Abstract: Collection enhanced materials, flue gas additives, and methods of making the enhanced materials and flue gas additives are provided. In one embodiment, a down stream addition system configured to control material passing through a metering device from a vessel to a gaseous exhaust path extending between a unit and an exhaust flue of the unit is provided. In alternative embodiments, methods are provided for introducing at least one of a flue gas additive and a collection enhanced material to a gaseous exhaust stream exiting a unit; exposing and removing at least a portion of at least one a of flue gas additive and a collection enhanced material from a gaseous exhaust stream exiting a unit prior to entering an exhaust flue; and recycling at least a portion of material removed a from a gaseous exhaust stream exiting a unit back to the gaseous exhaust stream without passing through the unit.

Abstract: Collection enhanced materials, flue gas additives, and methods of making the enhanced materials and flue gas additives are provided. In one embodiment, a down stream addition system configured to control material passing through a metering device from a vessel to a gaseous exhaust path extending between a unit and an exhaust flue of the unit is provided. In alternative embodiments, methods are provided for introducing at least one of a flue gas additive and a collection enhanced material to a gaseous exhaust stream exiting a unit; exposing and removing at least a portion of at least one a of flue gas additive and a collection enhanced material from a gaseous exhaust stream exiting a unit prior to entering an exhaust flue; and recycling at least a portion of material removed a from a gaseous exhaust stream exiting a unit back to the gaseous exhaust stream without passing through the unit.

Abstract: Collection enhanced materials, flue gas additives, and methods of making the enhanced materials and flue gas additives are provided. In one embodiment, a down stream addition system configured to control material passing through a metering device from a vessel to a gaseous exhaust path extending between a unit and an exhaust flue of the unit is provided. In alternative embodiments, methods are provided for introducing at least one of a flue gas additive and a collection enhanced material to a gaseous exhaust stream exiting a unit; exposing and removing at least a portion of at least one a of flue gas additive and a collection enhanced material from a gaseous exhaust stream exiting a unit prior to entering an exhaust flue; and recycling at least a portion of material removed a from a gaseous exhaust stream exiting a unit back to the gaseous exhaust stream without passing through the unit.

Abstract: Material withdrawal apparatus, methods, and systems of regulating material inventory in one or more units are provided. A material withdrawal apparatus includes a heat exchanger and transport medium junction configured to provide transport medium to transport the withdrawn material from the unit to the heat exchanger. Another material withdrawal apparatus includes a heat exchanger and shock coolant junction configured to provide shock coolant to the material withdrawn from the unit. Another material withdrawal apparatus includes a heat exchanger, shock coolant junction, and transport medium junction. Another embodiment of a material withdrawal apparatus includes a vessel and shock coolant junction. Another material withdrawal apparatus includes a vessel and transport medium junction. The vessel includes a wall, liner with heat insulating refractory material, fill port, and a discharge port.

Abstract: Material withdrawal apparatus and methods and systems of regulating material inventory in one or more units are provided. A material withdrawal apparatus includes a heat exchanger and a sensor. The heat exchanger includes a material inlet, material outlet, cooling fluid inlet, and cooling fluid outlet. The material inlet is coupled to the unit and the sensor is coupled to the heat exchanger to provide a metric indicative of the temperature at the material inlet; material outlet; cooling fluid inlet and cooling fluid outlet. Another embodiment of a material withdrawal apparatus includes a vessel having an outer wall, liner, fill port, and a discharge port. The liner at least partially covers the inner surface of the outer wall. The fill port and discharge port are defined in the vessel and the fill port is configured to receive withdrawn material from at least a unit. Other embodiments provide methods of withdrawing or regulating material in a unit.

Abstract: A method for monitoring a FCC catalyst injection system is provided. In one embodiment of the invention, the method includes automatically updating a catalyst available inventory information in a digital memory device in response to a catalyst usage event. A sufficiency of the updated catalyst available inventory is automatically determined. A re-supply action is then taken in response to a determination of insufficient catalyst available inventory. The method is repeated for each catalyst usage event.

Abstract: Material delivery systems, methods of delivering material and methods of calibrating such systems and methods are disclosed. The material delivery system includes a delivery vessel, a load cell, and automated weight calibration device. The delivery vessel has at least an outlet adapted for coupling to an unit. The load cell is configured to provide a metric indicative of an amount of material in the delivery vessel. The automated weight calibration device is configured to impart a known force onto the at least one load cell. A method includes delivering material to a unit and determining how much material is delivered by a change in weight of a delivery vessel, wherein the delivery vessel comprises a load cell; applying a known calibration force to the load cell; and comparing a metric from the load cell of the known calibration with an expected metric.

Abstract: Catalyst withdrawal apparatuses and methods for regulating catalyst inventory in one or more units are provided. In one embodiment, a catalyst withdrawal apparatus for removing catalyst from a FCC unit includes a vessel coupled to a flow control circuit. Another embodiment of a catalyst withdrawal apparatus includes a vessel, a delivery line, and control valve. The control valve is configured to control the amount of gas to the delivery line and entrained with the catalyst. Another embodiment of catalyst withdrawal apparatus includes a vessel coupled to a heat exchanger. The heat exchanger includes a first conduit; a housing confining a coolant volume around a portion of the first conduit; and a sliding seal sealing the housing to the first conduit in manner that allows longitudinal expansion. A fluid catalyst cracking system coupled to a catalyst withdrawal apparatus and method for withdrawing catalyst from a unit are also disclosed.

Abstract: An apparatus and method for loading catalyst to a fluid catalyst cracking unit are provided. In one embodiment, apparatus for loading catalyst to a fluid catalyst cracking unit includes a vessel disposed in a transportable housing. A plurality of catalyst storage regions are associated with the vessel. A metering device is interfaced with the vessel and configured to provide a metric indicative of an amount of catalyst provided from a selected one of the catalyst storage regions.

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: A method and apparatus for metering catalyst in a fluid catalytic cracking catalyst injection system are provided. In one embodiment, apparatus for metering catalyst in a fluid catalytic cracking catalyst injection system includes a low pressure storage vessel coupled to a pressure vessel that defines a high pressure side of the apparatus, where the determination of the amount of catalyst transferred is made on the low pressure side of the apparatus.

Abstract: A method for adding material to an FCC unit is provided. In one embodiment, a method for adding material to an FCC unit includes providing a first vessel under low pressure containing a first material, moving the material through a first eductor to the FCC unit, and determining an amount of material moved dispensed from the vessel through the eductor.

Abstract: A method for monitoring a FCC catalyst injection system is provided. One embodiment of the invention includes steps for determining an occurrence of a pre-defined event and establishing communication between a control module of the injection system and a remote device in response to the event. In another embodiment of the invention, a method is described which entails the acquisition of data from the injection system by a plurality of sensors. After the data is obtained, it is subsequently stored in the memory device of the control module. Communication is then established between a remote device and the control module to transfer the data.

Abstract: A fines injection apparatus, a fluid catalytic cracking (FCC) system having a fines injection apparatus, and a method for using the same are provided. In one embodiment, a FCC system includes a FCC unit, a fines collector, and a fines injector coupled to the fines collector for retuning the fines recovered in the fines collector to the FCC unit. In another embodiment, an apparatus for injecting fines into a FCC system includes a fines separator coupled to an effluent stream and an injection apparatus coupled to a regenerator. A conduit is provided for delivering collected fines from the fines separator to the injection apparatus. In yet another embodiment, a method for injecting fines into FCC system includes collecting fines from a waste stream of a FCC system, automatically transferring the collected fines to a fines injection apparatus, and periodically injecting the transferred fines into the FCC system.

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: A mobile fluid cracking catalyst injection system and a method of controlling a fluid catalyst cracking process is provided. In one embodiment, a mobile fluid catalyst cracking system includes a transportable platform, a catalyst reservoir coupled to the platform and a flow control device coupled to an outlet of the reservoir and adapted to control the flow of catalyst from the reservoir to a fluid catalyst cracking unit (FCCU).

Abstract: A method and apparatus for metering catalyst in a fluid catalytic cracking catalyst injection system are provided. In one embodiment, apparatus for metering catalyst in a fluid catalytic cracking catalyst injection system includes a low pressure storage vessel coupled to a pressure vessel that defines a high pressure side of the apparatus, where the determination of the amount of catalyst transferred is made on the low pressure side of the apparatus.

Abstract: The invention is a multi-catalyst injection system. In one embodiment, the system comprises a plurality of catalyst storage regions associated with a vessel and a metering device associated with the vessel. The metering device is configured to provide a metric indicative of an amount of catalyst dispensed from a selected one of the catalyst storage regions.

Abstract: A catalyst withdrawal apparatus and method for regulating catalyst inventory in a fluid catalytic cracking catalyst (FCC) unit is provided. In one embodiment, a catalyst withdrawal apparatus for removing catalyst from a FCC unit includes a pressure vessel having a metering device coupled to a fill port. A heat dissipater is located adjacent the metering device and is adapted to cool catalyst entering the pressure vessel. A sensor is coupled to the pressure vessel arranged to provide a metric indicative of catalyst entering the pressure vessel through the metering device. In another embodiment, a method for regulating catalyst inventory in a FCC unit includes the steps of determining a change of catalyst present in a FCC unit, withdrawing catalyst from the FCC unit into an isolatable storage vessel coupled to the FCC unit, measuring the amount of catalyst disposed in the storage vessel, and removing the measured catalyst from the storage vessel.

Abstract: The invention is a catalyst injection system and method for injecting catalyst. In one embodiment, a fluid catalytic injection system includes vessel configured to store one or more catalysts, a pressure transmitter, a pressure control valve, a discharge valve, and a controller. The pressure control valve is coupled to the vessel and regulates the gas pressure therein. The discharge valve is coupled to the vessel and controls a discharge of catalyst from the vessel. The pressure transmitter provides a metric of pressure to the controller as an input. The controller contains instructions, that when executed, prevents the simultaneous opening of the pressure control valve and the discharge valve. In another embodiment, a method for injecting catalyst into a fluid catalytic cracking unit is provided. The method includes regulating pressure within a catalyst storage vessel, changing an amount of catalyst in the storage vessel, and preventing a simultaneous occurrence of the regulating and changing steps.