A new configuration for decoking process in series reactors

In the present work, a new configuration for coke burning process in series reactors has been developed based on a pseudo-homogeneous mathematical model. Series reactors are very common in chemical engineering processes such as petrochemical and petroleum industries. Moreover, the catalyst regeneration procedure in this type of reactors is very important and this process should regenerate catalysts completely. It is notable that the conventional configuration has some complications for catalyst regeneration in series reactor. First of all, the dynamic model is validated with industrial data from conventional configuration. Then, the model is used to simulate new configuration of series reactors for regeneration process. The novel configuration suggests that each bed should regenerate separately. According to the model outputs, the new configuration not only leads the coke to burn completely, but also reduces the regeneration time dramatically. Furthermore, this novel system uses considerably less steam and nitrogen than the conventional one. Eventually, the proposed configuration is implemented in domestic petrochemical company for series reactors in acetylene hydrogenation plant. As a result, the regeneration period decreases significantly by 28 h. It is noticeable that the measured data from novel configuration and model outputs were in good agreement. Eventually, the effects of various parameters such as air flow rate and initial bed temperature on decoking process have been studied entirely and rigorously. Furthermore, a new regeneration protocol is achieved for the proposed configuration of series reactors.

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• A mathematical model was developed in order to simulate dynamic regeneration process.
• A comparison between mathematical and plant data show an acceptable agreement.
• A novel system for regeneration of series reactors is suggested.
• The new configuration leads to a significant decrease in operating costs.
• The effects of various parameters on decoking process have been investigated.