Description:FIELD OF THE INVENTION

The present disclosure generally relates to regenerators employed in a Fluid Catalytic Cracking (FCC) regenerator, and particularly, the present disclosure relates to a distributor assembly for uniformly distributing a spent catalyst in the Fluid Catalytic Cracking (FCC) regenerator.

BACKGROUND

Fluidized Catalytic Cracking (FCC) is an important process in an oil refinery, in which heavy hydrocarbon feed from crude oil is cracked into light hydrocarbon products in presence of a catalyst in a riser type reactor. The catalyst that has been used during the cracking process in the riser reactor is referred to as a spent catalyst. The spent catalyst has active sites covered with coke (a by-product of FCC) and due to the same, the spent catalyst becomes unusable for subsequent cracking reactions.

In order to reuse the spent catalyst, the spent catalyst is routed to a regenerator where the coke from active sites on the spent catalyst is combusted in presence of air to recover the active sites of the spent catalyst. The heat evolved during the coke combustion process also heats up the spent catalyst to obtain a regenerated catalyst. The spent catalyst is then sent to the riser reactor to participate in the catalytic cracking reactions again.

The efficiency of regeneration process of the spent catalyst greatly depends on how the catalyst is distributed in a regenerator bed. Non-uniform distribution of the catalyst in uneven oxygen concentration within the regenerator bed, leads to non-homogeneous combustion of deposited coke in some regions and presence of excess oxygen in other regions of the regenerated catalyst. the non-homogeneous combustion of coke produces Carbon Monoxide (CO) and relatively higher coke content on the regenerated catalyst. CO may combust in a dilute bed region due to the presence of excess oxygen, a phenomenon known as afterburning, and create a very high temperature in the dilute bed. The higher coke content in the regenerated catalyst reduces its activity and negatively impacts the conversion process. High temperature resulting from the uneven distribution of what? also leads to the combustion of nitrogen and results in the emission of harmful Nitrogen Oxides (NOx). Hot spots in a dense bed further aggravate the deactivation of catalyst particles due to sintering.

Therefore, uniform distribution of the spent catalyst in the regenerator is essential to ensure that the least possible amount of the coke is present in the regenerated catalyst which increases conversion in the reactor, and emissions of CO, NOx and excess O2 are prevented. Further, the uniform distribution also ensures that no hot spots are formed in the catalyst bed, thereby improving the retention of the catalyst and reducing the cost of catalyst manufacturing. Furthermore, the uniform distribution ensures that no after-burn is left in the regenerator, thereby improving the life of regenerator components.

Conventionally, several attempts have been made to improve the distribution of the spent catalyst inside the regenerator. Many such attempts focus on introducing a spent catalyst distributor at a stand-pipe outlet of the regenerator, which distributes the catalyst at multiple locations within the regenerator bed. However, the conventional spent ???? catalyst distributors require additional aeration air and have increased back pressure to the spent catalyst flow, which makes the FCC reactor less efficient. Further, the additional aeration requirements make the conventional FCC reactors more complex, and difficult to operate.

SUMMARY
This summary is provided to introduce a selection of concepts, in a simplified format, that are further described in the detailed description of the invention. This summary is neither intended to identify key or essential inventive concepts of the invention nor intended for determining the scope of the invention.

The present disclosure relates to a distributor assembly for uniformly distributing a spent catalyst in a Fluid Catalytic Cracking (FCC) regenerator. The distributor assembly includes a header adapted to receive the spent catalyst. A horizontal plate extends from the header, which includes a plurality of perforations adapted to fluidize a stream of air flowing therethrough and aerate the spent catalyst flowing across the horizontal plate. A plurality of vertical plates extends orthogonally from the horizontal plate defining a plurality of channels to discharge the spent catalyst.

The present disclosure further relates to a Fluid Catalytic Cracking (FCC) regenerator including a distributor assembly attached to a catalyst inlet pipe through a wall of the FCC regenerator. The distributor assembly is adapted to uniformly distribute a spent catalyst in the FCC regenerator and includes a header adapted to receive the spent catalyst. A horizontal plate extends from the header, which includes a plurality of perforations adapted to fluidize a stream of air flowing therethrough and aerate the spent catalyst flowing across the horizontal plate. A plurality of vertical plates extends orthogonally from the horizontal plate defining a plurality of channels to discharge the spent catalyst.

The distributor assembly disclosed herein divides the spent catalyst flow into multiple streams because of the plurality of channels, thereby ensuring increased spread of the spent catalyst within the FCC regenerator. The distributor assembly is a fully open type of distributor assembly, which helps in avoiding backflow of the spent catalyst in the FCC regenerator. Further, fluidizing air in the FCC regenerator uniformly aerates the spent catalyst in the distributor assembly, thus eliminating a need for additional aeration requirement. Furthermore, the distributor assembly offers a reduced volume fraction of catalyst at distribution points, which results in an efficient air-catalyst contact.

To further clarify advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which is illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

Figure 1 illustrates a Fluid Catalytic Cracking (FCC) reaction assembly, according to an embodiment of the present disclosure;
Figure 2a illustrates a top view of a distributor assembly inside an FCC regenerator of the FCC reaction assembly, according to an embodiment of the present disclosure;
Figure 2b illustrates a side view of the distributor assembly inside the FCC regenerator of the FCC reaction assembly, according to an embodiment of the present disclosure;
Figure 2c illustrates a front view of the distributor assembly inside the FCC regenerator of the FCC reaction assembly, according to an embodiment of the present disclosure;
Figure 2d illustrates a side view of the distributor assembly inside the FCC regenerator of the FCC reaction assembly, according to an embodiment of the present disclosure;
Figure 3a illustrates a simple distributor assembly for uniformly distributing a spent catalyst in the FCC regenerator of the FCC reaction assembly, according to an embodiment of the present disclosure;
Figure 3b illustrates the distributor assembly with uneven boundaries of a plurality of channels, according to an embodiment of the present disclosure;
Figure 3c illustrates the distributor assembly with diverters having a shorter length as compared to diverters of the distributor assembly in Figure 3a, according to an embodiment of the present disclosure;
Figure 3d illustrates the distributor assembly with the plurality of vertical walls initiating from the header, according to an embodiment of the present disclosure;
Figure 3e illustrates the distributor assembly with the diverters having flow spaces, according to an embodiment of the present disclosure;
Figure 4 illustrates a graphical representation for Computational Fluid Dynamics (CFD) analysis of spent catalyst velocity streamlines on the distributor assembly, according to an embodiment of the present disclosure;
Figure 5 illustrates a graphical representation for the CFD analysis of Volume fraction of the spent catalyst on the distributor assembly, according to an embodiment of the present disclosure;
Figure 6 illustrates a graphical representation for the CFD analysis of flow pressure of the spent catalyst on the distributor assembly, according to an embodiment of the present disclosure;

Further, skilled artisans will appreciate that elements in the drawings are illustrated for simplicity and may not have necessarily been drawn to scale. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having benefit of the description herein.

DETAILED DESCRIPTION OF FIGURES

For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated system, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skilled in the art to which this invention belongs. The system, methods, and examples provided herein are illustrative only and not intended to be limiting.

For example, the term “some” as used herein may be understood as “none” or “one” or “more than one” or “all.” Therefore, the terms “none,” “one,” “more than one,” “more than one, but not all” or “all” would fall under the definition of “some.” It should be appreciated by a person skilled in the art that the terminology and structure employed herein is for describing, teaching, and illuminating some embodiments and their specific features and elements and therefore, should not be construed to limit, restrict or reduce the spirit and scope of the present disclosure in any way.

For example, any terms used herein such as, “includes,” “comprises,” “has,” “consists,” and similar grammatical variants do not specify an exact limitation or restriction, and certainly do not exclude the possible addition of one or more features or elements, unless otherwise stated. Further, such terms must not be taken to exclude the possible removal of one or more of the listed features and elements, unless otherwise stated, for example, by using the limiting language including, but not limited to, “must comprise” or “needs to include.”

Whether or not a certain feature or element was limited to being used only once, it may still be referred to as “one or more features” or “one or more elements” or “at least one feature” or “at least one element.” Furthermore, the use of the terms “one or more” or “at least one” feature or element do not preclude there being none of that feature or element, unless otherwise specified by limiting language including, but not limited to, “there needs to be one or more…” or “one or more elements is required.”

Unless otherwise defined, all terms and especially any technical and/or scientific terms, used herein may be taken to have the same meaning as commonly understood by a person ordinarily skilled in the art.

Reference is made herein to some “embodiments.” It should be understood that an embodiment is an example of a possible implementation of any features and/or elements of the present disclosure. Some embodiments have been described for the purpose of explaining one or more of the potential ways in which the specific features and/or elements of the proposed disclosure fulfil the requirements of uniqueness, utility, and non-obviousness.

Use of the phrases and/or terms including, but not limited to, “a first embodiment,” “a further embodiment,” “an alternate embodiment,” “one embodiment,” “an embodiment,” “multiple embodiments,” “some embodiments,” “other embodiments,” “further embodiment”, “furthermore embodiment”, “additional embodiment” or other variants thereof do not necessarily refer to the same embodiments. Unless otherwise specified, one or more particular features and/or elements described in connection with one or more embodiments may be found in one embodiment, or may be found in more than one embodiment, or may be found in all embodiments, or may be found in no embodiments. Although one or more features and/or elements may be described herein in the context of only a single embodiment, or in the context of more than one embodiment, or in the context of all embodiments, the features and/or elements may instead be provided separately or in any appropriate combination or not at all. Conversely, any features and/or elements described in the context of separate embodiments may alternatively be realized as existing together in the context of a single embodiment.

Any particular and all details set forth herein are used in the context of some embodiments and therefore should not necessarily be taken as limiting factors to the proposed disclosure.

Embodiments of the present invention will be described below in detail with reference to the accompanying drawings.

The present disclosure relates to a Fluid Catalytic Cracking (FCC) reaction assembly including a riser reactor and a regenerator, as shown in Figure 1. Specifically, Figure 1 illustrates a Fluid Catalytic Cracking (FCC) reaction assembly 100. The FCC reaction assembly 100 includes a riser reactor 104, and an FCC regenerator 110.

The riser reactor 104 further includes a reactor section 102 wherein the FCC reaction takes place. A stripper tube 106 is provided in the reactor section 102, which is adapted to be fed with a feed required for the FCC reaction through an inlet 118. The stripper tube 106 is adapted to mix the feed with steam being inlet from a steam inlet 120, for performing the FCC reaction in the reactor section 102. The FCC reaction is performed in presence of a catalyst in the riser reactor 104. Product vapours produced during the FCC reaction are transferred to a fractionator (not shown) through an outlet 124. Once the catalyst is used, the spent catalyst is transferred to the FCC regenerator 110 through a spent catalyst inlet 108. The FCC regenerator 110 helps in making the spent catalyst reusable for the FCC reaction by removing coke from the active sites of the spent catalyst.

The FCC regenerator 110 includes a distributor assembly 200, and an air distributor 112. The distributor assembly 200 is attached to the spent catalyst inlet pipe 108 through a wall 126 of the FCC regenerator 110, as depicted in Figures 2a to 2d. Specifically, Figure 2a illustrates a top view of the distributor assembly 200 inside the FCC regenerator 110 of the FCC reaction assembly 100, and Figure 2b illustrates a side view of the distributor assembly 200 inside the FCC regenerator 110 of the FCC reaction assembly 100. Specifically, Figure 2c illustrates a front view of the distributor assembly 200 inside the FCC regenerator 110 of the FCC reaction assembly 100, and Figure 2d illustrates a side view of the distributor assembly 200 inside the FCC regenerator 110 of the FCC reaction assembly 100. As depicted, the distributor assembly 200 may be positioned towards a bottom side of the FCC regenerator 110. However, the distributor assembly 200 may be positioned even on an upper side of the FCC regenerator 110 or in the center of the FCC regenerator 110, as per requirement. The distributor assembly 200 is further adapted to uniformly distribute the spent catalyst in the FCC regenerator 110.

The construction and working of the distributor assembly 200 shall now be explained in detail with reference to Figure 3a. Specifically, Figure 3a illustrates a simple distributor assembly 200 for uniformly distributing the spent catalyst in the FCC regenerator 110 of the FCC reaction assembly 100. The distributor assembly 200 includes a header 202, a horizontal plate 212, and a plurality of vertical plates 206. The header 202 is a conduit or tube which is connected to the spent catalyst inlet 108 (as shown in Figure 1). The header 202 is adapted to receive the spent catalyst from the spent catalyst inlet 108 (as shown in Figure 1). In one example, the header 202 may have a circular geometry.

The header 202 is connected to the horizontal plate 212. The horizontal plate 212 extends from the header 202 towards a centre of the FCC regenerator 110 (shown in Figure 1). As the horizontal plate 212 extends towards the centre of the FCC regenerator 110, a width W of the horizontal plate 212 keeps increasing gradually and the horizontal plate 212 spreads radially within the FCC regenerator 110. In one embodiment, a length L and the width W of the horizontal plate 212 depend on a diameter D of the FCC regenerator 110. For instance, the length L and width W of the horizontal plate 212 may be of any length ranging from 10%, to 75% of the diameter D of the FCC regenerator 110.

In one example, the horizontal plate 212 includes a plurality of perforations 212A. The plurality of perforations 212A is adapted to fluidize a stream of air flowing therethrough and aerate the spent catalyst flowing across the horizontal plate 212. Further, aeration through the plurality of perforations 212A create an air cushion over the horizontal plate 212 to aid a smooth flow of the spent catalyst over the horizontal plate 212???. The fluidized stream of air is provided by the air distributor 112 placed below the distributor assembly 200, as shown in Figure 1. In one example, a diameter of each of the plurality of perforations 212A may be between 1 mm to 10 mm. In another example, a diameter of each of the plurality of perforations 212A may be less than 1mm and greater than 10mm. The plurality of vertical plates 206 extends orthogonally from the horizontal plate 212, in such a way, that the distance between plurality of vertical plates 206 keeps increasing gradually. In one embodiment, a height H of the plurality of vertical plates 206 is in a range of 10% to 100% of a diameter of the catalyst inlet pipe 108.

The horizontal plate 212 includes a flow path for the spent catalyst to be channelized. In one embodiment, the plurality of vertical plates 206 may define the flow path by dividing the horizontal plate 212 into a plurality of channels 204 to discharge the spent catalyst. The horizontal plate 212 is straight for some initial length after the header 202 and further gets divided into multiple arms 202-1, 202-2 extending towards the centre of the FCC regenerator 110. The plurality of vertical plates 206 divide a horizontal path of the horizontal plate 212 into a central axial path, and two radial paths along each arm 202-1, 202-2. In one example, the multiple arms 202-1, 202-2 are not limited to two, and may be formed in any number as per requirement.

The spent catalyst enters from the header 202 and flows towards the horizontal plate 212. In one embodiment, the horizontal plate 212 may be arranged at a predefined inclination with respect to the spent catalyst inlet pipe 108, such that the spent catalyst spreads easily onto the length L and the width W of the horizontal plate 212 due to gravity. In one example, the predefined inclination may range from 0 degrees to 60 degrees with respect to the spent catalyst inlet pipe 108. The smaller the predefined inclination, the lesser will be the momentum of the incoming spent catalyst, which may aid in a smooth flow and distribution of the spent catalyst along the horizontal plate 212.

In one embodiment, the horizontal plate 212 is arranged in such a way that a portion of the spent catalyst falls directly from the header 202 into the FCC regenerator 110, without entering the horizontal plate 212. The plurality of channels 204 on the horizontal plate 212 helps in dividing a single stream of the spent catalyst into multiple streams of the spent catalyst. The spent catalyst flows from the header 202 to ends of the plurality of channels 204 and a tip 208 of the horizontal plate 212. The gradual increase of distance between the plurality of vertical plates 206 helps in gradually increasing an area of each of the plurality of channels 204, thereby increasing the spread of catalyst gradually onto the horizontal plate 212.

Each catalyst stream in the plurality of channels 204 flows towards the centre of the FCC regenerator 110. As the plurality of channels 204 spreads radially, the catalyst streams also spread and get distributed uniformly at the tip 208 of the horizontal plate 212. In one embodiment, the tip 208 has a semi-circular geometry. The tip 208 of the horizontal plate 212 includes a diverter 210, which is adapted to divert a flow of the spent catalyst towards one of the plurality of channels 204. At least one of the plurality of channels 204 meets the diverter 210. For example, in Figure 1, the plurality of channels 204 in the centre of the horizontal plate 212 meet the diverter 210. The spent catalyst flows from the at least one of the plurality of channels 204 towards the diverter 210. The diverter 210 then divides the flow path of the spent catalyst into a plurality of flow paths. Finally, the spent catalyst after flowing through the plurality of channels 204, gets deposited at various radial and axial positions of the FCC regenerator 110 defined by the tip 208 and the diverter 210 of the horizontal plate 212. The distribution pattern of the spent catalyst at the tip 208 of the horizontal plate 212 is continuous and resembles a thin curtain.

The plurality of perforations 212A in the horizontal plate 212 helps a fluidizing air to pass through the horizontal plate 212 and aerate the spent catalyst flowing thereon. Aerating the spent catalyst ensures that stagnant zones in the spent catalyst are eliminated along the horizontal plate 212. In one embodiment, a portion of the catalyst may flow out into the FCC regenerator 110 through the plurality of perforations 212A. In one embodiment, a portion of the spent catalyst may flow over the diverter 210 and/or the tip 208 of the horizontal plate 212. In such a scenario, a height of the diverter 210 may be varied as per requirement, keeping in consideration a thickness of the spent catalyst stream.

In another embodiment, the plurality of channels 204 may have uneven length and may be unevenly divided by the plurality of vertical plates 206, as depicted in Figures 3b to 3e.

Particularly, Figure 3b illustrates a distributor assembly 300 with uneven boundaries 304A of the plurality of channels 304. Similar to the features of the distributor assembly 200 explained with respect to Figure 2, the distributor assembly 300 also includes a header 302, a plurality of vertical plates 306, a plurality of channels 304, a horizontal plate 312, a plurality of perforations 312A, a tip 308 and diverters 310. The spent catalyst in the distributor assembly 300 shall flow in a similar manner as explained with reference to Figure 3a, until the stream of the spent catalyst reaches boundaries 304A of the plurality of channels 304. The flow of the spent catalyst into the FCC regenerator 110 from the plurality of channels 304 shall be uneven due to the uneven boundaries 304A of the plurality of channels 304. Such uneven boundaries 304A of the plurality of channels 304 help in increasing an area of flow of the spent catalyst into the FCC regenerator 110 from the distributor assembly 300.

Particularly, Figure 3c illustrates a distributor assembly 400 with diverters 410 having a shorter length as compared to the diverter 210 explained with reference to Figure 3a. Similar to the features of the distributor assembly 200, 300 explained with respect to Figures 3a and 3b respectively, the distributor assembly 400 also includes a header 402, a plurality of vertical plates 406, a plurality of channels 404, a horizontal plate 412, a plurality of perforations 412A, a tip 408 and diverters 410. The spent catalyst in the distributor assembly 400 shall flow in a similar manner as explained with reference to Figure 3a, until it reaches an end of each of the diverters 410 on a left arm 414-2, and a right arm 414-1 of the distributor assembly 400. The spent catalyst shall flow into the FCC regenerator 110 directly from the plurality of channels on reaching an end of the diverters 410. Like the distributor assembly 300 explained with reference to Figure 3b, the short length of the diverters 410 in the distributor assembly 400 also helps in increasing an area of flow of the spent catalyst into the FCC regenerator 110 from the distributor assembly 400.

Particularly, Figure 3d illustrates a distributor assembly 500 with the plurality of vertical walls 506 initiating from the header 502 itself. Similar to the features of the distributor assembly 200, 300, 400 explained with respect to Figures 3a to 3c, the distributor assembly 500 also includes a header 502, a plurality of vertical plates 506, a plurality of channels 504, a horizontal plate 512, a plurality of perforations 512A, a tip 508 and diverters 510. The spent catalyst in the distributor assembly 500 shall not have a single stream of flow even at the beginning of the horizontal plate 512, unlike the single stream of spent catalyst explained for distributor assemblies 200, 300 and 400 with reference to Figures 3a, 3b and 3c. Once the spent catalyst enters the horizontal plate 512, it shall be divided into a plurality of streams, and shall further be diverted into a greater number of streams from the tip 508 of the horizontal plate 512, due to the distribution of a middle stream of the spent catalyst by the diverters 510 on the left arm 512-2 and the right arm 512-1.

Particularly, Figure 3e illustrates a distributor assembly 600 with diverters 610 having flow spaces 610A. Similar to the features of the distributor assembly 200, 300, 400, 500 explained with respect to Figures 3a to 3d, the distributor assembly 600 also includes a header 602, a plurality of vertical plates 606, a plurality of channels 604, a horizontal plate 612, a plurality of perforations 612A, a tip 608 and diverters 610. The spent catalyst in the distributor assembly 600 shall flow in a similar manner as explained with reference to the distributor assembly 500 in Figure 3d. However, the spent catalyst shall flow outwards into the FCC regenerator 110 from the flow spaces 610A between the diverters 610 on the left arm 602-2 and the right arm 602-1. Like the distributor assemblies 300 and 400 explained with reference to Figures 3b and 3c respectively, the flow spaces 610A in the diverters 610 also help in increasing an area of flow of the spent catalyst into the FCC regenerator 110 from the distributor assembly 600.

In one embodiment, a velocity of the spent catalyst decreases gradually on the horizontal plate 212, 312, 412, 512, 612 while flowing from the header 202, 302, 402, 502, 602 towards the centre of the FCC regenerator 110, as depicted in Figure 4. Specifically, Figure 4 illustrates a graphical representation 700 for Computational Fluid Dynamics (CFD) analysis of spent catalyst velocity streamlines on the distributor assembly 200, 300, 400, 500, 600. As can be seen, the velocity of the spent catalyst streamline is highest at the header 202, 302, 402, 502, 602, while the velocity of the spent catalyst streamline is the lowest at an end point of the horizontal plate 212, 312, 412, 512, 612.

In one embodiment, the distributor assembly 200, 300, 400, 500, 600 offers reduced volume fraction of catalyst at distribution points, which results in an efficient air-catalyst contact, as depicted in Figure 5. Specifically, Figure 5 illustrates a graphical representation 800 for CFD analysis of Volume fraction of the spent catalyst on the distributor assembly 200, 300, 400, 500, 600. As is clear from the graphical representation 800, volume fraction of the spent catalyst is almost uniform throughout the horizontal plate 212, 312, 412, 512, 612.

In one embodiment, the distributor assembly 200, 300, 400, 500, 600 is a fully open type of distributor assembly, which helps in avoiding backflow of the spent catalyst in the FCC regenerator 110, as depicted in Figure 6. Specifically, Figure 6 illustrates a graphical representation 900 for CFD analysis of flow pressure of the spent catalyst on the distributor assembly 200, 300, 400, 500, 600. As is clear from the graphical representation 900, the flow pressure of the spent catalyst is uniform throughout the horizontal plate 212, 312, 412, 512, 612.

The distributor assembly 200, 300, 400, 500, 600 disclosed herein divides the spent catalyst flow into multiple streams, thereby ensuring an increased spread of the spent catalyst within the FCC regenerator 110. Further, fluidizing air in the FCC regenerator 110 uniformly aerates the spent catalyst due to a uniform spread of the spent catalyst over the horizontal plate 212, 312, 412, 512, 612, thus eliminating the need for additional aeration requirement. Also, aeration through the plurality of perforations 212A, 312A, 412A, 512A, 612A create an air cushion over the horizontal plate 212, 312, 412, 512, 612 to aid a smooth flow of the spent catalyst over the horizontal plate 231.

While specific language has been used to describe the present disclosure, any limitations arising on account thereto, are not intended. As would be apparent to a person in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein. The drawings and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment.
, Claims:1. A distributor assembly (200, 300, 400, 500, 600) for uniformly distributing a spent catalyst in a Fluid Catalytic Cracking (FCC) regenerator (110), the distributor assembly (200, 300, 400, 500, 600) comprising:
a header (202, 302, 402, 502, 602) adapted to receive the spent catalyst;
a horizontal plate (212, 312, 412, 512, 612) extending from the header (202, 302, 402, 502, 602), wherein the horizontal plate (212, 312, 412, 512, 612) comprising a plurality of perforations (212A, 312A, 412A, 512A, 612A) adapted to fluidize a stream of air flowing therethrough and aerate the spent catalyst flowing across the horizontal plate (212, 312, 412, 512, 612); and
a plurality of vertical plates (206, 306, 406, 506, 606) extending orthogonally from the horizontal plate (212, 312, 412, 512, 612) defining a plurality of channels (204, 304, 404, 504, 604) to discharge the spent catalyst.

2. The distributor assembly (200, 300, 400, 500, 600) as claimed in claim 1, wherein the spent catalyst flows from the header (202, 302, 402, 502, 602) to ends of the plurality of channels (204, 304, 404, 504, 604) and a centre of the horizontal plate (212, 312, 412, 512, 612).

3. The distributor assembly (200, 300, 400, 500, 600) as claimed in claim 2, wherein a tip (208, 308, 408, 508, 608) of the horizontal plate (212, 312, 412, 512, 612) has a semi-circular geometry and includes at least one diverter (210, 310, 410, 510, 610) adapted to divert a flow of the spent catalyst towards one of the plurality of channels (204, 304, 404, 504, 604).

4. The distributor assembly (200, 300, 400, 500, 600) as claimed in claim 1, wherein:

at least one of the plurality of flow channels (204, 304, 404, 504, 604) meets the diverter (210, 310, 410, 510, 610),
the spent catalyst flows from the at least one of the plurality of flow channels (204, 304, 404, 504, 604) towards the diverter (210, 310, 410, 510, 610), and
the diverter (210, 310, 410, 510, 610) divides a flow path of the spent catalyst into a plurality of flow paths.

5. The distributor assembly (200, 300, 400, 500, 600) as claimed in clime 1, wherein a portion of the spent catalyst flows over the diverter (210, 310, 410, 510, 610).

6. A Fluid Catalytic Cracking (FCC) regenerator (110) comprising:

a distributor assembly (200, 300, 400, 500, 600) attached to a spent catalyst inlet pipe (108) through a wall (126) of the FCC regenerator (110) and adapted to uniformly distribute a spent catalyst in the FCC regenerator (110), the distributor assembly (200, 300, 400, 500, 600) comprising:
a header (202, 302, 402, 502, 602) adapted to receive the spent catalyst;
a horizontal plate (212, 312, 412, 512, 612) extending from the header (202, 302, 402, 502, 602), wherein the horizontal plate (212, 312, 412, 512, 612) comprising a plurality of perforations (212A, 312A, 412A, 512A, 612A) adapted to fluidize a stream of air flowing therethrough and aerate the spent catalyst flowing across the horizontal plate (212, 312, 412, 512, 612); and
a plurality of vertical plates (206, 306, 406, 506, 606) extending orthogonally from the horizontal plate (212, 312, 412, 512, 612) defining a plurality of channels (204, 304, 404, 504, 604) to discharge the spent catalyst.

7. The distributor assembly (200, 300, 400, 500, 600) as claimed in claim 6, wherein the horizontal plate (212, 312, 412, 512, 612) is arranged at a predefined inclination with respect to the spent catalyst inlet pipe (108).

8. The FCC regenerator (110) as claimed in claim 6, wherein
a length (W) of the horizontal plate (212, 312, 412, 512, 612) is in a range of 10% to 80% of a diameter of the FCC regenerator (110);
a width (W) of the horizontal plate (212, 312, 412, 512, 612) is in a range of 10% to 80% of a diameter of the FCC regenerator (110); and
a diameter of each of the plurality of perforations (212A, 312A, 412A, 512A, 612A) is in a range of 1mm to 10 mm.

9. The FCC regenerator (110) as claimed in claim 7, wherein the predefined inclination is in a range of 0 degrees to 60 degrees with respect to the spent catalyst inlet pipe (108)

10. The FCC regenerator (110) as claimed in claim 6, wherein a height (H) of the plurality of vertical plates (206, 306, 406, 506, 606) is in a range of 10% to 100% of a diameter of the catalyst inlet pipe (108).