Abstract: A method of operating a gasification facility includes injecting a carbonaceous material into a gasification reactor. The method also includes converting at least a portion of the carbonaceous material into a solid waste byproduct that includes residual carbon. The method further includes reactivating at least a portion of the residual carbon. The method also includes injecting at least a portion of the reactivated carbon into the gasification reactor.

Abstract: The present application provides multistage and multilayer reactors useful for the efficient and continuous production of carbon nanotubes and methods of using the apparatus in the preparation of carbon nanotubes. In one aspect, the multistage reactors include an array of interconnected fluidized-bed reactors. The multilayer reactors include a plurality of reaction zones.

Abstract: The present invention relates to a high-pressure fluidized bed reactor for preparing granular polycrystalline silicon, comprising (a) a reactor tube, (b) a reactor shell encompassing the reactor tube, (c) an inner zone formed within the reactor tube, where a silicon particle bed is formed and silicon deposition occurs, and an outer zone formed in between the reactor shell and the reactor tube, which is maintained under the inert gas atmosphere, and (d) a controlling means to keep the difference between pressures in the inner zone and the outer zone being maintained within the range of 0 to 1 bar, thereby enabling to maintain physical stability of the reactor tube and efficiently prepare granular polycrystalline silicon even at relatively high reaction pressure.

Abstract: An apparatus for stripping gases from catalyst material comprises baffles having a second face that extends toward a downcomer channel between baffles to spread catalyst out on adjacent baffles for better contact with stripping gas.

Abstract: A system for alkylating hydrocarbons which includes an improved method of safely handling alkylation catalyst is disclosed. The process includes passing the alkylation catalyst from a settler vessel to a catalyst receiving vessel, via a catalyst cooler, for containment therein in the presence of a condensible gas. Also disclosed is a method for controlling the pressure in the catalyst receiving vessel by controlling the rate of removal of vapors.

Abstract: The present invention relates to a system for the separation of suspensions of spent catalysts and hydrocarbons formed in an FCC unit with multiple ascending flow reaction tubes, comprising interconnections between each of the ascending flow reaction tubes and the separator vessel, each interconnection also comprises two sections. The outside sections of the separator vessel are inclined and are connected to a single vertical section, which penetrates into the interior of the separator vessel, and which has at its lower end an open device for draining the spent catalyst from the suspensions separated in this sector. In the same vertical section, at the end of its internal part at the separator vessel, a series of two sets of cyclones are installed, the first set containing cyclones without sealing legs, and the second set containing conventional cyclones of the first stage.

Abstract: A novel continuous process is used for production of carbon nanotubes (CNTs) by catalytic chemical vapor deposition (CCVD) of methane on iron floating catalyst in-situ deposited on MgO in a fluidized bed reactor. In the hot zone of the reactor, sublimed ferrocene vapors were contacted with MgO powder fluidized by methane feed to produce Fe/MgO catalyst in-situ. An annular tube was used to enhance the ferrocene and MgO contacting efficiency. Multi-wall as well as single-wall CNTs were grown on the Fe/MgO catalyst while falling down the reactor. The CNTs were continuously collected at the bottom of the reactor, only when MgO powder was used. The annular tube enhanced the contacting efficiency and improved both the quality and quantity of CNTs. The SEM and TEM micrographs of the products reveal that the CNTs are mostly entangled bundles with diameters of about 20 nm. Raman spectra show that the CNTs have low amount of amorphous carbon with IG/ID ratios as high as 10.2 for synthesis at 900° C.

Abstract: Solvent extraction is used to remove wax and contaminants from an iron-based Fischer-Tropsch catalyst in a natural circulation continuous-flow system. The wax-free catalyst is then subjected to controlled oxidation to convert the iron to its initial oxidized state, Fe203. Reactivation of the oxide catalyst precursor is carried out by addition of synthesis gas.

Abstract: Catalytic cracking riser reactor extending between an inlet for hydrocarbonaceous feed and catalyst particles and an outlet for discharging cracked products and spent catalyst particles, which riser reactor has been provided with at least one contacting device, wherein the contacting device comprises a composite of refractory material and a metal structure, which metal structure is connected to the outer wall of the riser reactor. If more contacting devices have been provided, they are preferably axially spaced apart and are disposed along the inner surface of the riser reactor.

Abstract: Process for heating a polymer-containing stream being transferred from a polymerization reactor to a degassing vessel operating at a pressure between 6 bara and 12 bara. The process includes passing the stream through a heater having a transfer line for the stream and a device for heating the transfer line. The pressure drop in the heater is between 5% and 50% of the total pressure drop between the polymerization reactor and the entry to the degassing vessel. The pressure drop across the length of the heater is less than 0.5 barh per tonne of polymer, and the average Reynolds number across the cross-section of the stream at any point along the length of the transfer line of the heater is greater than 500,000, such that at least 90 mol% of the hydrocarbon fluids withdrawn from the polymerization reactor operation are vaporized before entry into the degassing vessel.

Abstract: The gas-phase fluidized-bed reactor conducting reaction by feeding a gas, through a gas-distribution plate located at the lower part of a reaction vessel, into a fluidized bed formed on the gas-distribution plate, wherein the reaction vessel is made up so as to have a narrowed part at a specified position of the gas flow passage above the gas-distribution plate, and the fluidized bed is formed in the area from below the narrowed part to above the narrowed part. The gas-phase fluidized bed rector of the present invention allows manufacturing polymers having excellent homogeneity of polymer structure in gas-phase polymerization.

Abstract: A moving bed of catalyst loses activity as it moves through the reactor. Creating multiple passes for the process fluid moving across a catalyst bed, increases the utilization of the catalyst and creates a pseudo-counter current flow of catalyst and process fluid. The flow improves the temperature profile of the bed and allows higher temperature fluid contacting the less active catalyst.

Abstract: An improved spent catalyst regenerator which contains sub-troughs branching off from the main trough, distribution troughs which extend outward from the sides of the main trough and the sub-troughs, and downflow tubes extending downward from the bottom of the main trough and sub-troughs.

Abstract: Disclosed is a catalyst distributor and process for spreading catalyst over a regenerator vessel. Nozzles disposed angular to a header of the distributor spread catalyst throughout a full cross section of the catalyst bed.

Abstract: Process for heating a polymer-containing stream being transferred from a polymerization reactor to a degassing vessel operating at a pressure between 6 bara and 12 bara. The process includes passing the stream through a heater comprising a transfer line for the stream and a device for heating the transfer line. The ratio of the stream velocity at the outlet of the heater to that at the inlet, Vo/Vi, is at least 1.1, typically between 1.2 and 4, and the total specific heat transfer area of the transfer line is at least 0.5 m2 per tonne/h of production of polymer. The pressure drop across the length of the heater is less than 0.5 bar per tonne/h of polymer, such that at least 90 mol % of the hydrocarbon fluids withdrawn from the polymerization reactor operation are vaporized before entry into the degassing vessel.

Abstract: An integrated combustion chamber and fluidized bed pyrolysis reactor. In one embodiment, the combustion chamber is cylindrical and the pyrolysis reactor is provided annularly about the combustion chamber with an annular wall that provides a common surface for heat transfer. A lift tube in fluid communication with the pyrolysis reactor is provided within the combustion chamber for circulating biomass and an inert fluidizable media upwardly through the lift tube; this advantageously increases heat transfer and leads to more rapid pyrolysis. The media and biomass exit the lift tube into either a freeboard area of the pyrolysis reactor or into a low density region of the fluidized bed. A condensable gaseous product is produced during pyrolysis that has economic value. The apparatus and process are especially well suited to the pyrolysis of low density agricultural biomass. The apparatus is compact and particularly well suited to mobile operation.

Abstract: A gas-solids reaction system is provided for improving product recovery in a multiple reactor reaction system. The solids of the product gas-solids flows from the multiple reactors are separated out in a separation vessel having a baffled transition zone. Additional product vapor is stripped from the solids as the solids pass through the baffled transition zone. The solids are then returned to the multiple reactors.

Abstract: An apparatus for mixing regenerated and carbonized catalyst involves obstructing upward flow of catalyst by one or more baffles between a catalyst inlet and a feed distributor. Each catalyst stream may be passed to opposite sides of a riser. Baffles obstruct upward flow to effect mixing of regenerated and carbonized catalyst to obtain a more uniform temperature and catalyst mixture before contacting the feed.

Abstract: Methods and systems for cracking hydrocarbon material in a nozzle reactor and processing any un-cracked hydrocarbon material passing through the nozzle reactor. The nozzle reactor used may have a configuration whereby cracking material is injected into the nozzle reactor at a high velocity, including supersonic speed. The hydrocarbon material is injected into the nozzle reactor and intersects with the cracking material to crack hydrocarbon material. Any hydrocarbon material that pass through the nozzle reactor un-cracked can be re-injected into the nozzle reactor. An increase in the concentration and amount of un-cracked hydrocarbons injected into the nozzle reactor may increase the overall conversion of hydrocarbons into lighter hydrocarbons.

Abstract: A fluidized bed reactor for removing phosphorus and nitrogen from wastewater has a column comprising a number of sections. The diameter of the column changes stepwise between the sections. A flow velocity in excess of 100 cm/min is maintained in a lowermost one of the sections and lower flow velocities are maintained in subsequent sections. A struvite supersaturation ratio is controlled in part by recycling wastewater from an outlet of the column. Struvite pellets are removed periodically from the bottom of the column.

Abstract: Material delivery systems and methods are disclosed. Material delivery system includes delivery vessel, metering device, dispense mechanism, and mixer. The delivery vessel is configured to dispense material to a unit and metering device provides a metric indicative of the dispensed material to the unit. The dispense mechanism is configured to couple the delivery vessel to the unit. The mixer is coupled to the delivery vessel and configured to sufficiently mix the material with an activating agent. The method includes dispensing metered material from a dispense mechanism of a delivery vessel coupled to a mixer, wherein a metric is indicative of the dispensed material to the unit; sufficiently mixing the metered material with an activating agent in the mixer to activate the material, the mixer coupled to the unit; and delivering the activated material to the unit via the mixer. Systems and method also include providing material to plurality of units.

Abstract: In an FCC process in which swirl arms are used to discharge gas and catalyst from a riser, a baffle is used to direct descending catalyst away from a wall of a disengaging vessel proximate a stripping section comprising elongated strips of metal.

Abstract: Disclosed is an optimized process and apparatus for more efficiently and economically carrying out the liquid-phase oxidation of an oxidizable compound. Such liquid-phase oxidation is carried out in a bubble column reactor that provides for a highly efficient reaction at relatively low temperatures. When the oxidized compound is para-xylene and the product from the oxidation reaction is crude terephthalic acid (CTA), such CTA product can be purified and separated by more economical techniques than could be employed if the CTA were formed by a conventional high-temperature oxidation process.

Abstract: Disclosed is an FCC apparatus and process in which spent catalyst is recycled to the base of the riser to contact fresh feed through a passage disposed within the riser.

Abstract: Included are a nano-carbon material production unit for producing a nano-carbon material using a fluidized catalyst formed by granulating a carrier supporting an active component, an acid treatment unit for dissolving and separating a catalyst by an acid solution by feeding a catalyst-containing nano-carbon material into the acid solution, and a pH adjustment unit, which is an anti-agglomeration treatment unit, provided on a downstream side of the acid treatment unit, for performing an anti-agglomeration treatment to prevent agglomeration among nano-carbons due to repulsion caused by dissociation among oxygen-containing functional groups added to the nano-carbon material.

Abstract: Method and apparatus for a point-of-origin catalytic abatement system, for treatment of gaseous organic solvent emissions is disclosed. The heating element, forced fresh air fan and catalyst bed material are sized, constructed, arranged, and operated to affect a catalytic oxidation of gaseous organic solvent emissions in the catalyst bed material of the disclosed apparatus to yield essentially only carbon dioxide and water products. The arrangement and process are such that direct contact of solvent gasses with the heating element is avoided to prevent pre-ignition of these solvents in gas phase. In the process, the hot air stream is used to entrain cooler, ambient fresh air to manage both the surface temperature of the enclosure and the outlet temperature of the clean process exhaust.

Abstract: A system for reducing carbon dioxide emissions from gasses generated in burning fossil fuel, includes a vessel, separator and reheater. The upper portion of the vessel receives downward flowing, first type solid particles capable of absorbing heat from upward flowing gasses and second type solid particles capable of capturing carbon dioxide from the gasses. The separator separates the second type solid particles with the captured carbon dioxide from the gasses discharged from the first vessel discharge, and directs the separated second type solid particles with the captured carbon dioxide to a separator discharge. The reheater directs the first type solid particles and the second type solid particles with the captured carbon dioxide in a downwardly flow to a first reheater discharge, such that heat from the first type solid particles causes the captured carbon dioxide to be released from the second type solid particles.

Abstract: In order to improve sealing properties between a downcomer and a high-speed layer and in order to efficiently take out produced gas obtained through gasification of, for example, a solid reactant, a syphon for sealing between a downcomer and a high-speed layer through temporary storage of particles moving from the downcomer to the high-speed layer comprises a reactor portion for causing the solid reactant to conduct chemical reaction through action of the particles, a downcomer seal portion in communication, at upper and lower ends thereof, with the downcomer and a lower portion the reactor portion, respectively, a particle outlet seal portion provided in a spaced apart relationship from the downcomer seal portion and in communication, at upper and lower ends thereof, with the high-speed layer and the lower portion of the reactor portion, respectively, and a freeboard portion formed above the reactor portion.

Abstract: A process for at least one of a chemical and a physical treatment of fluidizable substances in a reactor. The process includes introducing a hot gas into an interior of the reactor through a gas supply tube and cooling at least one of the hot gas and the gas supply tube with a coolant. The cooling is performed by contacting the hot gas with the coolant so as to provide a temperature of a wall of the gas supply tube at least 50° C. lower than a temperature of the gas at an inlet of the gas supply tube facing away from the interior of the reactor.

Abstract: A circulating fluidized bed power plant 100 includes; a circulating fluidized bed boiler 110 which generates flue gases, a flash dry absorber scrubber 140 configured to receive the flue gases from the circulating fluidized bed boiler 110, and a lime feed 150 configured to introduce lime into the flash dry absorber scrubber 140.

Abstract: A preferred embodiment of a system for loading catalyst and/or additives into a fluidized catalytic cracking unit includes a bin for storing at least one of the catalyst and/or additives, and a loading unit in fluid communication with the storage bin and the fluidized catalytic cracking unit on a selective basis. The loading unit is capable of being evacuated so that a resulting vacuum within the loading unit draws the catalyst and/or additive from the bin. The loading unit is also capable of being pressurized so that the catalyst and/or additive is transferred from the loading unit to the fluidized catalytic cracking unit.

Abstract: An apparatus and method for loading catalyst to a fluid catalyst cracking unit are provided. In one embodiment, apparatus for loading catalyst to a fluid catalyst cracking unit includes a vessel disposed in a transportable housing. A plurality of catalyst storage regions are associated with the vessel. A metering device is interfaced with the vessel and configured to provide a metric indicative of an amount of catalyst provided from a selected one of the catalyst storage regions.

Abstract: A reactor in which a multi-phase mixture, including gas and a catalyst slurry or liquid, is to be conducted. The reactor includes a reaction chamber having a substantially unencumbered center portion through which the multi-phase mixture is conducted upwardly. A downcomer arrangement is disposed laterally outwardly of the center portion and adjacent to an inner surface of the reaction chamber. An external pump communicates with a lower portion of the reaction chamber for circulating components of the mixture downward from an upper end of the downcomer arrangement to a lower end thereof. A collection chamber is disposed below the reaction chamber into which the components exiting the downcomer arrangement are introduced and where the gas is separated from the remainder of the components. The separated gas can be reintroduced into the reaction chamber.

Abstract: This invention describes gas-solid, liquid-solid and gas-solid-liquid processes in microchannels devices including such processes as heterogeneous catalysis, particle formation, particle attrition, particle separation and adsorption or desorption of selected species. Various processes can be enhanced by the unique properties of microchannels such as the predominance of laminar flow, high rates of shear, high rates of heat transfer and high rates of mass transfer. Also encompassed by this invention are methods for the introduction to and removal from microchannels of particle containing fluid streams.

Abstract: A system for depressurizing and cooling a high pressure, high temperature dense phase solids stream having coarse solid particles with entrained gas therein. In one aspect, the system has an apparatus for at least partially depressurizing and cooling the high pressure, high temperature dense phase solids stream having gas entrained therein and a pressure letdown device for further depressurization and separating cooled coarse solid particles from a portion of the entrained gas, resulting in a lower temperature, lower pressure outlet of solid particles for downstream processing or discharge to a storage silo for future use and/or disposal. There are no moving parts in the flow path of the solids stream in the system.

Abstract: An addition apparatus, a fluid catalytic cracking (FCC) system having an addition apparatus, and a method for adding material to an FCC unit are provided. In one embodiment, an addition system having the capability of interfacing with a material container is provided that allows the addition system to obtain information relating material held in the container. In one embodiment, at least some of the information is contained on a tag affixed to the container. Other information may be retrieved and/or sent to the addition system controller from a remote data source, such as a catalyst supplier.

Abstract: The present invention relates to a method for production of silane where particulate quartz in a fluidized bed is treated with a gas containing hydrogen at a temperature below 0° C., with the quartz in the fluidized bed subjected to an alternating electric field having a frequency equal to the intrinsic resonant frequency of at least a part of the quartz particles to create vibrational energy in the particles, thereby causing a chemical reaction between quartz and hydrogen to produce silane. The invention also relates to an apparatus for carrying out the method.

Abstract: Process and apparatus for gas-phase polymerization of olefin(s), including a fluid or stirred bed reactor, a bed level controller, and at least one conduit for withdrawing polymer, provided with an isolation valve. The conduit connects the side wall of the reactor to at least one uplift conduit, at least one recovery gas lock hopper equipped with a discharge valve, and at least one degassing chamber. At least one flushing device is provided for flushing the at least one uplift conduit.

Abstract: One exemplary embodiment can include an apparatus for transferring catalyst from a regeneration zone to a reaction zone in a hydrocarbon conversion unit. The hydrocarbon conversion unit can include a transfer vessel, and first, second, and third lines. The transfer vessel can transfer regenerated catalyst from the regeneration zone at a first pressure to the reaction zone at a second pressure where the second pressure is greater than the first pressure. Generally, the first line communicates the catalyst to the transfer vessel and is coupled to a first valve to allow catalyst into the transfer vessel and the second line communicates the catalyst from the transfer vessel and is coupled to a second valve to allow catalyst out of the transfer vessel. The third line for allowing the passage of gas therethrough may be at a pressure higher than the first pressure having a first portion communicating with the transfer vessel and having a second portion coupled to third and fourth valves.

Abstract: Disclosed is an apparatus and process for disengaging regenerated catalyst from flue gas in a catalyst regenerator so as to avoid re-entrainment of catalyst that has settled into a bed in the catalyst regenerator using a disengaging device. A disengaging arm of the disengaging device has an outer shell that encloses the arm, an inner shell with a slot for allowing catalyst and flue gas to exit the arm and an outer baffle having a lower edge located below the opening in the outer wall. The baffle directs the catalyst and flue gas downwardly and limits radial flow. Catalyst and flue gas enter the disengaging arm through an opening in an outer wall of a riser section at a first superficial velocity and exits through a slot in a bottom of the disengaging arm at no more than 1.33 the first superficial velocity.

Abstract: A stripping apparatus is described for the gas-solid separation process in a fluidized bed in a counter-current flow of a stripping fluid. The apparatus includes sets of perforated baffle-plates with holes, fixed in series, alternating central and lateral plates inside a stripping chamber. The holes in the baffle-plates, in number, size and in circular or elliptical lay-out, are oriented in offset position in relation to the holes in the parallel and subsequent baffle-plates, reducing the damage of erosion on the perforated baffle-plates and optimizing stripping of the fluidized solid particles.

Abstract: A gas-solids reaction system is provided for improving product recovery in a multiple reactor reaction system. The solids of the product gas-solids flows from the multiple reactors are separated out in a separation vessel having a baffled transition zone. Additional product vapor is stripped from the solids as the solids pass through the baffled transition zone. The solids are then returned to the multiple reactors.

Abstract: A device for the thermal decomposition of a volatile compound, and for deposition of particles which are formed by the decomposition, includes (a) a pressure vessel, (b) at least one reaction tube located inside the pressure vessel such that, an open end of the reaction tube extends into the pressure vessel and an other end of the reaction tube is located outside the pressure vessel and is provided with a gas feed, wherein a longitudinal axis of the reaction tube is oriented in the direction of gravity and parallel to a longitudinal axis of the pressure vessel and wherein the reaction tube can be heated on a gas inlet side and cooled on a gas outlet side, wherein the pressure vessel, in its lower part, comprises a collection cone, wherein the open end of the at least one reaction tube extends into a gas space of the collection cone, wherein the collection cone is connected to an outlet lock for particles, and (c) a gas outlet unit located mainly inside the pressure vessel, the gas outlet unit comprising a gas

Abstract: The invention concerns methods and systems for minimizing back-mixing of feedstock flow in converting oxygenates to olefins. In one embodiment, back-mixing is reduced by providing a reactor that includes baffles to reduce the hydraulic diameter of at least a portion of the reactor. Some or all of the baffles can also serve as cooling tubes for reducing temperature gradients in the reactor, and thereby maximize light olefin production.

Abstract: The gasifier described includes, in its preferred embodiments, a vertically elongated (“oblong”) primary gasifier chamber with an auger and a fluidized bed, allowing for large amounts of fuel input when necessary. The gasifier further includes a gas treatment chamber receiving gases discharged from the gasifier chamber. The fluidized bed in the gasifier chamber as well as the gas treatment chamber contain metallic particles, with these metallic particles circulating in a closed loop between the gasifier chamber and the gas treatment chamber. This system offers numerous benefits. Some or all of said metallic particles can serve as a catalyst in the gasification of the gasifiable materials being processed, including serving as a catalyst for a Fisher Tropsch chemical process in the gasification of said gasifiable materials. In the gas treatment chamber particularly, some or all of said metallic particles serve to clean gases produced in the gasification of said gasifiable materials.

Abstract: An improved radial or cross flow moving bed regenerator or reactor, in which the solid particle residence time in the vessels can be changed in different section of the regenerator or reactor. The improvement results from the placement of one or multiple screen inserts which divides the radial or cross flow bed into separate solid flow channels. The residence time of the solid in each solid flow channels are optimized based on the regeneration or reaction requirement by changing the location, orientation and geometry of the screen inserts. As a result of the optimization of solid residence time in different section in the radial flow bed, the efficiency of a regenerator or a reactor is improved.

Abstract: The present invention relates to a method for mass preparation of granular polycrystalline silicon in a fluidized bed reactor, comprising (a) a reactor tube, (b) a reactor shell encompassing the reactor tube, (c) an inner zone formed within the reactor tube, where a silicon particle bed is formed and silicon deposition occurs, and an outer zone formed in between the reactor shell and the reactor tube, which is maintained under an inert gas atmosphere, and (d) a controlling means to keep the pressure difference between the inner zone and the outer zone being maintained within the range of 0 to 1 bar, thereby capable of maintaining physical stability of the reactor tube and efficiently preparing granular polycrystalline silicon even at a relatively high reaction pressure.

Abstract: A device for discharging, through a central rotating chimney, fluids from a fluidized bed driven in a rotational movement in the same direction by the rotation of the outer circular wall of a reaction chamber and/or by injection of part of these fluids along the circular wall of a fixed or rotating chamber, and methods for catalytic polymerization, drying, or other treatments of solid particles in suspension in a rotating fluidized bed or for cracking or other catalytic conversions of fluids using this device.

Abstract: A gas-solids reaction system with termination devices to connect a riser with one or more separation devices. The termination devices have a radius of curvature that is at least 1.0 times as great as the diameter of the conduit forming the termination device. The termination devices can be openly or closely coupled to the separation devices.

Abstract: A cost-effective biomass gasification method and system for converting biomass materials into gaseous fuel. The system and method are capable of converting at least about 50-70% of the carbon in a biomass material into gaseous carbon at a temperature lower than about 1300° F. Also provided is a highly-efficient, cost-effective biomass gasification system comprising a combustor and a gasifier with an inside diameter of at least about 36 inches and a height of at least about 40 feet.