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In the mid-1970s, Catalyst Recovery, Inc. pioneered ex-situ catalyst regeneration with its moving-belt process, providing an environmentally friendly alternative to in-situ regeneration. The moving-belt process with its sophisticated control system eliminated problems with channeling, hot spots, and sintering, allowing a greater recovery of catalytic activity.

In the moving-belt process (see picture below), a thin bed of material is transported through multiple regeneration zones on a porous, stainless steel belt. Radiant tube burners, located under the belt, heat the air and combustion gasses that flow through the catalyst or adsorbent bed. Multiple thermocouples in each zone monitor the bed temperatures as the carbon and sulphur contaminants are removed through controlled oxidation. The burners and airflow are adjusted to keep the bed temperatures below the maximum allowable regeneration temperature. Good temperature control is critical during regeneration to avoid sintering catalytic metals, collapsing pores, and reducing surface area. Several ploughs along the regeneration belts gently turn over the catalyst or adsorbent to ensure that it is regenerated evenly.

CRI implemented the optiCAT Plus^SM process in 1996 in the Louisiana plant and in 2000 in the Luxembourg plant. By combining a fluidized bed pretreater with the moving belt, we restore catalysts and adsorbents to their maximum potential without increased attrition. The improved stripping efficiency reduces residence time on the belt-generator, increasing throughput and improving product quality. The less time catalysts and adsorbents spend at high temperature, the less opportunity there is for sintering and surface area loss.

The optiCAT Plus^SM pretreater is also effective at removing reactive carbon and sulfur compounds in the "exothermic" stage of regeneration (see figure below). The fluidized bed provides excellent heat transfer and temperature control during this regeneration stage. Afterwards the moving-belt provides a gentle heat soak to remove the remaining carbon and sulphur embedded deep within the catalyst or adsorbent pores. By minimizing the residence time in the fluidized bed and using it only where it's really needed, we avoid particle attrition normally associated with fluidized bed processes.

The benefits of the optiCAT Plus^SM process are described in the December/January 1998/99 issue of Hydrocarbon Engineering. and the Hart’s NPRA Q&A Show Special from October 8–10, 1997.

optiCAT Plus^SM is currently installed in our Lafayette and Luxembourg plants.

Porocel retains the ability to strip precious metal "eggshell" catalysts in inert gas on the regeneration belt. ("Eggshell" precious metal catalysts have the bulk of their valuable metals near the exterior surface of the catalyst particles. Thus, attrition must be kept to an absolute minimum.)