Abstract: A method is disclosed for recovering bitumen from a carbonaceous solid feed and for recovering a carbonaceous liquid from a fines-containing carbonaceous liquid feed by extraction of the feed with a solvent of predetermined solvency power, wherein the recovered product has a low fines content.

Abstract: A fluid catalytic cracking (FCC) process and apparatus containing a reactor riser zone and radially extending sidearms as the first catalyst-hydrocarbon product separation means. Hydrocarbon products separated in the sidearms are conducted through an enclosed passageway to a secondary separation means, such as a cyclone. The catalyst is also conducted through the enclosed passageway to a stripping apparatus, wherein entrained hydrocarbons are removed therefrom. The enclosed passageway contains a means for accommodating sudden surges of catalyst flow and increased pressure, e.g., a trickle valve.

Abstract: A fluid catalytic cracking (FCC) apparatus and process comprising a reactor riser zone, a primary and a secondary cyclones, connected in series to the riser zone, and a stripping zone. The riser zone, the primary and the secondary cyclones, and the stripping zone, are placed within a single reactor vessel. The primary cyclone is connected to the reactor riser zone by an enclosed conduit which prevents random post-riser thermal cracking of the hydrocarbons after they exit the reactor riser zone. The conduit contains a trickle valve, or other means, to accommodate sudden increased surges of flow of the hydrocarbons and catalyst mixture.

Abstract: Disclosed is a method and apparatus for fluid catalytic cracking (FCC) of a hydrocarbon feed in an open or closed system, which includes a multistage stripper system. The multistage stripper system comprises a means for spinning a gasiform mixture of catalyst and cracked hydrocarbons exiting from a riser, a first means for stripping the spun gasiform mixture, and a means for deflecting the gasiform mixture to separate catalyst from the cracked hydrocarbons.

Abstract: A process for the clean-up of particulate containing gases is provided wherein a difference in pressures between the pressure of particulate-containing gases in the inlet to cyclone separation means and the pressure in an underflow exit is maintained and controlled. In a preferred embodiment, the particulate-containing gases comprise flue gas from a catalyst regeneration process comprising two separate regeneration zones comprising a low temperature regeneration zone followed by a higher temperature regeneration zone. A CO rich flue gas is recovered from the low temperature regeneration zone and a CO.sub.2 rich flue gas is recovered from the higher temperature regeneration zone. The high temperature CO.sub.2 rich flue gas is passed through a heat exchanger to produce steam and cool the CO.sub.2 rich flue gas. The cooled CO.sub.2 rich flue gas is passed through cyclone separators to capture catalyst particles.

Abstract: A method and apparatus for separating regenerated catalyst from gaseous combustion products within a regenerator. The apparatus comprises a downcomer within the regenerator vessel through which the catalyst and gaseous combustion products flow. Means are provided at the lower end of the downcomer for utilizing the momentum of the catalyst particles to separate them from the gaseous combustion products.

Abstract: An improved fluid coking process is provided in which an aqueous sludge comprising an organic waste is used as quench in a quench elutriator to cool the coke product and convert at least a portion of the organic waste to a vaporous compound (e.g., hydrocarbon) which is recycled to the heating zone to increase the fuel value of the heating zone gaseous effluent.

Abstract: This invention relates to an apparatus and method embodied in a TRC system for rapidly separating particulate solids from a mixed phase solids-gas stream which may be at velocities up to 150 ft./sec. and at high temperature. Specifically, the device is designed for incorporation at the discharge of solid-gas reacting TRC systems having low residence time requirements and carried out in tubular type reactors. Separation is effected by projecting solids by centrifugal force against a bed of solids as the gas phase makes a 180.degree. directional change, said solids changing direction only 90.degree. relative to the incoming stream.

Abstract: A residual oil conversion process which comprises converting residual oils and regenerating the conversion catalyst wherein the catalyst is selected from LZ-210, LZ-210-M, LZ-210-T, LZ-210-A and mixtures thereof and is a zeolitic aluminosilicate which has a mole ratio of oxide in the dehydrated state of(0.85-1.1)M.sub.2/n O:Al.sub.2 O.sub.3 :x SiO.sub.2wherein M is a cation having a valence of "n", "x" is the number of moles of SiO.sub.2, said zeolitic aluminosilicate has a X-ray powder diffraction pattern having at least the d-spacings of Table A, and said zeolitic aluminosilicate has extraneous silicon atoms in the crystal lattice in the form of framework SiO.sub.4 tetrahedra.

Abstract: A fluid catalytic hydrocarbon conversion process and apparatus in which hot freshly regenerated catalyst is contacted with hydrocarbon feedstock in a gravity flow catalytic reactor. Spent catalyst from the reactor is separated from reactants in a ballistic separator and completely regenerated in a riser regenerator.

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: The present invention relates to a baffle arrangement that improves separation of gaseous hydrocarbon reaction products from catalyst within the reactor vessel of a fluidized catalytic cracker unit. The catalytic reactor vessel includes an outer generally cylindrical shell having a stripping zone arranged at the lower end of the vessel. An inlet riser conduit forming a primary reaction zone extends generally within the shell from the lower end of the vessel to a location near the top of the vessel. A shroud surrounds the upper end of the riser conduit and forms an annular outlet for downwardly discharging a mixture of hydrocarbon and catalyst. According to the present invention, an annular catalyst disengaging riser baffle for deflecting the mixture from the outlet toward the wall of the vessel is arranged on the outside of the riser conduit below the annular outlet and above the stripping zone.

Abstract: A particular aspect of the invention concepts disclosed and described is directed to the use of a vented cup ballistic separation device and method of use for achieving rapid separation of a suspension of fluidized solid particulate and gasiform material. The vented cup ballistic separation apparatus is particularly discussed in conjunction with separating a suspension of catalyst particles from vaporous hydrocarbon reaction products of catalytic cracking discharged from a riser cracking operation. The vented cup ballistic separation apparatus particularly comprises an annular chamber about the upper periphery of an open ended riser conduit. The annular chamber is open in the upper end and one or more open end conduits extend outwardly from the annular chamber comprising means for attachment to cyclone separation means. The riser with vented cup or annular chamber terminates within a larger diameter chamber.

Abstract: A process and related apparatus for separating particulate solids from a stream comprising vapors and particulate solids passed in admixture through an elongated contacting zone. The stream is discharged downwardly at an angle to the vertical along the inside wall of a cylindrical disengagement zone and at an angle to the horizontal of greater than 0.degree. and less than 45.degree.. The solids separate due to centripetal acceleration and fall to the bottom of the disengagement zone.

Abstract: The method and means of this invention comprises discharging a suspension of solids (inert or catalytic) in gasiform material (whether hydrocarbon vapors, combustion product flue gases, stripping gases or combinations thereof) from a riser contact zone through a plurality of radiating confined passageway emanating from the upper discharge periphery of the riser each of which is in tangential communication at the outer end of the confined passageway with a cylinder open in the bottom end thereof. The cylinder is closed at the top except for a coaxially aligned conduit of smaller diameter extending downwardly through said cylinder with its bottom open end terminating adjacent a lower portion of the inlet of the confined passageway.

Abstract: A method and apparatus for separating regenerated catalyst from gaseous combustion products within a regenerator. The apparatus comprises a downcomer within the regenerator vessel through which the catalyst and gaseous combustion products flow. Means are provided at the lower end of the downcomer for utilizing the momentum of the catalyst particles to separate them from the gaseous combustion products.

Abstract: A two-stage catalytic hydroconversion process for heavy hydrocarbon feedstocks usually containing fine particulate solids to produce lower boiling hydrocarbon liquid and gas products. The feedstock is fed into a first stage ebullated bed reactor containing fine sized catalyst and operated at moderate reaction conditions for hydroconversion to produce hydrocarbon gas and liquid fractions, from which a low boiling liquid fraction is separated and withdrawn as a product. The remaining gas and heavier liquid fractions are recombined and fed to a second stage ebullated bed reactor containing larger size catalyst for further hydroconversion reactions at less severe conditions to produce lower boiling hydrocarbon liquid fractions. Following product distillation steps, liquid product fractions are withdrawn and a portion of vacuum bottoms material is recycled to the second stage reactor to provide increased hydroconversion and improved yields of the light hydrocarbon liquid product.

Abstract: Catalyst and hydrocarbon vapors are separated in a cyclone zone attached to the discharge of a riser cracking operation. Vortex stabilizing means separating the cyclone zone from a stripping zone allows stripping gas from said stripping zone to be passed upwardly into said cyclone zone countercurrent to the downward flow of catalyst, thereby improving the separation and stripping of gaseous hydrocarbons from separated catalyst. The combined cyclone-stripping zone reduces catalyst hydrocarbon contact time, thereby improving gasoline yield and olefin content, decreasing gas make, and reducing coke deposits.

Abstract: A process and an apparatus for the fluidized catalytic cracking of hydrocarbons are disclosed. A small vent conduit extends upward out of the flow diversion device mounted on the top of the riser reactor. This vent conduit preferably carries between about 2 and 10 percent of the vapor and catalyst leaving the top of the riser upward into the upper portion of the receiving vessel. This reduces coke deposits in the upper portion of the vessel. The remainder of the vapors and catalyst are preferably directed downward upon leaving the top of the riser.

Abstract: A suspension of catalyst and gasiform material is separated by a catalyst particle concentrating means which discharges the catalyst into a steam stripping zone and transmits the separated gasiform material to a cyclone separator by means of a restricted passageway which minimizes the time the gasiform material is exposed to the catalytic reaction product temperature.

Abstract: A process and related apparatus for separating particulate solids from a stream comprising vapors and particulate solids passed in admixture through an elongated contacting zone. The stream is discharged at an angle to the vertical along the inside wall of a cylindrical disengagement zone. The solids separate due to centripetal acceleration and fall to the bottom of the disengagement zone.

Abstract: An apparatus for the fluidized catalytic cracking of a hydrocarbon feedstock comprises a riser reactor and a collar positioned along the same axis as the downstream end of the riser reactor. The collar is further positioned in close proximity to, but not in contact with, the riser reactor such that an annular space is defined between the riser reactor and the collar. The collar has a diameter greater than the diameter of the riser reactor at its downstream end and communicates directly and laterally with the inlets of the cyclone separation system. The riser reactor may or may not include a flow reversal cap to redirect the flow of the hydrocarbons and the catalyst.

Abstract: A particular aspect of the invention concepts disclosed and described is directed to the use of a vented cup ballistic separation device and method of use for achieving rapid separation of a suspension of fluidized solid particulate and gasiform material. The vented cup ballistic separation apparatus is particularly discussed in conjunction with separating a suspension of catalyst particles from vaporous hydrocarbon reaction products of catalytic cracking discharged from a riser cracking operation. The vented cup ballistic separation apparatus particularly comprises an annular chamber about the upper periphery of an open ended riser conduit. The annular chamber is open in the upper end and one or more open end conduits extend outwardly from the annular chamber comprising means for attachment to cyclone separation means. The riser with vented cup or annular chamber terminates within a larger diameter chamber.

Abstract: An improved Thermal Regenerative Cracking (TRC) apparatus and process includes: (10) an improved low residence time solid-gas separation device and system; and (2) an improved solids feeding device and system; as well as an improved sequential thermal cracking process; an improved solids quench boiler and process; an improved preheat vaporization system; and an improved fuel gas generation system for solids heated. One or more of the improvements may be incorporated in a conventional TRC system.

Abstract: Dust is removed from distillation gases, particularly from gases from the distillation of oil shale, by electrostatic precipitation at temperatures above the dew point of the oil components, preferably between 470.degree. and 550.degree. C.

Abstract: An apparatus for the fluid catalytic cracking of hydrocarbons having a riser reactor with structure at its lower end for introduction of hydrocarbon feedstock and particulate catalyst and having its upper end opening into a separator vessel. A flow reversal structure attached to a downwardly directed flow reversal conduit is provided at the upper end of the riser and within the separator vessel. The flow reversal structure and conduit serve to direct cracked hydrocarbon products and particulate catalyst downwardly toward a stripper located at the bottom of the separator vessel. Cyclones having gas inlet ducts in communication through the wall of the flow reversal conduit are provided. The cyclones are connected to vent cracked hydrocarbon products outside of the separator vessel.

Abstract: A process is disclosed for recovering mechanical energy from a particle-containing pressurized high temperature gas stream such as the flue gas stream of an FCC regenerator. Heat is removed from the gas stream in two different indirect heat exchangers in series flow and the gas stream is then scrubbed by contact with a liquid to remove entrained particles. The gas stream is then reheated by exchange against itself in the second heat exchanger and depressurized in a power recovery expander which produces useful mechanical energy. The scrubbed gas stream may be further heated in the FCC regenerator or some other high temperature location prior to being depressurized in the power recovery expander.

Abstract: A process is disclosed for the production of high octane gasoline and/or other valuable lower molecular weight products from carbo-metallic oils. Examples include crude oil, topped crude, reduced crude, residua, the extract from solvent de-asphalting and other heavy hydrocarbon fractions. These carbo-metallic oils contain quantities of coke precursors and heavy metal catalyst poisons substantially in excess of what is normally considered acceptable for FCC processing (fluid catalytic cracking) and substantial amounts of sulfur, nitrogen and other troublesome components may also be present. Such carbo-metallic oils are converted to the desired products in a catalytic conversion process. Named "RCC" (Reduced Crude Conversion) after a particularly common or useful carbo-metallic feed, the present process is by no means restricted to reduced crude or to oils of petroleum origin, having utility in the processing of oils from coal, shale and other sources.

Abstract: A side by side hydrocarbon conversion-two staged stacked catalyst regeneration arrangement is provided wherein the first stage of catalyst regeneration is temperature restricted to achieve incomplete removal of carbon deposits and a second higher temperature regeneration is accomplished in an upflowing catalyst contact system under conditions to accomplish removal of residual carbon on the catalyst and produce a CO.sub.2 -rich flue gas. A special external cyclone separator arrangement may be attached to either of the second stage regeneration operation or the riser hydrocarbon conversion operation to effect separation of catalyst particles from gasiform material.

Abstract: A hydrocarbon conversion-catalyst regeneration process and apparatus is described for converting residual oils and regeneration of catalyst in two separate low and higher temperature regeneration stages stacked one above the other on the same or different vertical axis to provide catalyst at a temperature above the residual feed psuedo-critical temperature. A CO rich flue gas is recovered from the low temperature regeneration stage and a CO.sub.2 rich flue gas is recovered from the higher temperature regeneration stage. The temperature of the catalyst mixed with the residual oil feed is sufficient to obtain substantially complete vaporization of the residual oil charge. A special arrangement of apparatus is provided in the lower portion of a riser conversion zone to obtain the intimate vaporization contact between residual oil feed and the high temperature catalyst charged to the riser.

Abstract: A hydrocarbon conversion-catalyst regeneration process and apparatus is described for converting residual oils and regeneration of catalyst in two separate low and higher temperature regeneration stages stacked one above the other on the same or different vertical axis to provide catalyst at a temperature above the residual feed pseudo-critical temperature. A CO rich flue gas is recovered from the low temperature regeneration stage and a CO.sub.2 rich flue gas is recovered from the higher temperature regeneration stage. The temperature of the catalyst mixed with the residual oil feed is sufficient to obtain substantially complete vaporization of the residual oil charge. A special arrangement of apparatus is provided in the lower portion of a riser conversion zone to obtain the intimate vaporization contact between residual oil feed and the high temperature catalyst charged to the riser.

Abstract: An improved Thermal Regenerative Cracking (TRC) apparatus and process includes: (1) an improved low residence time solid-gas separation device and system; and (2) an improved solids feeding device and system; as well as an improved sequential thermal cracking process; an improved solids quench boiler and process; an improved preheat vaporization system; and an improved fuel gas generation system for solids heated. One or more of the improvements may be incorporated in a conventional TRC system.

Abstract: An apparatus for the catalytic cracking of hydrocarbons having two independent transfer line reactors, each of which is associated with an independent cyclone separation system and wherein the cyclone separation systems are located within a common separator vessel. More particularly, the improved apparatus can be used for the simultaneous fluidized catalytic cracking of a hydrocarbon feedstock and the recracking of a selected fraction of the products from said cracking without commingling the feedstock and the selected fraction to be recracked.

Abstract: An improved apparatus for separating solid particles from vapor is disclosed which in one embodiment employs at least one zone defined by at least two generally vertical and at least two generally horizontal vanes and in another embodiment optionally employs at least one vane to inhibit turbulence in a lower portion of this apparatus to aid the settling of particles within a particle outlet means.This apparatus is particularly suited to at least partially separating solid particles from a mixture of vapors and solid particles which arise either when restoring the catalytic activity of solid particles that had previously been used to promote a chemical conversion or when carrying out a chemical conversion, such as for example hydrocarbon cracking or reforming.Improved methods employing such apparatus are also disclosed.

Abstract: A method and apparatus for the fluid catalytic cracking of petroleum hydrocarbons wherein an ascending cocurrent stream of vaporous hydrocarbon and entrained catalyst particulates is effected in a tubular reaction zone the method including the following steps: (1) altering the direction of flow of said stream of hydrocarbons and particulates to a downward direction by conducting the stream into a flow reversing zone, (2) accelerating the rate of downward flow of the particulates by gravitational force augmenting fluid flow drag forces to impart momentum thereto, (3) withdrawing cracked hydrocarbons laterally from the downwardly flowing particulates, and (4) contacting the downwardly flowing particulates with inert stripping gas, the momentum of said particulates preventing their passage laterally with the cracked hydrocarbons and permitting their passage counter current to the upward movement of stripping steam.

Abstract: A promoter comprising from about 500 ppm to about 1% of a Group V, Group VI, or Group VIII metal on a support is combined with a hydrocarbon conversion catalyst under fluidizing conditions, in an effective proportion, to enhance the removal of carbonaceous material from the catalyst. Typically, the promoter is a mixture of platinum and palladium supported on gamma alumina and is included in a fluidized catalytic cracking (FCC) unit in a sufficient proportion to provide from about 0.05 to about 50 ppm metal based on the weight of the catalyst.

Abstract: A riser cracking-catalyst regeneration operation is described wherein a suspension discharged from a riser operation is separated by catalyst particle concentrating means which discharge a concentrated stream of catalyst separated from gasiform material into a downcomer zone and out of further contact with discharged gasiform material in the suspension. A stripping gas is used to particularly aid the separation of catalyst and hydrocarbon vapors.

Abstract: In a reactant-fluid catalyst suspension system, an arrangement of apparatus is provided contiguous with a riser discharge which centrifugally initially separates the suspension into a solids phase and a gasiform material phase prior to discharge from the riser. The catalyst may be further stripped if desired in equipment above and about the riser discharge. The arrangement contributes substantially to the efficiency and economics of the separation of catalyst from gasiform products including products of hydrocarbon conversion and combustion products of catalyst regeneration.

Abstract: An improved method for hydrocarbon conversion wherein a hydrocarbon feedstock is contacted with solid particles capable of promoting said hydrocarbon conversion at hydrocarbon conversion conditions to form at least one hydrocarbon conversion product in a mixture of solid particles and vapor, the improvement which comprises at least partially separating said solid particles from said vapor by means of an apparatus having one or more improvements, all of which lessen particle attrition.

Abstract: An apparatus for the removal or collection of solid dispersoids in gases which structurally comprises a combination of a gravity settling chamber and a cyclonic separator. In operation, the bulk of the entrained solids of a gas/solid fluid stream is alone discharged from a conduit transporting said stream into the settling chamber and collected therein whereas the gas phase containing only residual amounts of entrained solids is simultaneously diverted through a cyclonic separator to complete the removal of the solids from the gas stream.

Abstract: In a coking process wherein a stream of fluidized solids is passed from a fluidized bed coking zone to a second fluidized bed, entrained coke fines recovered from the gaseous effluent of the second fluidized bed zone are recycled as dry fines to the coking zone.

Abstract: Catalyst and hydrocarbon vapors are separated in a cyclone attached to the discharge of a riser cracking operation. The cyclone is modified to include a separate cyclonic stripping of catalyst separated from hydrocarbon vapors.

Abstract: An effective and economical supply of energy from residual oil for power generation can be obtained by a sequential process of partial combustion of a crude or residual oil such as Bunker C and other high sulfur stocks, in the presence of air and steam in a fluidized bed of inert particles followed by a fluidized bed heat exchange for the production of steam and control of solids build-up, the solids-free gas being desulfurized by commerical processes and thence being available for combustion for gas turbine operation to produce transportable electrical power or other types of mechanical power such as a compressor driver. Emission levels of contaminants are within forseeable requirements and turbine maintenance problems are reduced. Coal solids can be used as a supplement to the residual oil. Alternatively, the low BTU gas can be effectively added to pipeline gas as a supplementary source of energy when dilution of high-Btu gas is permitted or used directly as a low-Btu desulfurized industrial fuel.

Abstract: An improvement in a regenerator which incorporates an external plenum on the exterior of the regenerator apparatus for receiving and collecting the flue gases separated from regenerated catalyst by a plurality of cyclone separators or other separating apparatus is disclosed. The external plenum communicates by means of stand pipes through the wall of the regenerator. This supports the cyclone separators or other separating means mechanically and avoids certain thermal stresses which would otherwise occur in the plenum if it were placed on the interior of the regeneration chamber.