Abstract: A process and apparatus for fluidized bed catalyst regeneration. A mixture of spent catalyst, recycled hot regenerated catalyst and regeneration gas are charged to a riser having an outlet connective with a coke combustor immersed in a fluidized bed of catalyst. The coke combustor outlet is covered by the dense phase fluidized bed. Additional combustion air may be added to the fluidized bed of catalyst covering the coke combustor outlet for additional catalyst regeneration. Indirect heat exchange may heat spent catalyst in the riser and/or the coke combustor.

Abstract: Disclosed is a method of and apparatus for reducing the level of extremely small catalyst particles ("fines") in an FCC system by temporarily retaining particles separated from the secondary cyclone separator in either a reactor vessel or catalyst regenerator. These particles can be withdrawn from the temporary retaining area, which takes them out of the active catalyst inventory within the reactor/regenerator system. The withdrawing of catalyst "fines" reduces the particulate contamination both in flue gas exhausted to the atmosphere from the catalyst regenerator and in the main column bottom (MCB) products from the fractionation stage. Preferred embodiments includes withdrawal of "fines" from either the regenerator or the reactor vessels and the secondary cyclones contained in each of these vessels.

Abstract: Disclosed is a method and apparatus for fluid catalytic cracking (FCC). The output of a reactor riser zone is fed to a riser cyclone separator, a primary cyclone separator, and secondary cyclone separators, connected in series within a single reactor vessel. The riser cyclone separator is connected to the primary cyclone separator by a conduit, which prevents random post-riser thermal cracking of the hydrocarbons after they exit the riser cyclone separator. The conduit contains an annular port to allow strippping gas to enter the conduit to improve the separator of hydrocarbons from catalyst. Catalyst separated in the riser cyclone separator drops through a riser cyclone dipleg and passes through a dipleg seal which comprises a seal pot or catalyst held around the dipleg. The conduit is formed by two overlapping parts, one having a larger diameter than the other to form the annular port and packing or spacers may be used to align and space the overlapping parts.

Abstract: Process for the continuous conversion of light olefin gas feed containing ethene, propene and butene to produce heavier hydrocarbons by contacting the light olefin feed in a fluidized bed reaction zone with a medium pore molecular sieve zeolite catalyst under oligomerization conditions to convert the light olefin feed to heavier hydrocarbons. The catalytic reaction causes the conversion of the light olefins to heavier hydrocarbons, the deposition of coke by-product on the catalyst and the absorption of hydrocarbon product on the catalyst. The deposited coke causes the partial deactivation of the catalyst. A portion of the partially deactivated catalyst containing deposited coke and absorbed hydrocarbon product is continuously withdrawn from the reaction zone and transferred to a catalyst stripping zone in which the catalyst is contacted with an inert stripping gas to remove the absorbed hydrocarbons from the catalyst.

Abstract: Disclosed is a method and apparatus for fluid catalytic cracking (FCC). The output of a reactor riser zone is fed to a riser cyclone separator, a primary cyclone separator, and secondary cyclone separators, connected in series within a single reactor vessel. The riser cyclone separator is connected to the primary cyclone separator by a conduit, which prevents random post-riser thermal cracking of the hydrocarbons after they exit the riser cyclone separator. The conduit contains an annular port to allow stripping gas to enter the conduit to improve the separation of hydrocarbons from catalyst. Catalyst separated in the riser cyclone separator drops through a riser cyclone dipleg and passes through a dipleg seal which comprises a seal pot or catalyst held around the dipleg. The conduit is formed by two overlapping parts, one having a larger diameter than the other to form the annular port and packing or spacers may be used to align and space the overlapping parts.

Abstract: A process and apparatus for fluid catalytic cracking (FCC) of a hydrocarbon feed. The process and apparatus includes a riser which upwardly discharges into a deflector baffle located within a stripping vessel. The stripping vessel is located within a disengaging vessel. The deflector baffle is spaced from the riser and the stripping vessel. Preferably, the deflector baffle is shaped similarly to a large bubble cap. Catalyst passes downwardly from the baffle into a stripping zone within a lower portion of the stripping vessel. Hydrocarbons stripped from the catalyst pass upwardly away from the stripping zone, then pass to a cyclone located outside the stripping vessel and then discharge from the disengaging vessel.

Abstract: Disclosed is a method of and apparatus for reducing the level of extremely small catalyst particles ("fines") in an FCC system by temporarily retaining particles separated from the secondary cyclone separator in a reactor vessel or catalyst regenerator. These particles can be intermittently withdrawn from the temporary retaining area in order to achieve particle flow at a low volume rate, which takes them out of the active catalyst inventory within the reactor/regenerator system. The intermittent withdrawing of catalyst "fines" reduces the particulate contamination both in flue gas exhausted to the atmosphere from the catalyst regenerator and in the main column bottom (MCB) products from the fractionation stage. Preferred embodiments include intermittent withdrawal of "fines" from either the regenerator or the reactor vessels and the secondary cyclones contained in each of these vessels.

Abstract: A method and apparatus for improving the stripping of hydrocarbons from catalyst particles in a fluidized catalytic cracking (FCC) unit. A stripper vessel is located directly adjacent the exhaust barrel of a separator and immediately begins stripping hydrocarbon from catalyst particles. The stripper is sealed at the catalyst exit by a catalyst seal pot, with the drain sized so as to permit only a portion of catalyst flow to pass therethrough, with the remainder catalyst overflowing the seal pot. The location of the stripper adjacent the separator exhaust and the provision of a catalyst seal pot, in other embodiments, can be combined either separately or together with a short contact time (SCT) stripper and/or a catalyst particle deflector in order to reduce the "residence" time of hydrocarbons with catalyst particles.

Abstract: Disclosed is a method and apparatus for fluid catalytic cracking (FCC). The output of a reactor riser zone is fed to a riser cyclone separator, a primary cyclone separator, and secondary cyclone separators, connected in series within a single reactor vessel. The riser cyclone separator is connected to the primary cyclone separator by a conduit, which prevents random post-riser thermal cracking of the hydrocarbons after they exit the riser cyclone separator. The conduit contains an annular port to allow stripping gas to enter the conduit to improve the separation of hydrocarbons from catalyst. Catalyst separated in the riser cyclone separator drops through a riser cyclone dipleg and passes through a dipleg seal which comprises a seal pot or catalyst held around the dipleg. The conduit is formed by two overlapping parts, one having a larger diameter than the other to form the annular port and packing or spacers may be used to align and space the overlapping parts.

Abstract: A process and apparatus for cracking heavy hydrocarbons using a mixture of fluid cracking catalyst and a demetallizing additive differing in physical characteristics from the cracking catalyst is described. A heavy, metals containing feed such as a resid contacts demetallizing additive in the base of a riser reactor. The demetallized resid is cracked by contact with a stream of hot, regenerated catalyst. A mixture of metal containing additive, deactivated cracking catalyst, and cracked products is discharged from the riser. The metal containing additive and deactivated catalyst are stripped, preferably with steam, and charged to a two-stage regenerator. The first stage of the regenerator partially regenerates the cracking catalyst and separates it by elutriation from the demetallizing additive, which accumulates as a dense phase fluidized bed in a lower portion of the first stage regenerator.

Abstract: Disclosed is a method of and apparatus for reducing the level of extremely small catalyst particles ("fines") in an FCC system by temporarily retaining particles separated from the secondary cyclone separator in either a reactor vessel or catalyst regenerator. These particles can be withdrawn from the temporary retaining area, which takes them out of the active catalyst inventory within the reactor/regenerator system. The withdrawing of catalyst "fines" reduces the particulate contamination both in flue gas exhausted to the atmosphere from the catalyst regenerator and in the main column bottom (MCB) products from the fractionation stage. Preferred embodiments include withdrawal of "fines" from either the regenerator or the reactor vessels and the secondary cyclones contained in each of these vessels.

Abstract: A process and apparatus for mixing fluid catalytic cracking hydrocarbon feed and catalyst is disclosed. The invention passes lift gas through a first conduit which is axially aligned with a second conduit. A downstream end of the first conduit and an upstream end of the second conduit are located within a catalyst bed enclosed by a chamber. Furthermore, the second conduit axially injects catalyst and lift gas into an upstream end of an elongated fluid catalytic cracking riser while passing hydrocarbon feed into the riser through an annular zone about the upstream end of the riser. Preferably steam also passes through this annular zone. The process and apparatus achieves substantially uniform catalyst-to-oil ratio across a horizontal cross-section of the riser. A process and apparatus for control of the level of the catalyst bed in the enclosed chamber by employing a control gas stream is also disclosed.

Abstract: Disclosed is a method of and apparatus for reducing the level of extremely small catalyst particles ("fines") in an FCC system by temporarily retaining particles separated from the secondary cyclone separator in a reactor vessel or catalyst regenerator. These particles can be intermittently withdrawn from the temporary retaining area in order to achieve particle flow at a low volume rate, which takes them out of the active catalyst inventory within the reactor/regenerator system. The intermittent withdrawing of catalyst "fines"]reduces the particulate contamination both in flue gas exhausted to the atmosphere from the catalyst regenreator and in the main column bottom (MCB) produces from the fractionation stage. Preferred embodiments include intermittent withdrawal of "fines" from either the regenerator or the reactor vessels and the secondary cyclones contained in each of these vessels.

Abstract: A process and apparatus for fluid catalytic cracking (FCC) of a hydrocarbon feed. The process and apparatus includes a riser which upwardly discharges into a deflector baffle located within a stripping vessel. The stripping vessel is located within a disengaging vessel. The deflector baffle is spaced from the riser and the stripping vessel. Preferably, the deflector baffle is shaped similarly to a large bubble cap. Catalyst passes downwardly from the baffle into a stripping zone within a lower portion of the stripping vessel. Hydrocarbons stripped from the catalyst pass upwardly aaway from the stripping zone, then pass to a cyclone located outside the stripping vessel and then discharge from the disengaging vessel.

Abstract: A fluid catalytic cracking (FCC) process and apparatus is described which includes a high temperature stripper (hot stripper) to control the carbon level, hydrogen level, and sulfur level on spent catalyst, followed by single or multi-stage regeneration. The high temperature stripper may operate at a temperature between 100.degree. F. above the temperature of a catalyst hydrocarbon mixture exiting a riser and 1500.degree. F. The regenerator may operate at a temperature between 100.degree. F. above that of the catalyst in the hot stripper and 1600.degree. F. Hot regenerated catalyst recycles to the hot stripper to maintain the hot stripper temperature. The present invention has the advantage that it separates hydrogen from catalyst to eliminate hydrothermal degradation, and separates sulfur from catalyst as hydrogen sulfide and mercaptans which are easy to scrub. The present invention also provides a method and apparatus for converting a TCC unit to a FCC unit, with maximum use of the TCC unit.

Abstract: A method and apparatus for improving the separation of a catalyst phase from a gas suspension phase in a fluidized catalytic cracking (FCC) unit. In a vertical separation embodiment, a cyclone separator inlet is located in the upper portion of a riser conversion zone and draws off gaseous hydrocarbon materials, while catalyst particles continue vertically to the end of the riser conversion zone, and pass through a catalyst conduit to a catalyst storage area. In a horizontal separation embodiment, the catalyst/hydrocarbon mixture is transported horizontally from the end of the riser conversion zone past a cyclone separator inlet towards a catalyst conduit. The cyclone inlet draws off gaseous hydrocarbon materials, while the catalyst particles pass through the catalyst conduit to a catalyst storage area.

Abstract: In a method and apparatus for improving the flow of catalyst particles from a riser conversion zone to a separator in a fluidized catalytic cracking (FCC) unit, the exit of the riser conversion zone is equipped with a deflector mounted so as to redirect catalyst particle and gas suspension movement toward a separator inlet, thus preventing rebound back into the riser conversion zone. The catalyst deflector can be combined with one or more of a short contact time stripper, a stripper mount in or adjacent the exhaust barrel of a separator, and/or a catalyst seal pot, all serving to reduce "residence" time of hydrocarbons with catalyst particles.

Abstract: A method and apparatus for fluid catalytic cracking (FCC) in which the output of a riser conversion zone is fed to a riser cyclone separator, a primary cyclone separator, and secondary cyclone separator, connected in series within a single reactor vessel. The riser cyclone separator is connected to the primary cyclone separator by a conduit which prevents random post-riser thermal cracking of the hydrocarbons after they exit the riser cyclone. Means are also provided to blend stripping gas with the cracked hydrocarbons as they travel from the riser conversion zone to said primary cyclone separator. The stripping gas blends with the cracked hydrocarbons to improve the separation of hydrocarbons from catalyst. Steam may also be directly injected into the riser cyclone separator to aid in separation of hydrocarbons from catalyst.

Abstract: A process and apparatus for mixing fluid catalytic cracking hydrocarbon feed and catalyst is disclosed. The invention passes lift gas through a first conduit which is axially aligned with a second conduit. A downstream end of the first conduit and an upstream end of the second conduit are located within a catalyst bed enclosed by a chamber. Furthermore, the second conduit axially injects catalyst and lift gas into an upstream end of an elongated fluid catalytic cracking riser while passing hydrocarbon feed into the riser through an annular zone about the upstream end of the riser. Preferably steam also passes through this annular zone. The process and apparatus achieves substantially uniform catalyst-to-oil ratio across a horizontal cross-section of the riser. A process and apparatus for control of the level of the catalyst bed in the enclosed chamber by employing a control gas stream is also disclosed.

Abstract: A catalyst recovery apparatus is provided for separating finely divided solid particles from a hot gas stream comprising a vertical metal shell having a lower hot gas inlet and an upper clean gas outlet, a plurality of thermally expandable metal cyclone assemblies supported at their top regions by a horizontal plate, each of the cyclone assemblies having a downwardly extending dip-leg which exits into a centrally disposed solids collector, a vertically slidable particle collector outlet conduit which extends from the collector bottom downwardly through the enclosed shell, and a compressible seal means or packing gland arrangement disposed around the collector outlet conduit and comprising an annular packing holding member, a vertically movable packing compression member, and a compressible packing material.