Abstract: Dewaxing, preferably catalytic dewaxing over zeolite beta or ZSM-5, improves the crackability of a heavy, waxy feed to a catalytic cracking unit. When the catalytic dewaxing occurs at temperatures above about 360.degree. C., using ZSM-5 dewaxing catalyst, high octane gasoline is obtained as a by product of catalytic dewaxing.

Abstract: A catalytic cracking catalyst and process which tolerates high levels of vanadium and coke precursors in the feed is disclosed. A zeolite in an alumina free binder or coating, preferably silica, is used as the cracking catalyst. RE-USY in silica is especially preferred as it has a low affinity for vanadium, low coking characteristics and high stability. Preferably a vanadium getter additive is present as separate particles to act as a vanadium sink. The catalyst and process may be used in fluidized bed catalytic cracking (FCC) or in moving bed catalytic cracking units. A method of making a coated catalyst, by adding a layer of an alumina free material to a core of alumina containing cracking catalyst is also disclosed.

Abstract: A process is provided for preparing pipelineable syncrude and asphalt from a heavy crude oil. The syncrude has substantially less metals content and Conradson Carbon Residue than the precursor crude oil, and may be used as feed for catalytic cracking or as fuel oil. The asphalt is adaptable for paving. The process consists of air-blowing the crude, deasphalting the air-blown product, and thermally cracking the deasphalted oil to reduce its viscosity, in that order.The process is adaptable to on-site use in or near a heavy oil field, using skid-mounted equipment.

Abstract: Shape selective zeolites, such as ZSM-5, are added to the equilibrium catalyst in a catalytic cracking unit in large amounts. Sufficient fresh zeolite is added to result in an unacceptable increase in production of wet gas (C.sub.3 /C.sub.4) by the catalytic cracking unit, if operated at normal charge rates and operating conditions. To compensate, conditions in the catalytic cracking unit are adjusted, such as by reducing feed rate, catalyst/oil ratio, or cracking reaction temperature, to reduce the production of "light ends" to an amount which can be tolerated by the catalytic cracking unit. Within a few days to a few weeks, excessive production of wet gas will diminish so that unit operation may be returned to normal. Resumption of normal cracking operations using a catalyst inventory containing a relatively large amount of shape selective zeolite additive results in significant increases in the octane number of the catalytically cracked gasoline.

Abstract: Addition of a CO combustion promoter to a circulating fluid bed (CFB) combustion unit and reduction of the air addition rate to 100-110% of stoichiometric improves the efficiency of CO burning, reduces emissions of CO and improves the efficiency of the unit. Stable, reduced temperature operation with air rates close to stoichiometric, reduces NO.sub.x emissions. A circulating (100-400 micron particles) or fast settling (400-1200 micron particle) CO combustion promoter may be used.

Abstract: Addition of a readily fluidizable, 100-400 micron average diameter particular CO combustion promoter to a circulating fluid bed (CFB) combustion unit improves the efficiency of CO burning, reduces emissions of CO and improves the efficiency of the unit.

Abstract: A catalytic cracking process and apparatus operates with multiple feed injection points to a riser reactor with several enlarged regions. An elutriable catalyst mixture is used, comprising a conventionally sized cracking catalyst and a faster settling, shape selective additive cracking catalyst. Straight run naphtha, and a light, H.sub.2 -rich aliphatic stream are added to the base of a riser reactor. A resid feed is added higher up in the riser, with a gas oil and recycled heavy cycle oil and naphtha streams added even higher up in the riser. The riser has an elutriating base, and an elutriating upper portion, which increase residence time of the shape selective zeolite additive relative to the conventionally sized cracking catalyst.

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: A lubricant dewaxing process which is useful with difficult feeds, especially highly waxy feeds having paraffin contents in excess of 25 weight percent of feeds with high nitrogen levels, employs two-step dewaxing in which the first stage is carried out under relatively mild conditions to obtain extended catalyst cycle life between successive reactivations with a constant temperature for the duration of each dewaxing cycle. The second stage dewaxing is carried out under conditions which maintain the target pour point for the product with a progressively increasing temperature during each dewaxing cycle. More than one preliminary dewaxing stage may be provided in order to reduce severity in each stage with mild conditions and constant temperature being maintained in the preliminary steps. Using this process, extended catalyst cycle lives may be obtained with difficult feeds.

Abstract: The present invention describes improved FCC and TCC stripper operations by incorporating a stripper operated at a reduced pressure. The improved strippers of the invention will increase total liquid hydrocarbon yield while reducing the coke load on the regenerator. Novel porous TCC bead catalysts are disclosed wherein at least 1/3 of the pore volume of catalyst pores having a pore diameter of at least 3000 Angstroms. These macropores facilitate flash vaporization of hydrocarbons in a stripping zone of the spent catalyst upstream of a regeneration zone.

Abstract: An improved method for passivating metals in a hydrocarbon feedstock during catalytic cracking has been discovered. The method involves contacting the feedstock with a passivating agent comprising a precipitated porous rare earth oxide, alumina, and aluminum phosphate precipitate. The passivating agent may be coated on a cracking catalyst, be part of the matrix of a cracking catalyst, or be added to the cracking operation as discrete particles.

Abstract: A process for removing catalyst fines from slurry oil is disclosed. A settling reagent, such as coal, alumina, or coke, is added to a fines containing heavy oil bottoms product from a fractionator downstream of a catalytic cracking unit. The settling reagent promotes rapid settling and removal of fines from heavy oil product. Settling may be performed in a slurry settler, or a centrifuge. A catalytic cracking process for heavy, metals laden oil is also disclosed using a settling reagent to clarify slurry oil, then recycling settled settling reagent to contact the heavy oil in the catalytic cracking process.

Abstract: A lubricant dewaxing process which is useful with difficult feeds, especially highly waxy feeds having paraffin contents in excess of 25 weight percent or feeds with high nitrogen levels, employs two-step dewaxing in which the first stage is carried out under relatively mild conditions using a binder-free zeolite dewaxing catalyst to obtain extended catalyst cycle life between successive reactivations with a constant temperature for the duration of each dewaxing cycle. The second stage dewaxing is also carried out with a binder-free catalyst under conditions which maintain the target pour point for the product with a progressively increasing temperature during each dewaxing cycle. More than one preliminary dewaxing stage may be provided in order to reduce severity in each stage with mild conditions and constant temperature being maintained in the preliminary steps. Using this process, extended catalyst cycle lives may be obtained with difficult feeds.

Abstract: An improved process for stripping, or desorbing, entrained hydrocarbon material and, where present, sulfur-containing material, from a catalyst mixture recovered from a catalytic cracking reaction zone is described which comprises:(a) providing a quantity of catalyst mixture containing entrained hydrocarbon material and, optionally, sulfur-containing material, in at least one stripping zone in which a stripping gas removes said entrained hydrocarbon material and, where present, sulfur-containing material, the catalyst mixture comprising, as a first catalyst component, an amorphous and/or large pore crystalline cracking catalyst and, as a second catalyst component, a shape selective medium pore crystalline silicate zeolite catalyst, said first and second catalyst components being present in admixture within a common stripping zone or segregated into separate stripping zones; and,(b) conducting an exothermic reaction within the common stripping zone or within the separate stripping zone containing segregated se

Abstract: New catalyst compositions of superior hydrothermal stability, which evidence increased gasoline plus distillate yields, improved coke selectivity and reduced C.sub.4.sup.- gas yields, are based on framework dealuminated faujasitic zeolites having a framework silica to alumina molar ratio of from about 5 to 100. In a preferred embodiment, an "ultrastable Y" composited with a matrix, is subjected to a treatment with a source of aluminum and rare earth compounds followed by hydrothermal treatments to improve the hydrothermal stability and selectivity of the catalyst for catalytic cracking. This is evidenced by higher gasoline plus distillate yields and lower coke and gas production at lower catalyst useage per barrel of feed relative to commercial cracking catalysts currently being used.

Abstract: A catalytic cracking process is described featuring multiple risers in which a variety of hydrocarbon conversion reactions takes place, a stripping unit in which entrained hydrocarbon material is removed from catalyst and a regeneration zone in which spent cracking catalyst is regenerated, which comprises:(a) converting a relatively high boiling hydrocarbon charge material in a first riser in the presence of a catalyst mixture comprising, as a first catalyst component, an amorphous cracking catalyst and/or a large pore crystalline cracking catalyst and, as a second catalyst component, a shape selective medium pore crystalline silicate to provide lighter products including naphtha and C.sub.3 and/or C.sub.4 olefin;(b) converting an ethylene-rich charge material introduced to a second riser at a lower level thereof in the presence of said catalyst mixture to provide heavier products and to increase the temperature of the catalyst in said region; and,(c) converting C.sub.3 and/or C.sub.