Abstract: A method for preparing a mixture of FCC catalyst components for use in an FCCU, which comprises: performing an analysis of an FCCU operation; determining the catalyst requirements for the FCCU, based on said analysis; determining the catalytic properties of at least two FCC catalyst components selected from the group consisting of untreated equilibrium FCC catalyst, reactivated equilibrium FCC catalyst, demetallized equilibrium FCC catalyst, reactivated and demetallized equilibrium FCC catalyst and fresh high activity FCC catalyst containing a zeolite component; and blending said at least two components in proportions, based on the determined properties of said at least two components and the determined catalyst requirements, to form a mixture of the components suitable for addition to the FCCU.

Abstract: A method for preparing a mixture of FCC catalyst components for use in an FCCU, which comprises: performing an analysis of an FCCU operation; determining the catalyst requirements for the FCCU, based on said analysis; determining the catalytic properties of at least two FCC catalyst components selected from the group consisting of untreated equilibrium FCC catalyst, reactivated equilibrium FCC catalyst, demetallized equilibrium FCC catalyst, reactivated and demetallized equilibrium FCC catalyst and fresh high activity FCC catalyst containing a zeolite component; and blending said at least two components in proportions, based on the determined properties of said at least two components and the determined catalyst requirements, to form a mixture of the components suitable for addition to the FCCU.

Abstract: A fluidized particulate solids contacting process for reducing regenerator flue gas NOx emissions and/or permitting operating with an increased equilibrium solids vanadium level, which process may be an FCC process or a fluidized particulate solid hydrocarbon treating process, wherein spent FCC catalyst or other spent solid is in a regenerator with an oxygen-containing regeneration gas under catalyst (solid) regeneration conditions which include a combination of at least a regeneration temperature and an oxygen level in the regeneration gas which is effective to burn off the spent solid a majority of carbonaceous deposits thereon, while substantially preventing the formation of NOx, and thereby produce a regenerated solid having a carbon level reduced from that of the spent solid and a flue gas; maintaining the regenerated solid in a fluidized state with a fluidizing media that substantially prevents any further oxidation or regeneration; and returning the fluidized regenerated solid to the reactor (contactor

Abstract: A process for increasing the activity of a zeolite-containing particulate solid containing contaminants which block the pores of the zeolite and adversely affect the activity thereof wherein the contaminated zeolitic material is slurried with a liquid containing an acid, detergent or surfactant, the slurry is agitated to liberate the pore-blocking contaminants from the zeolite pores so that they are suspended in the liquid, a portion of the liquid is withdrawn from the slurry and filtered to remove the suspended contaminants, the resulting liquid is returned to the slurry, and the treated zeolite-containing particulate solid is liquid from the solution and recovered.

Abstract: A spent zeolite-containing hydrocarbon cracking catalyst is treated by regenerating it to remove carboneous deposits. A portion of the regenerated catalyst is withdrawn from the circulating catalyst inventory of a hydrocarbon processing unit and slurried with a liquid containing an activating agent to solubilize and/or dislodge contaminants which block the pores of the zeolite and adversely affect the activity of the catalyst. The slurry is agitated to dissolve or dislodge the contaminants from the zeolite pores, and the agitated slurry, without being permitted to settle, is transferred to a fluidized drying zone where the liquid and solubilized and/or dislodged contaminants are removed from the treated catalyst which has a level of cracking activity higher than that of the catalyst in the circulating catalyst inventory. The treated catalyst is then recycled to the unit and contacted with a hydrocarbon feedstock under cracking conditions.

Abstract: A fluidized process which comprises contacting a hydrocarbon feedstock with a fluidized particulate solid in a contacting zone wherein carbonaceous deposits accumulate on the solid and the solid becomes spent and wherein the carbonaceous deposits are burned from the spent solid to produce a regenerated solid; removing a stream of the fluidized spent solid and entrained hydrocarbons from the contacting zone; introducing the fluidized spent solid/entrained hydrocarbon stream and a stream of hot regenerated solid into a lower portion of a zone; introducing a stream of a fluid stripping medium, e.

Abstract: A process wherein a fluidized particulate solid is contacted with a hydrocarbon feedstock in a vertically extending contacting zone, which process comprises introducing a stream of the particulate solid into the contacting zone and introducing a plurality of streams of liquid hydrocarbon feedstock into the contacting zone to intimately contact the particulate solid therein, the plurality of streams each being introduced into the contacting zone from one of a plurality of nozzles spaced apart in the contacting zone, and each stream having a flow path extending into the contacting zone and a flow pattern having a thickness which is substantially constant and a width which diverges from the point of introduction into the contacting zone.

Abstract: The method of controlling the flow of a fluidizable particulate solid, e.g., FCC catalyst, which comprises: (a) passing a fluidized stream of the particulate solid downwardly from a source of the particulate solid, e.g., an FCC regenerator, in a first conduit to a junction with a second conduit where the solid particulate is mixed with a stream of a fluid transport medium from a third conduit; (b) passing a stream of the resulting mixed solid particulate/transport medium upwardly in the second conduit at an angle less than 90.degree. from the first conduit for a distance at least as great as the diameter of the first conduit at the junction into a fourth conduit; (c) transporting the particulate solid/fluid transport medium stream in the fourth conduit to a desired location; and (d) controlling the mass flow of the particulate solid in the fourth conduit by setting the flow rate of the transport medium in the third conduit.

Abstract: The disclosed method and apparatus provides for providing addition of micro-spheroidal ("MS") Fluid Catalytic Cracking ("FCC") catalyst additives and/or bulk catalyst to an in situ circulating, active catalyst inventory of a fluid catalytic cracking unit at times and rates precisely controlled to sustain an effective additive concentration. In a preferred version of this invention, each of a series of such apparatus comprising one such device for each catalyst additive, is operated on a basic cycle time length during a portion of which the unit is engaged in active addition while in the remainder of the time it is passive.

Abstract: A fluidized solid process for upgrading or converting a hydrocarbon feedstock wherein carbonaceous deposits accumulate on a particulate fluidized solid and are burned in a regenerator to regenerate the solid, the regenerated solid and entrained combustion products are introduced into a vertical lift pipe, a fluid lift medium is introduced into the lift pipe and the regenerated solid is separated from the lift medium and combustion products to improve the quality of the regenerated solid contacted with the hydrocarbon feedstock.

Abstract: Apparatus for separating particulate solids from a process gas stream which includes one or more primary separation chambers, preferably ballistic separation chambers, for removing a major portion of the solids entrained in the gas stream. One or more secondary separator chambers containing multi-cyclones are employed for removing substantially all of the remaining solids from the gas discharged from the primary separator chamber. The ballistic separation chamber has an inlet portion and a larger diameter outlet portion, and it may have an arcuate shape to aid in the separation.

Abstract: A fluid catalytic cracking process wherein a hydrocarbon charge-stock is atomized and injected, in a contactor/reactor, into a vertical curtain of hot regenerated catalyst to vaporize and crack hydrocarbons in the charge-stock, wherein the catalyst preferably contains at least 40% by weight of a zeolitic cracking component and the contact time of the hydrocarbon vapors and the catalyst in the contactor/reactor is ultra-short, preferably not greater than 0.5 second.

Abstract: Apparatus for the treatment of a liquid hydrocarbon charge containing solids or solids-forming contaminants, e.g., inorganic solids, metals and asphaltenes, which includes a contactor vessel having a liquid charge inlet, a vaporizing media inlet above the charge inlet and a vapor-solids outlet. An atomizer is positioned in the charge inlet for forming small particles of the liquid charge and directing the particles of liquid in a substantially horizontal flat pattern into the contactor vessel. A premix downcomer having a dispersion grid positioned therein is located in the vaporizing media inlet for introducing a fluidized mixture of a gas dispersion media and hot circulating solid particles into the contactor vessel in a substantially vertical flat pattern to traverse the path of the liquid particles and intimately contact the liquid particles.

Abstract: An improved continuous cyclic process for removing oxides of sulfur from a waste gas with a regenerable particulate adsorbent in which hot adsorbent particles pick up SOx in a first fluid transport riser, followed by separation of clean gas from sulfur-contained particles which are then recycled to a desorber in which they are contacted at elevated temperature with a mixture of reducing gas and water vapor for release of sulfur as hydrogen sulfide. The adsorbent particles are then recycled in the process. Means are provided for removing particulates in the waste gas.

Abstract: A continuous fluidized process for upgrading a heavy liquid hydrocarbon charge-stock containing solid or solid-forming contaminants, e.g., inorganic solids, metals and asphaltenes. The charge is atomized to provide a stream of liquid particles introduced horizontally into a horizontal contacting zone to contact a vertical curtain of fluidized hot solid particles so as to vaporize hydrocarbons in the charge without substantial cracking, the solid particles being solely derived from the contaminants in the charge. The mixture of hydrocarbon vapors and solid particles are rapidly separated, carbon is burned from the separated particles, and the resulting hot solid particles are recycled to the contacting zone. The hydrocarbon vapors are condensed and there is recovered a liquid product having a substantially reduced content of contaminants.

Abstract: An improved hydrocarbon conversion process is disclosed of the type employing circulating solids between a reactor (contactor) and regenerator (combustor). The entire process is in the dilute phase and is characterized by all the catalyst passing through the cyclones and never returning to a dense bed in either the reactor or regenerator.

Abstract: A method for updating a concentrate of tar sands bitumen containing fine mineral matter and optionally coarse mineral matter in which solvent-diluted bitumen is contacted for a short time in a riser with hot attrition-resistant substantially catalytically inert acid-resistant fluidizable particles, causing a selective vaporization of the lighter high hydrogen content components of the bitumen. The preferred particles are composed of silica-alumina, most preferably a mixture of mullite and crystalline silica or mullite, crystalline silica and an acid-resistant form of alumina. A portion of the heavier asphaltenes and most of the components which contain metals, sulfur and nitrogen remain on the attrition-resistant fluidizable particles. Fine mineral matter in the bitumen feed also deposits on the fluidized particles instead of being carried over with the vaporized hydrocarbon product.

Abstract: A method for upgrading a concentrate of tar sands bitumen containing colloidal clay in which solvent-diluted bitumen is contacted for a short time in a riser with hot attrition-resistant substantially catalytically inert fluidizable microspheres, causing a selective vaporization of the lighter high hydrogen content components of the bitumen. A portion of the heavier asphaltenes and most of the components which contain metals, sulfur and nitrogen remain on the attrition-resistant microspheres. Colloidal clay in the bitumen feed also deposits on the microspheres instead of being carried over with the vaporized hydrocarbon product. The contact material, with deposit, is passed to a burner provided with high velocity air jets which attrites the colloidal clay away from the microspheres and the material removed by attrition is recovered. The heated microspheres are reintroduced into the riser for further contact with incoming diluted bitumen charge.

Abstract: An improved heat balanced hydrocarbon conversion process is disclosed of the type employing circulating solids between a riser reactor (contactor) and regenerator (combustor). The ratio of circulating solid to hydrocarbon feed (C/O or cat-oil ratio) is increased by: directly cooling a portion of hot freshly regenerated contact material; passing a portion of hot regenerated material into the steam stripper; cooling hot regenerated contact material and charging it to the riser downstream of charging uncooled hot regenerated material which charging hydrocarbon feed to the base of the riser along with lift gas or steam; or lifting hot regenerated contact material by a carbonizable lift gas into the riser before contacting it with hydrocarbon feed which is injected higher in the riser.

Abstract: An improved heat balanced hydrocarbon conversion process is disclosed of the type employing circulating solids between a riser reactor (contactor) and regenerator (combustor). The ratio of circulating solid to hydrocarbon feed (C/O or cat-oil ratio) is increased by: directly cooling a portion of hot freshly regenerated contact material; passing a portion of hot regenerated material into the steam stripper; cooling hot regenerated contact material and charging it to the riser downstream of charging uncooled hot regenerated material which charging hydrocarbon feed to the bese of the riser along with lift gas or steam; or lifting hot regenerated contact material by a carbonizable lift gas into the riser before contacting it with hydrocarbon feed which is injected higher in the riser.