single exit standpipe <NUM> located at the bottom of the particulate solid collection area <NUM>. The exit standpipe <NUM> was not positioned on a central axis <NUM> of the first particulate solid collection area <NUM>. The first particulate solid collection area <NUM> also includes several cordal beam supports covered with subway grating <NUM>.

The second particulate solid collection area <NUM> is depicted in <FIG>, and had a cylindrical shape and an exit standpipe <NUM> located at the bottom of the particulate solid collection area <NUM>. The exit standpipe <NUM> was positioned on a central axis <NUM> of the second particulate solid collection area <NUM>. The second particulate solid collection area <NUM> also includes several cordal beam supports covered with subway grating <NUM>.

Computational fluid dynamics (CFD) simulations were conducted to model the flow of particulate solids through the first and second particulate solid collection areas. As such, solid residence time distributions (RTD) in each vessel were obtained. For the purposes of the simulation, the diameter of each of the first and second particulate solid collection areas was set to <NUM> (<NUM> inches). The superficial gas velocity at the bottom of each vessel was <NUM>/sec (<NUM> ft/sec) and the average particulate solid flux was <NUM>/m<NUM>-sec (<NUM> lb/ft<NUM>-sec). Additionally, the average turnaround time for the particulate solids was <NUM> minutes.

The CFD simulation for the first particulate solid collection area predicted that that the shortest residence time of the particulate solids was about <NUM> seconds, due to short-circuiting of the particulate solids on the outlet standpipe side of the vessel. The CFD simulation also predicted that about <NUM>% of the particulate solids had a residence time of less than <NUM> minutes. The CFD simulations for the second particulate solid collection area predicted that the shortest residence time for the particulate solids would be greater than <NUM> minute and that only <NUM>% of the particulate solids had a residence time shorter than <NUM> minutes.

The RTDs for the first and second particulate solid collection areas are graphically depicted in <FIG>. The RTD for the first particulate solid collection area is depicted by line <NUM> and the RTD for the second particulate solid collection area is depicted by line <NUM>. Additionally, RTDs for one continuous stirred tank reactor (CSTR) and three CSTRs in series are displayed in <FIG> for reference. The RTD for one CSTR is depicted by line <NUM> and the RTD for three CSTRs in series is depicted by line <NUM>. As displayed in <FIG>, the RTD for the first particulate solid collection area is comparable to the RTD for a single CSTR and the RTD for the second particulate solid collection area is comparable to the RTD for three CSTRs in series. The second particulate solid collection area provides a benefit over the first particulate solid collection area because the flow of particulate solids through the second particulate solid collection area more closely resembles plug flow. As such, fewer particulate solids exit the particulate solid collection area quickly and fewer particulate solids are retained in the particulate solid collection area for a long time. This results in more consistent treatment of particulate solids in the particulate solid collection area.

The present invention provides a method for regenerating a particulate solid The method comprises regenerating a particulate solid in a particulate solid treatment vessel. The regenerating of the particulate solid comprises one or more of oxidizing the particulate solid by contact with an oxygen-containing gas; combusting coke present on the particulate solid; or combusting a supplemental fuel to heat the particulate solid. The method further comprises passing the particulate solid through a riser. The riser extends through a riser port of an outer shell of a particulate solid separation section such that the riser comprises an interior riser segment positioned in an interior region of the particulate solid separation section and an exterior riser segment positioned outside of an outer shell of the particulate solid separation section. The particulate solid separation section comprises at least the outer shell defining an interior region of the particulate solid separation section. The outer shell comprises a gas outlet port, a riser port, and a particulate solid outlet port. The outer shell houses a gas/solids separation device and a particulate solid collection area in the interior region of the particulate solid separation section. The riser port is positioned on a sidewall of the outer shell such that it is not located on a central vertical axis of the particulate solid separation section. The method further comprises separating the particulate solid from gases in the gas/solids separation device and passing the particulate solids, separated from the gasses, to the particulate solid collection area located proximate the central vertical axis of the particulate solid separation section.

In a preferred embodiment of the invention, the particulate solid treatment vessel has a maximum cross sectional area that is at least <NUM> times the maximum cross sectional area of the riser.

In a preferred embodiment of the invention, the riser extends through the riser port in a non-vertical direction.

In a preferred embodiment of the invention, the riser extends through the riser port in a diagonal direction, wherein the diagonal direction is from <NUM> to <NUM> degrees from vertical.

In a preferred embodiment of the invention, the riser extends through the riser port in a substantially horizontal direction.

In a preferred embodiment of the invention, the interior riser segment comprises a vertical portion, a non-vertical portion proximate the riser port, and a non-linear portion connecting the vertical portion and the non-vertical portion.

In a preferred embodiment of the invention, the outer shell further houses a riser termination device and wherein the riser termination device is positioned proximate to the interior riser segment.

In a preferred embodiment of the invention, the exterior riser segment comprises a vertical portion proximate to the particulate solid treatment vessel, a non-vertical portion proximate to the riser port, and a non-linear portion connecting the vertical portion and the non-vertical portion.

In a preferred embodiment of the invention, a maximum cross sectional area of the outer shell is at least three times a maximum cross sectional area of the riser.

In a preferred embodiment of the invention, a maximum cross sectional area of the outer shell is from <NUM> to <NUM> times a maximum cross sectional area of the riser.

In a preferred embodiment of the invention, the gas/solids separation device comprises one or more cyclones.

In a preferred embodiment of the invention, the riser does not pass through the particulate solid collection area.

In a preferred embodiment of the invention, the particulate solid collection area comprises an oxygen soak zone, an oxygen stripper, a reduction zone, or combinations thereof.

In a preferred embodiment of the invention, the particulate solid treatment vessel is supported by spring supports.

In a preferred embodiment of the invention, the particulate solid outlet port is located on the central vertical axis of the particulate solid separation section.

The subject matter of the present disclosure has been described in detail and by reference to specific embodiments. It should be understood that any detailed description of a component or feature of an embodiment does not necessarily imply that the component or feature is essential to the particular embodiment or to any other embodiment. Further, it should be apparent to those skilled in the art that various modifications and variations can be made to the described embodiments without departing from the scope of the claimed subject matter.

For the purposes of describing and defining the present disclosure it is noted that the terms "about" or "approximately" are utilized in this disclosure to represent the inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement, or other representation. The terms "about" and/or "approximately" are also utilized in this disclosure to represent the degree by which a quantitative representation may vary from a stated reference without resulting in a change in the basic function of the subject matter at issue.

It is noted that one or more of the following claims utilize the term "wherein" as a transitional phrase. For the purposes of defining the present technology, it is noted that this term is introduced in the claims as an open-ended transitional phrase that is used to introduce a recitation of a series of characteristics of the structure and should be interpreted in like manner as the more commonly used open-ended preamble term "comprising.

It should be understood that where a first component is described as "comprising" a second component, it is contemplated that, in some embodiments, the first component "consists" or "consists essentially of" that second component. It should further be understood that where a first component is described as "comprising" a second component, it is contemplated that, in some embodiments, the first component comprises at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, or even at least <NUM>% that second component (where % can be weight % or molar %).

Additionally, the term "consisting essentially of" is used in this disclosure to refer to quantitative values that do not materially affect the basic and novel characteristic(s) of the disclosure. For example, a chemical composition "consisting essentially" of a particular chemical constituent or group of chemical constituents should be understood to mean that the composition includes at least about <NUM>% of a that particular chemical constituent or group of chemical constituents.

Claim 1:
A method for regenerating a particulate solid, the method comprising:
regenerating the particulate solid in a particulate solid treatment vessel, where the regenerating of the particulate solid comprises one or more of:
oxidizing the particulate solid by contact with an oxygen-containing gas;
combusting coke present on the particulate solid; or
combusting a supplemental fuel to heat the particulate solid;
passing the particulate solid through a riser, the riser extending through a riser port of an outer shell of a particulate solid separation section such that the riser comprises an interior riser segment positioned in an interior region of the particulate solid separation section and an exterior riser segment positioned outside of the outer shell of the particulate solid separation section, wherein the particulate solid separation section comprises at least the outer shell defining the interior region of the particulate solid separation section, the outer shell comprising a gas outlet port, the riser port, and a particulate solid outlet port, and wherein the outer shell houses a gas/solids separation device and a particulate solid collection area in the interior region of the particulate solid separation section, and wherein the riser port is positioned on a sidewall of the outer shell such that it is not located on a central vertical axis of the particulate solid separation section;
separating the particulate solid from gasses in the gas/solids separation device; and
passing the particulate solid, separated from the gasses, to the particulate solid collection area located proximate the central vertical axis of the particulate solid separation section.