Method and apparatus for monitoring catalyst requirements of a fluid catalytic cracking catalyst injection system

• US 20040117158A1
• Filed: 12/16/2002
• Published: 06/17/2004
• Est. Priority Date: 12/16/2002
• Status: Active Grant

• Current Assignee: Johnson Matthey Process Technologies Inc. (Johnson Matthey PLC)
• Original Assignee: Intercat Equipment, Inc.
• Inventors: Evans, Martin
• Granted Patent: US 6,859,759 B2
• Time in Patent Office: Days
• US Class Current: 702/188
• CPC Class Codes: B01J 2208/00752 Feeding
• CPC Class Codes: B01J 2208/00761 Discharging
• CPC Class Codes: B01J 2208/00769 Details of feeding or discharging
• CPC Class Codes: B01J 8/0015 Feeding of the particles in the reactor; Evacuation of the particles out of the reactor
• CPC Class Codes: B01J 8/003 in a downward flow
• CPC Class Codes: B01J 8/0035 Periodical feeding or evacuation
• CPC Class Codes: C10G 11/18 according to the "fluidised-bed" technique
• CPC Class Codes: C10G 11/187 Controlling or regulating

Abstract

A method and apparatus for monitoring catalyst requirements of a fluid catalytic cracking catalyst injection system is provided. In one embodiment, a method for monitoring catalyst requirements of a fluid catalytic cracking catalyst injection system includes the steps of communicating with a memory device of a control module of the catalyst injection system that is adapted to control the amount of catalyst injected into a fluid catalyst cracking unit and determining if catalyst inventory needs to be replenished. The method enables both suppliers and processors to remotely monitor inventory requirements and take appropriate action if inventories fall below a predefined level or reorder point.

Claims

1. A method for monitoring catalyst requirements of a fluid catalytic cracking catalyst injection system, the method comprising:

communicating with a memory device of a control module of the catalyst injection system adapted to control an amount of catalyst injected into a fluid catalyst cracking unit; and

determining if catalyst inventory needs to be replenished.

2. The method of claim 1, wherein the step of communicating with the memory device further comprises:

establishing communication between the memory device and a device remote to the control module without opening the control module.

3. The method of claim 2, wherein the step of establishing communication with the remote device further comprises:

communicating with the memory device over voice or data lines.

4. The method of claim 3, wherein the step of communicating with the remote device further comprises:

initiating communication with the memory device from the remote device.

5. The method of claim 3, wherein the step of communicating with the remote device further comprises:

initiating communication with the remote device from the memory device.

6. The method of claim 3, wherein the step of communicating with the remote device further comprises:

downloading information to the memory device.

7. The method of claim 6, wherein the step of downloading further comprises:

transferring catalyst inventory information to the memory device.

8. The method of claim 7, wherein the step of determining further comprises:

adding downloaded catalyst inventory information and an amount of catalyst disposed in the catalyst injection system and subtracting an amount of catalyst added to the catalyst injection system to determining a total inventory amount; and

comparing the total inventory amount with a reorder level.

9. The method of claim 8, wherein the amount of catalyst disposed in catalyst injection system is determined by weight of a storage vessel.

10. The method of claim 8, wherein the step of determining further comprises:

subtracting an amount of catalyst dispensed by the catalyst injection system from downloaded catalyst inventory information to determining a total inventory amount; and

comparing the total inventory amount with a reorder level.

11. The method of claim 3, wherein the step of communicating with the remote device further comprises:

retrieving catalyst information from the memory device.

12. The method of claim 11, wherein the catalyst information is at least one of metric of catalyst remaining or injected by the catalyst injection system.

13. The method of claim 11, wherein the step of determining further comprises:

utilizing the retrieved catalyst injection history to determine a total catalyst inventory; and

comparing the total catalyst inventory with a reorder level.

14. The method of claim 13 further comprising:

issuing a notification if total catalyst inventory is less than or equal to a reorder level.

15. The method of claim 14, wherein the step of issuing the notification further comprises at least one of a warning light, a warning sound, an automatic telephonic message, an automatic electronic mail, or placing a sales call.

16. The method of claim 13 further comprising releasing a shipment of catalyst in response to the total catalyst inventory being less than or equal to a reorder level.

17. The method of claim 1, wherein the step of determining is made by a processor housed within the control module.

18. The method of claim 1, wherein the step of determining is made by a device located external to an enclosure housing the control module, the device communicating with the memory device without opening the enclosure.

19. A method for monitoring catalyst requirements of a fluid catalytic cracking catalyst injection system, the method comprising:

recording a metric of catalyst handled by a catalyst injection system to a memory device disposed in a control module of the catalyst injection system coupled to a fluid catalytic cracking unit;

accessing the recorded metric without opening the control module; and

evaluating inventory levels of catalyst based on the recorded metric of catalyst.

20. The method of claim 19, wherein the metric of catalyst is at least one of an amount of catalyst dispensed by the catalyst injection system over a predetermined period or an amount of catalyst remaining in the catalyst injection system.

21. The method of claim 20, wherein the step of evaluating inventory levels further comprising:

subtracting the amount of catalyst dispensed from an amount of catalyst inventoried.

22. The method of claim 21 further comprising:

dispensing catalyst from a storage vessel; and

weighing the storage vessel to determine a metric indicative of the amount of catalyst dispensed.

23. The method of claim 21 further comprising:

dispensing catalyst from a storage container into a shot pot;

pressurizing the shot pot; and

injecting catalyst from the shot pot into the fluid catalytic cracking unit.

24. The method of claim 19 further comprising:

transferring catalyst inventory information to a device remote to the control module.

25. The method of claim 23, wherein the step of evaluating inventory levels further comprises:

adding downloaded catalyst inventory information and an amount of catalyst disposed in the catalyst injection system and subtracting an amount of catalyst added to the catalyst injection system to determining a total inventory amount; and

comparing the total inventory amount with a reorder level.

26. The method of claim 25, wherein the amount of catalyst disposed in catalyst injection system is determined by weight of a storage vessel.

27. The method of claim 23, wherein the step of evaluating inventory levels further comprises:

subtracting an amount of catalyst dispensed by the catalyst injection system from downloaded catalyst inventory information to determining a total inventory amount; and

comparing the total inventory amount with a reorder level.

28. The method of claim 19 further comprising:

transferring catalyst inventory information from the memory device to a device remote to the control module.

29. The method of claim 28, wherein the catalyst information is at least one of metric of catalyst remaining or injected by the catalyst injection system.

30. The method of claim 28, wherein the step of determining further comprises:

utilizing the retrieved catalyst injection history to determine a total catalyst inventory; and

comparing the total catalyst inventory with a reorder level.

31. The method of claim 30 further comprising:

issuing a notification if total catalyst inventory is less than or equal to a reorder level.

32. The method of claim 31, wherein the step of issuing the notification further comprises at least one of a warning light, a warning sound, an automatic telephonic message, an automatic electronic mail, or placing a sales call.

33. The method of claim 30 further comprising releasing a shipment of catalyst in response to the total catalyst inventory being less than or equal to a reorder level.

34. A computer-readable medium having stored thereon a plurality of instructions, the plurality of instructions including instructions which, when executed by a processor, cause the processor to indicate a need for catalyst replenishment for catalyst injection system that controls the amount of catalyst injected into a fluid catalyst cracking unit, the instructions comprising:

accessing a metric of catalyst inventory from a memory device of a control module of the catalyst injection system without opening the control module;

determining if a total catalyst inventory based on the accessed metric is less than or equal to a predetermined level; and

issuing a notification in response to the total catalyst inventory.

35. The computer-readable medium of claim 34, wherein the step of issuing the notification further comprises at least one of a warning light, a warning sound, an automatic telephonic message, an automatic electronic mail, or placing a sales call.

36. The computer-readable medium of claim 34 further comprising releasing a shipment of catalyst in response to the total catalyst inventory being less than or equal to the predetermined level.

37. Apparatus for monitoring catalyst requirements of a fluid catalytic cracking catalyst injection system, comprising:

a catalyst injection system adapted to dispense catalyst to a fluid catalyst cracking unit;

a control module adapted to control an amount of catalyst injected by the catalyst injection system;

an enclosure housing the control module;

a mean for communicating with a memory device of the control module without opening the enclosure; and

a mean for determining if catalyst inventory need to be replenished.

38. The apparatus of claim 37, wherein the mean for communicating is a communication port consisting of at least one of a serial port, a parallel port, a wireless transceiver and an optical transceiver.

39. The system of claim 38, wherein the communication port is coupled to a remote device through a window disposed in the enclosure.

40. The system of claim 37, wherein the mean for communicating further comprises:

a modem coupled to the control module.

41. The system of claim 40, wherein the modem is accessible from an exterior of the enclosure and sealably coupled to the enclosure.

42. The apparatus of claim 37, wherein the mean for determining comprises:

a processor disposed in the control module and coupled to the memory.

43. The apparatus of claim 37 further comprising:

a processor located remotely from the control module and coupled to the memory by the means for communicating.