Abstract: A flow splitter may include an inlet, at least two outlets, and an internal vane comprising a first end corresponding to the inlet and a second end corresponding to the at least two outlets, wherein the internal vane is configured to turn, between the first end and the second end, an internal flowing fluid from 0 degrees to a degree between about 60 degrees and 150 degrees. Methods of dividing fluid flow are also provided.

Abstract: A feed injector may have a body having an outer wall and an inner wall with a first conduit formed between the outer wall and the inner wall. The first conduit is configured to receive a atomizing gas. Additionally, a second conduit may be formed by the inner wall, and the second conduit is configured to receive a liquid. The first conduit and the second conduit are separated by the inner wall. Further, a mixing chamber may be provided at an outlet of the first conduit and an outlet of the second conduit. The atomizing gas from the first conduit and the liquid from the second conduit hit and/or mix together in the mixing chamber to form liquid droplets and a mixture of the atomizing gas and the liquid. Furthermore, a flow cone may have a first end in the second conduit and a second end in the mixing chamber.

Abstract: Disclosed is a slug catcher skid that is comprised of an integral inlet separator sized for a single compressor flow and each slug catcher skid is only used with a single compressor. The flow through the integral inlet separator is determined by the flow rate through the single compressor to which it is attached. Additionally, the other piping on an individual slug catcher skid such as the common gas inlet pipe headers, the common liquid drain pipe headers, and the common gas discharge pipe headers are sized for the flow of multiple compressors in a single facility. Some embodiments of the slug catcher skid are further comprised of an inlet filter separator, a Positive Shut Off (PSO) system, and/or an equalizing system in various combinations. The slug skids of the claimed invention may be further comprised of post compressor functional equipment including but not limited to a discharge gas oil separation vessel and a glycol separation vessel.

Abstract: A process for upgrading vacuum residuum and vacuum gas oil hydrocarbons is disclosed. The process may include: contacting a heavy distillate hydrocarbon fraction and hydrogen with a zeolite selective hydrocracking catalyst in a first ebullated bed hydrocracking reaction zone to convert at least a portion of the vacuum gas oil to lighter hydrocarbons. Contacting a residuum hydrocarbon fraction and hydrogen with a non-zeolite base metal hydroconversion catalyst in a second ebullated bed hydroconversion reaction zone may produce a vapor stream containing unconverted hydrogen, acid gases and volatilized hydrocarbons which may be fed along with the vacuum gas oil in the first ebullated bed hydrocracking zone.

Abstract: A multi-stage process is described for upgrading pyrolysis tar, such as steam cracker tar, by hydroprocessing in at least two stages. Hydroprocessing in a first stage is performed in the presence of a utility fluid. The utility fluid has a boiling point distribution from about 120° C. to about 480° C. and is separated from the first stage product.

Abstract: A multi-stage process for upgrading tars is provided. A predominantly hydrotreating stage can be applied before a cracking stage, which can be a hydrocracking or a thermal cracking stage. Alternatively, a predominantly cracking stage, which can be a hydrocracking or a thermal cracking stage, can be applied before a hydrotreating stage. Apparatus suitable for performing the method is also provided.

Abstract: Methods of extracting 1-4 cycle heterocyclic compounds and 2-5 cycle polynuclear aromatic hydrocarbons from a hydrocarbon feedstock are described. The methods include providing a hydrocarbon feedstock containing crude oil fractions, and determining an A/R ratio and an asphaltene concentration of the hydrocarbon feedstock. Based upon the A/R ratio and the asphaltene concentration, the treatable hydrocarbon feedstock undergoes one or more of cracking and fractionating. Subsequently, at least one targeted portion of the heterocyclic compounds is extracted from the fractionated stream with an aqueous solvent. A stream containing the 2-5 cycle polynuclear aromatic hydrocarbons is transferred to an extractor and the 2-5 cycle polynuclear aromatic hydrocarbons are extracted with a solvent system comprising an aprotic solvent.

Abstract: A process for processing mixed plastics comprising simultaneous pyrolysis and dechlorination of the mixed plastics, the process comprising contacting the mixed plastics with a zeolitic catalyst in a pyrolysis unit to produce a hydrocarbon product comprising a gas phase and a liquid phase; and separating the hydrocarbon product into a hydrocarbon gas stream and a hydrocarbon liquid stream, wherein the hydrocarbon gas stream comprises at least a portion of the gas phase of the hydrocarbon product, wherein the hydrocarbon liquid stream comprises at least a portion of the liquid phase of the hydrocarbon product, wherein the hydrocarbon liquid stream comprises one or more chloride compounds in an amount of less than about 100 ppmw chloride, based on the total weight of the hydrocarbon liquid stream, and wherein the hydrocarbon liquid stream is characterized by a viscosity of less than about 400 cP at a temperature of 300° C.

Abstract: Disclosed is a slug catcher skid that is comprised of an integral inlet separator sized for a single compressor flow and each slug catcher skid is only used with a single compressor. The flow through the integral inlet separator is determined by the flow rate through the single compressor to which it is attached. Additionally, the other piping on an individual slug catcher skid such as the common gas inlet pipe headers, the common liquid drain pipe headers, and the common gas discharge pipe headers are sized for the flow of multiple compressors in a single facility. Some embodiments of the slug catcher skid are further comprised of an inlet filter separator, a Positive Shut Off (PSO) system, and/or an equalizing system in various combinations. The slug skids of the claimed invention may be further comprised of post compressor functional equipment including but not limited to a discharge gas oil separation vessel and a glycol separation vessel.

Abstract: An apparatus and process for spraying liquids and producing very fine mist with the apparatus, the apparatus including: a needle injector that includes a capillary line (1) and an outer tube (8); a liquid supply (5); and a gas supply (4), where: the capillary line (1) is arranged in the interior space of the outer tube (2); the internal diameter of the capillary line in the needle injector is in the range of 2-1000 ?m; the capillary line is in active communication with a gas supply (4); and the outer tube (2) is in active communication with a liquid supply (5).

Abstract: Multiphase separators, processes and systems for converting an oxygenate and/or olefin feedstock to a hydrocarbon product are described herein.

Abstract: Disclosed are processes for producing a transportation fuel from a high quality oil sands-derived crude oil. The oil sands-derived crude oil is provided as a feed source for a catalytic conversion reaction, which produces the product useful as the transportation fuel. The oil sands-derived crude oil has an ASTM D7169 5% distillation point of from 400° F. to 700° F. Transportation fuel is produced from the provided oil sands-derived crude oil by treating the oil sands-derived crude oil through at least one catalytic cracking process and mild hydrotreating process.

Abstract: An improved process and an improved apparatus for minimizing attrition of catalyst particles, especially propane dehydrogenation catalyst particles, entrained in a combined flow of such particles and an entraining gas in a catalyst recovery means during separation of such particles from the entraining gas, by use of a pre-treatment step in which the combined flow is at a rate between 7.6 and 15.2 meters per second are provided.

Abstract: A system and method for improving the quality of a raw gas or raw syngas passes the raw gas or raw syngas past a catalytic element comprising catalyst with an optional sorbent. A downstream measurement of one or more parameters of the improved gas is fed back to a controller configured to regulate the regeneration of the catalyst and optional sorbent and, optionally, the flow rate of the regeneration fluid to the catalytic element. The system and method are particularly suitable for improving raw syngas generated from a carbonaceous material in a fixed bed or fluidized-bed or entrained-flow gasifier. One or more undesirable syngas constituents are subject to one or more of catalytic cracking, reforming, partial oxidation and/or decomposition to promote their conversion into desirable syngas constituents. At least one catalytic element is regenerated in situ, either periodically, continuously, or in a combination of these two modes.

Abstract: Disclosed herein is a field replaceable multifunction cartridge for the conversion of composite high molecular weight hydrocarbon vapors, extracted from homogenous or heterogeneous, segregated or unsegregated, wet or dry, unclean miscellaneous multi-feed waste input, to produce low molecular weight fractions of industriously combustible fuel products through catalytic cracking. The multifunction cartridge system is constructed in a modular fashion is capable of performing the catalytic, cleaning and scrubbing functions through the temperature range ranging from ambient to 500° C., owing to the high mechanical strength, low coefficient of expansion, resistance to thermal fatigue etc.

Abstract: A process for converting a solid biomass material by contacting the solid biomass material with a catalytic cracking catalyst at a temperature of more than 400° C. in a riser reactor to produce one or more cracked products is provided, wherein the riser reactor is an internal riser reactor.

Abstract: A method and to a device for delivering deliverable materials through a hollow chamber that is closed off from the outside air in a pressure-tight manner and that is supplied with materials via a storage container serving as a lock and that ends in the furnace chamber via a connecting tube. The delivery of the materials within the hollow chamber closed off from the outside air in a pressure-tight manner is carried out by means of depressurized mechanical conveyors.

Abstract: Systems and methods are provided for processing a heavy oil feed, such as an atmospheric or vacuum resid, using a combination of solvent assisted hydroprocessing and slurry hydroconversion of a heavy oil feed. The systems and methods allow for conversion and desulfurization/denitrogenation of a feed to form fuels and gas oil (or lubricant base oil) boiling range fractions while reducing the portion of the teed that is exposed to the high severity conditions present in slurry hydroconversion.

Abstract: Systems and methods are provided for slurry hydroconversion of a heavy oil feed, such as an atmospheric or vacuum resid. The systems and methods allow for slurry hydroconversion using catalysts with enhanced activity and/or catalysts that can be recycled as a side product from a complementary refinery process.

Abstract: A staged fluidized catalytic cracker and method for cracking a hydrocarbonaceous material includes a plurality of staged reactors that have catalyst particles flowing in series from one reactor to the next and hydrocarbon feed that is delivered in parallel to the reactors. Between each reactor the partially spent catalyst is actively stripped to partially reactivate the catalyst. Once the catalyst is fully spent in the final reactor the catalyst can be oxidatively regenerated.

Abstract: The present invention is directed to the upgrading of heavy petroleum oils of high viscosity and low API gravity that are typically not suitable for pipelining without the use of diluents. The method comprises introducing a particulate heat carrier into an up-flow reactor, introducing the feedstock at a location above the entry of the particulate heat carrier, allowing the heavy hydrocarbon feedstock to interact with the heat carrier for a short time, separating the vapors of the product stream from the particulate heat carrier and liquid and byproduct solid matter, collecting a gaseous and liquid product mixture comprising a mixture of a light fraction and a heavy fraction from the product stream, and using a vacuum tower to separate the light fraction as a substantially bottomless product and the heavy fraction from the product mixture.

Abstract: A process for mixing regenerated and carbonized catalyst involves obstructing upward flow of catalyst by one or more baffles between a catalyst inlet and a feed distributor. Each catalyst stream may be passed to opposite sides of a riser. Baffles obstruct upward flow to effect mixing of regenerated and carbonized catalyst to obtain a more uniform temperature and catalyst mixture before contacting the feed.

Abstract: A reactor design and process for the dehydrogenation of hydrocarbons is presented. The reactor design includes a multibed catalytic reactor, where each of the reactor beds are fluidized. The catalyst in the reactor cascades through the reactor beds, with fresh catalyst input into the first reactor bed, and the spent catalyst withdrawn from the last reactor bed. The hydrocarbon feedstream is input to the reactor beds in a parallel formation, thereby decreasing the thermal residence time of the hydrocarbons when compared with a single bed fluidized reactor, or a series reactor scheme.

Abstract: A method for separating and recovering ultrafine particulate solid material from a suspension or slurry of the solid material and a hydrocarbon liquid by precipitation or flocculation of a heavy fraction of the hydrocarbon liquid with an effective amount of a precipitation or flocculation agent such that the precipitated heavy fraction encapsulates the particulate solid material. The method further comprises coking the precipitated heavy fraction and grinding the coked product to an ultrafine size.

Abstract: An addition apparatus, a fluid catalytic cracking (FCC) system having an addition apparatus, and a method for adding material to an FCC unit are provided. In one embodiment, an addition system having the capability of interfacing with a material container is provided that allows the addition system to obtain information relating material held in the container. In one embodiment, at least some of the information is contained on a tag affixed to the container. Other information may be retrieved and/or sent to the addition system controller from a remote data source, such as a catalyst supplier.

Abstract: In an FCC apparatus in which swirl arms are used to discharge gas and catalyst from a riser, a baffle is used to direct descending catalyst away from a wall of a disengaging vessel proximate a stripping section comprising elongated strips of metal.

Abstract: An apparatus and method for processing different feeds in a fluid catalytic cracking unit are disclosed which result in improved yields of C3, C4 and gasoline range hydrocarbons as compared to conventional systems. The process comprises injecting a main hydrocarbon feed into a catalyst-containing riser reactor through a plurality of main feed injectors, and injecting a light hydrocarbon feed into the riser reactor at a location upstream from the main feed injectors and downstream from a control valve such as a regenerated catalyst slide valve, the light feed being injected in a region having a high density of catalyst particles. The light feed is injected in a dispersed way such the amount of feed injected corresponds to the density of catalyst particles at that particular point, with greater amounts of feed being injected at locations having a large number of catalyst particles.

Abstract: A method for separating and recovering ultrafine particulate solid material from a suspension or slurry of the solid material and a hydrocarbon liquid by precipitation or flocculation of a heavy fraction of the hydrocarbon liquid with an effective amount of a precipitation or flocculation agent such that the precipitated heavy fraction encapsulates the particulate solid material. The method further comprises coking the precipitated heavy fraction and grinding the coked product to an ultrafine size.

Abstract: A process and device to optimize the yield of fluid catalytic cracking products through a reactive stripping process are disclosed. One or more hydrocarbon streams (3) are introduced in an intermediary region of the stripper (1) of a fluid catalytic cracking unit (FCC), from a device that allows a homogeneous distribution with adequate dispersion. This/these stream(s) react(s) with the catalyst of FCC, although its activity is reduced due to the adsorption of hydrocarbons in the reaction zone, generating products that improve and/or change the global distribution of products, providing a refinery profile adequate to meet quality demands and requirements.

Abstract: Disclosed is a process for making middle distillate and lower olefins. The process includes catalytically cracking a gas oil feedstock within a riser reactor zone by contacting under suitable catalytic cracking conditions within the riser reactor zone the gas oil feedstock with a middle distillate selective cracking catalyst that comprises amorphous silica alumina and a zeolite to yield a cracked gas oil product and a spent cracking catalyst. The spent cracking catalyst is regenerated to yield a regenerated cracking catalyst. Within an intermediate cracking reactor such as a dense bed reactor zone and under suitable high severity cracking conditions a gasoline feedstock is contacted with the regenerated cracking catalyst to yield a cracked gasoline product and a used regenerated cracking catalyst. The used regenerated cracking catalyst is utilized as the middle distillate selective catalyst.

Abstract: This invention relates to the feed injection zone of a FCC. The feed injection zone is non-circular in shape allows for optimal penetration between feed and catalyst in the feed injection zone.

Abstract: A method is provided for introducing or reintroducing a gas into a slurry vessel holding a slurry comprising a liquid and solid particles and having a gas distributor for injecting a gas into the slurry, where the gas distributor includes a sparger device comprising an apertured sparger portion inside the slurry vessel, an inlet portion leading into the slurry vessel and an outlet portion leading from the slurry vessel, and a valve, external of the slurry vessel, operable to allow or deny flow from the sparger portion out through the outlet portion of the sparger device. The method comprises operating the valve to allow flow through the outlet portion of the sparger device, flushing the sparger device through the outlet portion to remove settled material which may be present in the sparger device, operating the valve to deny flow through the outlet portion of the sparger device, and introducing or reintroducing the gas into the slurry vessel through the sparger device.

Abstract: The present invention is directed to a method for producing an emulsified aqueous hydrocarbon solution comprising, providing a liquid hydrocarbon stream at a particular temperature and a separate water stream, mixing the water stream with a surfactant at a predetermined ratio, raising the pressure of the hydrocarbon stream to a pressure greater than the vapor pressure of steam at the temperature, spraying the water into the hydrocarbon stream at a pressure greater than that of the hydrocarbon stream in a pre-mix chamber; and passing the pressurized hydrocarbon-water mixture through a static mixing chamber.

Abstract: An addition apparatus, a fluid catalytic cracking (FCC) system having an addition apparatus, and a method for adding material to an FCC unit are provided. In one embodiment, an addition system for an FCC unit includes a container, a first eductor and a sensor. The eductor is coupled to an outlet of the container. The sensor is configured to detect a metric of material dispensed from the container through the eductor. A valve is provided for controlling the flow through the eductor. A controller provides a control signal for regulating an operational state of the valve. In another embodiment, an FCC system having an addition system is provided. In yet another embodiment, a method for adding material to an FCC unit is provided.

Abstract: The present invention provides a feedstock composition for increasing the efficiency of atomization in hydrocarbon processing that includes a water-in-hydrocarbon oil emulsion including a non-ionic surfactant capable of stabilizing the emulsion and having a hydrophilic-lipophilic balance of greater than about 12. The emulsion includes water droplets of about 5 to about 10 microns in diameter, the droplets being dispersed substantially uniformly in the hydrocarbon oil phase. These surfactants are capable of stabilizing the water-in-hydrocarbon oil emulsion under relevant temperature and pressure conditions for hydrocarbon processing. The inventive feedstock composition provides a metastable water-in-oil emulsion where expanding water vapor explodes under spray conditions where the system pressure is released, demolishing a larger oil droplet and producing smaller oil droplets.

Abstract: Method of metering at least one solid, particulate catalyst into a reactor containing a fluidized bed (11) of particles in an at least partly gaseous medium, in which the catalyst is metered discontinuously at prescribed time intervals into the fluidized bed (11) at at least one metering point (10). According to the present invention, a fluid stream is firstly introduced into the reactor (5) so that a region having a reduced particle density is formed in the fluidized bed (11) around the metering point (10) and the catalyst is subsequently metered into this region. As a result of the prior introduction of a fluid stream (“preblowing”) before the actual introduction of the catalyst, the catalyst can penetrate significantly deeper into the fluidized bed from the metering point due to the reduced particle density and is dispersed better.

Abstract: A process for upgrading a residua feedstock using a short vapor contact time thermal process unit comprised of a horizontal moving bed of fluidized hot particles. The residua feedstock is preferably atomized so that the Sauter mean diameter of the residua feedstock entering the reactor is less than about 2500 ?m. One or more horizontally disposed screws is preferably used to fluidize a bed of hot particles.

Abstract: A process is disclosed for discharging and transferring upwardly fluidized particles from a dense fluidizing layer forming section to a high-velocity transferring section having a diameter which is smaller than that of the dense fluidizing fluidized layer forming section, wherein at least one intermediate cylindrical section is provided between the dense fluidizing fluidized layer forming section and the high-velocity transferring section. The process can decrease the degree of changes in the amount of particles to be discharged from the dense fluidizing layer forming section and transferred by the riser, thereby proving a stable and uniform transfer of the fluidized particles.

Abstract: A stripping apparatus for desorbing gases from solid particles through which flows counter-currently a stripping fluid is described, which comprises a series of sets of at least two parallel, segmented, baffle plates each, with the segmented baffles being oriented so that the rows are offset relative to rows of other levels, where the thickness and separation of said sets of baffles is so dimensioned as to reduce coalescence of the size of the formed bubbles and optimize the hydrocarbons desorption from said fluidized solid particles. The solid particles are mainly spent catalyst particles from a FCC process. The stripping process to be carried out in a fluidized bed comprises contacting the spent catalyst with a stripping fluid that flows upwardly in the fluidized bed in the form of bubbles. Adsorbed hydrocarbons present in the spent catalyst are transferred from the catalyst emulsion that flows downwardly to the upwardly moving bubbles, so as to promote the efficient recovery of cracked products.

Abstract: Disclosed is an apparatus and process for controlling space velocity in a fluidized catalytic conversion reactor. The catalyst flux rate can be adjusted during the process of the reaction to adjust the space velocity and maintain a fast fluidized flow regime therein. The set parameter in the reactor may be pressure drop which is proportional to catalyst density.

Abstract: A cooling method of a hydrotreating plant having a desulfurization section (1) including a furnace (12) for heating liquid to be processed, reactors (14, 15) for hydrotreating sulfur to generate hydrogen sulfide, a hydrogen sulfide absorber (19) for absorbing the hydrogen sulfide generated in the reactors (14, 15), and a compressor (21) for compressing and transferring fluid from the hydrogen sulfide absorber (19) toward the reactors (14, 15), the cooling method comprising the steps of gradually depressurizing the hydrotreating plant at the desulfurization section (1) to a pressure level at which reactor material does not embrittle and gas does not leak due to difference of mechanical thermal expansion in the plant after stopping supply of the liquid to be processed, operating the compressor (21) approximately at the maximum rotation number, and completely extinguishing burners (12A, 12B) in the furnace (12) during plant shutdown operation.

Abstract: A bitumen/steam pre-mixer and atomizing nozzle combine to produce a jet of minute liquid droplets (bitumen) in carrier gas (steam). The jet is injected into a draft tube mixer positioned in a fluid bed of hot coke particles suspended in steam and contained within a fluid coking reactor. The movement of the jet through the draft tube passageway induces a stream of coke particles in steam to be drawn into the passageway, where the jet and stream mix vigorously and bitumen droplets have an enhanced probability of contacting coke particles.

Abstract: In a cyclone separator used for separating solids from gases, we discovered placing at least one opening in a lateral surface of a gas outlet conduit on a side facing away from an inlet to the cyclone separator prevents coke deposits from forming thereon. A plurality of openings may be placed on the side of the lateral surface of the gas outlet conduit facing away from the inlet. In an embodiment, no openings are placed on a side of the lateral surface facing the inlet to the cyclone separator.

Abstract: This invention is to a circulating fluid bed reactor that is designed so as to have the ability to adjust catalyst holdup within the reaction zone of the reactor while maintaining substantially constant catalyst circulation rate through the reaction zone. The ability to adjust catalyst hold up independently of catalyst circulation rate provides an advantage of having the ability to maintain a constant conversion level as catalyst activity or feed rates change.

Abstract: A process for contacting a bed of particulate material, usually catalyst, with a transverse flow of fluid is disclosed. The particulate material moves or is prevented from not moving, while the fluid passes through the bed at a rate greater than the stagnant bed pinning flow rate. This invention is applicable to hydrocarbon conversion processes and allows for higher fluid throughput rates compared to prior art processes.

Abstract: A baffle-style stripper for an FCC process comprising sloped baffles in which a greater volumetric flow rate of stripping medium permeates openings in a bottom section of the baffle than through a top section of the baffle for low catalyst flux stripping operations. When low catalyst flux is used, the catalyst runs from baffle to baffle closer to the bottom edge of the baffle. Hence, more fluidization from stripping medium is concentrated near the lower edge of the baffle. The greater fluidization at the bottom section of the baffle is accomplished by providing greater opening area per baffle area in the lower section of the baffle than in the top section of the baffle.

Abstract: A slurry phase reactor is designed to treat extra heavy petroleum crude in a combination of thermal-zone and catalytic-zone in a counterflow system where liquid feed is added to the top and hydrogen at the bottom. Feed enters the gas-phase thermal zone, where it passes to a liquid-phase thermal zone. In the liquid-phase thermal zone, the hydrocarbon is thermally cracked and the unreacted liquid is further passed to a catalytic-zone below in communication with the thermal-zone. Catalyst can be added or removed as required in a continuous mode without shutting down the system. The heat generated inside the catalytic cracking zone is distributed to the entire reactor as the gaseous product flows upward. Feed is brought to the reaction conditions by the heat recovered from the gas-phase zone. Reaction temperature could be controlled by feed temperature.

Abstract: Disclosed is an apparatus and process for controlling reactor volume in a fluidized catalytic conversion reactor. Changing volume results in controllable residence time and/or space velocity. Reactor volume may be changed by altering the feed distributor elevation, diluent flow rate or the number of reaction subsections to which feed is distributed.

Abstract: Disclosed is an apparatus and process for controlling space velocity in a fluidized catalytic conversion reactor. The catalyst flux rate can be adjusted during the process of the reaction to adjust the space velocity and maintain a fast fluidized flow regime therein. The set parameter in the reactor may be pressure drop which is proportional to catalyst density.

Abstract: The present invention relates to a method for separating entrained particles from a gas in a fluidised bed reactor system and fluidised bed reactor system including a particle separator for separating entrained particles from a gas. The particles are separated from the gas flowing in a direction other than the main gas flow direction, whereby the separation is multidimensional. The gas is allowed to pass from the outside of the configuration to the inside thereof and/or vice versa, wherein the particles are separated from the gas during such a travel. The gas flow can be multileveled.