Abstract: A process for producing a low benzene content gasoline is disclosed. Catalytic reforming produces a benzene rich reformate which is fractionated to yield a benzene rich C6 fraction which is then over-alkylated, preferably with C2/C3 olefins from an FCC, to produce heavy alkylate having too high an end point for use as gasoline. Heavy alkylate is charged to an FCC reactor, along with a conventional heavy FCC feed, and converted back into a gasoline boiling range product. Heavy alkylate also produces reactive alkyl fragments in the cracking reactor which react with benzene produced during cracking of FCC heavy feed.

Abstract: A process and apparatus for controlling the flow of FCC catalyst around a catalyst regenerator, using a non-mechanical valve, is disclosed. The preferred non-mechanical valve provides a de-aeration section, addition of fluidizing gas, a "U" trap seal, and venturi gas outlet on the top of the trap, for reliable flow control of non-uniform settling particles such as FCC catalyst. Control of the flow of a fluidizing gas to such a valve changes the flow properties of the FCC catalyst and permits flow control without resort to plug valves, or other internal mechanical valves, which are difficult to use in the harsh environment experienced within FCC regenerators.

Abstract: Oxides of nitrogen (NO.sub.x) emissions from an FCC regenerator are reduced by operating the regenerator in partial CO burn mode and adding substoichiometric, or just stoichiometric air to the flue gas. Much CO and most NO.sub.x and NO.sub.x precursors are thermally converted at 2000.degree.-2900.degree. F., then the gas is cooled below about 1800.degree. F. and burning of CO completed.

Abstract: A "leaking" cyclone and process for fluidized catalytic cracking of heavy oils is disclosed. Gas and entrained solids are added tangentially to swirl around a vapor outlet tube in a cylindrical tube cyclone body. A concentrated stream of solids and some gas is withdrawn from the device through openings in the cylindrical sidewall remote from the inlet. Tangential withdrawal via an offset slit in the sidewall, or withdrawal through holes in the sidewall, replaces or reduces conventional underflow of solids from an end of the cyclone body. Fine (0-5 micron) particles removal is enhanced by withdrawing solids as soon as solids reach the cylindrical sidewall. The device may be used as a third stage separator on an FCC regenerator.

Abstract: A process and apparatus for low cracking or recracking of liquid hydrocarbons with FCC catalyst containing 0.2 to 1.5 wt % coke is disclosed. FCC naphtha, or a thermally or hydrocracked naphtha, contacts spent FCC catalyst in a naphtha recracking reactor for limited conversion to lighter products and an increase in octane number. Spent catalyst from the recracking reactor can be recycled to the FCC reactor without stripping or regeneration. Naphtha recracking products are preferably cooled, then used as an absorbent to recover gasoline boiling range products from the FCC main column overhead vapor. Use of spent catalyst and controlled conversion conditions minimizes overcracking of the light liquid and minimizes formation of heavy ends.

Abstract: A process and apparatus for regeneration of spent FCC catalyst in a bubbling bed regenerator having a stripper mounted over the regenerator. Spent catalyst is regenerated in a fast fluidized bed coke combustor heated by direct contact heat exchange with catalyst recycled to the coke combustor via an internal "trough" trap. Catalyst recycle flow to the combustor is controlled by varying gas flow in the trough trap.

Abstract: A process and apparatus for increasing the coke burning capacity of FCC catalyst regenerators is disclosed. An auxiliary regenerator receives spent catalyst from an FCC stripper and burns some of the coke at turbulent or fast fluidized bed conditions. Partially regenerated catalyst and flue gas enter a low pressure drop cyclone discharging more than 90% of the partially regenerated catalyst down into a bubbling or fast fluidized bed in the primary regenerator. Flue gas from the auxiliary regenerator is discharged into the dilute phase above the bed in the primary regenerator. Catalyst entrainment from the fluidized bed in the primary regenerator may be reduced because less combustion air is needed as a result of partial regeneration in the auxiliary regenerator. Reduced NOx and dust emissions, and/or increased coke burning capacity, may be achieved, especially when a bubbling dense bed primary catalyst regenerator is used.

Abstract: An FCC process and apparatus for atomizing heavy feed are disclosed. A liquid feed containing stacked asphaltenes is pressurized, and preferably heated, with a gas such as light hydrocarbons. Pressurized gas and liquid discharge at high velocity into an expansion chamber, where shear force and sudden expansion disrupt stacked structures. Preferably, some thermal conversion, visbreaking, occurs in the expansion chamber. The disrupted feed is discharged into an FCC reactor, preferably to the base of a riser reactor, with a lighter feed, such as a gas oil, added higher up in the riser. Improved atomization and vaporization of the heavy feed in the riser increases conversion and reduces coke make.

Abstract: A process for multistage regeneration of spent FCC catalyst in an "Orthoflow" or stacked FCC unit having a stripper mounted over the regenerator. Spent catalyst is discharged into a fast fluidized bed coke combustor heated by direct contact heat exchange with catalyst and large particles or beads of CO combustion promoter. The large particle CO combustion promoter is trapped in the coke combustor, to permit complete CO combustion, with limited coke combustion.

Abstract: Thermal degradation of furfural in solvent refining of lubricating oil stocks is reduced by use of a thin-film evaporator for the final stages of furfural recovery, permitting increased pressure to be used in each stage of furfural recovery.

Abstract: A process for fluidized catalytic cracking of heavy feed to minimize yields of heavy fuel oil is disclosed. Operating a reactor with a 15:1 to 30:1 cat:oil ratio, at a reactor temperature of 1000.degree. to 1100.degree. F., and 1.5 to 5.0 seconds of catalyst residence time produces large volumes of gasoline and less than 5.0 wt % heavy fuel oil. A catalyst cooler is essential, to provide cool catalyst to the riser while permitting the regenerator to operate at 1200.degree. F. or higher. FCC catalyst with over 25 wt % large pore zeolite is preferred.

Abstract: Distress feeds, such as refinery sludge and slop oils are upgraded over hot equilibrium catalyst (E-Cat) removed from an FCC regenerator. Hot E-Cat demetallizes and/or demulsifies slop and sludge streams in an auxiliary reactor without contaminating the FCC catalyst inventory. Waste streams are upgraded with a "waste" catalyst stream. The auxiliary reactor and FCC reactor may share a product fractionator.

Abstract: A process for fluidized catalytic cracking of heavy feed to make more catalytically cracked products and less thermally cracked products such as butadiene is disclosed. Operating an upflow riser reactor with a riser top temperature of 1050 to 1150 .degree.F., and a short catalyst residence time, yields large volumes of gasoline and light olefins, but reduced yields of butadiene. Preferably cooled catalyst in large amounts contacts severely preheated feed. FCC catalyst with over 30 wt % Y zeolite is preferred.

Abstract: A process and apparatus for fluidized catalytic cracking of heavy oil feed using a plurality of feed nozzles. Flow through each nozzle is controlled based on distribution of feed, steam or catalyst in the reactor, as determined by a scanner such as a rotating gamma ray source and detector. More uniform contact of catalyst and feed improves conversion.

Abstract: Catalyst stripping in the fluid catalytic cracking process is improved by cooling the spent catalyst to quench catalytic condensation reactions, then stripping the cooled catalyst in a primary stripper, followed by heating and a stage of hot stripping. Quenched stripping reduces coke make by reducing conversion of light olefins, made during the FCC process, into coke.

Abstract: A process and apparatus for mixing feed and catalyst in the base of a fluidized catalytic cracking (FCC) reactor are disclosed. Regenerated catalyst flows through an annular region into a deceleration zone of increased cross-sectional area which induces vortices of circulating catalyst. Liquid feed is injected into the vortices, preferably via radially distributed feed outlets on a centrally mounted, truncated cone injector support means having a vortex convergence prevention means just above the feed outlets. Preferably catalyst and feed accelerate from the mixing device into the base of a riser reactor.

Abstract: A process is provided for converting feedstock hydrocarbon compounds over a catalyst composition which comprises a large-pore molecular sieve material and an additive catalyst composition comprising crystalline material having the structure of ZSM-5 and a silica/alumina mole ratio of less than about 30. An embodiment of the present invention comprises an improved catalytic cracking process to produce high octane gasoline, increased alkylate and potential alkylate, and increased lower olefins, especially propylene.

Abstract: A process and apparatus for fluidized bed regeneration of FCC catalyst are disclosed. Oxides of nitrogen (NO.sub.x) emissions from an FCC regenerator operating in complete CO combustion mode, and hydrothermal catalyst deactivation, are reduced by reducing the average bed temperature. Dilute phase afterburning superheats catalyst entrained in the dilute phase region above the fluidized bed. Cyclone separators recover superheated, entrained catalyst and preferentially recycle this catalyst to the FCC reactor, permitting cooler operation of the dense phase fluidized bed.

Abstract: A nozzle, and FCC process using the nozzle for atomizing heavy feed to a riser reactor, are disclosed. A liquid feed stream is atomized by radial out-to-in impingement of atomizing vapor, discharged onto an impingement plug in an annular expansion region, then sprayed through an outlet. Baffles at the expansion region outlet, and an orifice outlet improve feed atomization and feed/FCC catalyst contact in a riser reactor. The nozzle may be used to distribute liquid over other reactor beds, or to add liquid to distillation columns.

Abstract: A process for short contact time cracking of heavy feed. A falling, annular curtain of hot regenerated FCC catalyst, or hot inert solids, is formed over a cone shaped plug valve. Hydrocarbons pass from under the cone, or via a hollow stem, in radial in to out flow to contact the falling curtain of solids. After 0.01 to 1.0 seconds of contact time, solids and cracked vapor are separated, preferably in a bell separator beneath the reaction zone. Downflow of reactants into a contiguous upflowing stripper minimizes attrition.