Abstract: An FCC process comprising an enlarged riser section and a distributor in an elevated position and with an opening in its tip away from riser walls may reduce coke build-up along the interior walls of a riser. Catalytic mixing may be improved, which could reduce riser coking by increasing hydrocarbon contact with catalyst before contacting the riser wall. Increasing the distance between the introduction of the hydrocarbon and the riser wall may increase this likelihood for hydrocarbon-catalyst contact. Highly contaminated hydrocarbons cause greater coking than do normal hydrocarbons and this FCC process may be effective in decreasing riser coking on such heavy hydrocarbons.

Abstract: In at least one embodiment of the present invention, a method of recovering energy from a FCC unit having a reactor and a regenerator for overall CO2 reduction is provided. The method comprises cooling syngas to a predetermined low temperature to define cooled syngas. A turbo-expander including a first compressor is provided. The turbo-expander train is configured to combust and expand gas to drive the first compressor. The cooled syngas is compressed with the first compressor to define compressed syngas. A first stream of gas comprising CO2 and a second stream of gas comprising CO are separated from the compressed syngas. O2 and the first and second streams of gas are introduced to the turbo-expander train. The first stream of gas is expanded and the second stream of gas is combusted and expanded with the O2 to recover energy, driving the first compressor and producing the syngas.

Abstract: This invention is directed to a method and apparatus for regenerating a catalyst used in an FCC unit, including providing a spent catalyst into an upper portion of a regenerator, maintaining a calcination phase, a gasification phase, and a combustion phase of fluidized catalyst in the regenerator, combusting carbon in the combustion phase and producing a combustion flue gas, reacting carbon in the gasification phase with the combustion flue gas to form a carbon monoxide rich flue gas, and calcining the spent catalyst with the carbon monoxide rich flue gas.

Abstract: Disclosed is a process for disengaging regenerated catalyst from flue gas in a catalyst regenerator so as to avoid re-entrainment of catalyst that has settled into a bed in the catalyst regenerator using a disengaging device. A disengaging arm of the disengaging device has an outer shell that encloses the arm, an inner shell with a slot for allowing catalyst and flue gas to exit the arm and an outer baffle having a lower edge located below the opening in the outer wall. The baffle directs the catalyst and flue gas downwardly and limits radial flow. Catalyst and flue gas enter the disengaging arm through an opening in an outer wall of a riser section at a first superficial velocity and exits through a slot in a bottom of the disengaging arm at no more than 1.33 the first superficial velocity.

Abstract: In at least one embodiment of the present invention, a method of recovering energy from a FCC unit having a reactor and a regenerator for overall CO2 reduction is provided. The method comprises cooling syngas to a predetermined low temperature to define cooled syngas. A turbo-expander including a first compressor is provided. The turbo-expander train is configured to combust and expand gas to drive the first compressor. The cooled syngas is compressed with the first compressor to define compressed syngas. A first stream of gas comprising CO2 and a second stream of gas comprising CO are separated from the compressed syngas. O2 and the first and second streams of gas are introduced to the turbo-expander train. The first stream of gas is expanded and the second stream of gas is combusted and expanded with the O2 to recover energy, driving the first compressor and producing the syngas.

Abstract: In at least one embodiment of the present invention, a method of recovering energy from a FCC unit having a reactor and a regenerator for overall CO2 reduction is provided. The method comprises cooling syngas to a predetermined low temperature to define cooled syngas. A turbo-expander including a first compressor is provided. The turbo-expander train is configured to combust and expand gas to drive the first compressor. The cooled syngas is compressed with the first compressor to define compressed syngas. A first stream of gas comprising CO2 and a second stream of gas comprising CO are separated from the compressed syngas. O2 and the first and second streams of gas are introduced to the turbo-expander train. The first stream of gas is expanded and the second stream of gas is combusted and expanded with the O2 to recover energy, driving the first compressor and producing the syngas.

Abstract: An FCC process comprising an enlarged riser section and a distributor in an elevated position and with an opening in its tip away from riser walls may reduce coke build-up along the interior walls of a riser. Catalytic mixing may be improved, which could reduce riser coking by increasing hydrocarbon contact with catalyst before contacting the riser wall. Increasing the distance between the introduction of the hydrocarbon and the riser wall may increase this likelihood for hydrocarbon-catalyst contact. Highly contaminated hydrocarbons cause greater coking than do normal hydrocarbons and this FCC process may be effective in decreasing riser coking on such heavy hydrocarbons.

Abstract: One exemplary embodiment can be a process for fluid catalytic cracking. The process can include withdrawing a catalyst from a reaction vessel to replace a catalyst inventory over a period of about 10- about 35 days for maximizing propylene yield.

Abstract: Disclosed is an apparatus and process for disengaging regenerated catalyst from flue gas in a catalyst regenerator so as to avoid re-entrainment of catalyst that has settled into a bed in the catalyst regenerator using a disengaging device. A disengaging arm of the disengaging device has an outer shell that encloses the arm, an inner shell with a slot for allowing catalyst and flue gas to exit the arm and an outer baffle having a lower edge located below the opening in the outer wall. The baffle directs the catalyst and flue gas downwardly and limits radial flow. Catalyst and flue gas enter the disengaging arm through an opening in an outer wall of a riser section at a first superficial velocity and exits through a slot in a bottom of the disengaging arm at no more than 1.33 the first superficial velocity.

Abstract: Systems and methods of reducing refinery carbon dioxide emissions by increasing synthesis gas production in a fluid catalytic cracking unit having a reactor and a regenerator are disclosed. In one example, a method comprises separating spent catalyst from a hydrocarbon product in the reactor, the spent catalyst having trapped hydrocarbon thereon. The method further comprises reacting an additional feed with the spent catalyst in the reactor to deposit additional coke on the spent catalyst, defining a gas product. The method further separating the gas product and the trapped hydrocarbon from the spent catalyst with a stripping gas. The method further comprises removing coke from the spent catalyst in the regenerator, thereby increasing the amount of synthesis gas production.

Abstract: An FCC process and apparatus comprising an enlarged riser section and a distributor in an elevated position and with an opening in its tip away from riser walls may reduce coke build-up along the interior walls of a riser. Catalytic mixing may be improved, which could reduce riser coking by increasing hydrocarbon contact with catalyst before contacting the riser wall. Increasing the distance between the introduction of the hydrocarbon and the riser wall may increase this likelihood for hydrocarbon-catalyst contact. Highly contaminated hydrocarbons cause greater coking than do normal hydrocarbons and this FCC process and apparatus may be effective in decreasing riser coking on such heavy hydrocarbons.

Abstract: A process and apparatus for improving flow properties of crude may include processing a first crude stream, which may in turn include cracking the first crude stream with catalyst to form a cracked stream and spent catalyst, hydrotreating a portion of the cracked stream and then mixing the hydrotreated stream with an unprocessed second crude stream.

Abstract: A process and apparatus for improving flow properties of crude may include processing a first crude stream, which may in turn include cracking the first crude stream with catalyst to form a cracked stream and spent catalyst, hydrotreating a portion of the cracked stream and then mixing the hydrotreated stream with an unprocessed second crude stream.

Abstract: One exemplary embodiment can be a fluid catalytic cracking system. The system can include a reaction zone operating at conditions to facilitate olefin production and including at least one riser. The at least one riser can receive a first feed having a boiling point of about 180-about 800° C., and a second feed having more than about 70%, by weight, of one or more C4+ olefins.

Abstract: A liquid distribution device including a liquid distributor having an inlet pipe connected to a piping manifold that further includes a plurality of liquid distribution pipes each liquid distribution pipe including an inlet connected to the piping manifold and an outlet, and a liquid impact portion having a plurality of pans located in close proximity to the outlet of one or more of the liquid distribution pipes.

Abstract: In at least one embodiment of the present invention, a method of heating a FCC unit having a regenerator and a reactor having overall CO2 reduction is provided. The method comprises compressing syngas to define compressed syngas. Separating a first stream of gas comprising CO2 from the compressed syngas. A second stream of gas comprising O2 is expanded with the first stream of gas to produce a feed gas. The feed gas is introduced to the regenerator at gasification conditions to burn coke from coke heavy spent catalyst advanced from the reactor, producing syngas and heat for operating the reactor at reaction temperatures.

Abstract: In at least one embodiment of the present invention, a method of heating a FCC unit having a regenerator and a reactor for over CO2 reduction is provided. The method comprises compressing syngas to define compressed syngas. CO2 is separated from the compressed syngas to provide a first stream of gas comprising CO2. The first stream of gas is expanded with a second stream of gas comprising O2 to define a feed gas. The feed gas and an injected hydrocarbon feed are introduced to the regenerator having spent catalyst from the reactor. The regenerator is at gasification conditions to burn the injected hydrocarbon feed and coke from the spent catalyst producing the syngas and heat for operating the reactor at reaction temperatures.

Abstract: Process for increasing mixing in a fluidized bed. A slide, which may be in the form of a tube or trough, transports particles from an upper zone downward to a lower zone at a different horizontal position, thereby changing the horizontal position of the particle and creating lateral mixing in the fluidized bed. Increased mixing may improve efficiency for an apparatus using a fluidized bed. For example, increased lateral mixing in a regenerator may increase temperature and oxygen mixing and reduce stagnation to improve efficiency. A slide may be relatively unobtrusive, inexpensive, and simple for a retrofit or design modification and may improve combustion efficiency at high rates by enhancing the lateral blending of spent and regenerated catalyst.

Abstract: This invention is directed to a method and apparatus for regenerating a catalyst used in an FCC unit, including providing a spent catalyst into an upper portion of a regenerator, maintaining a calcination phase, a gasification phase, and a combustion phase of fluidized catalyst in the regenerator, combusting carbon in the combustion phase and producing a combustion flue gas, reacting carbon in the gasification phase with the combustion flue gas to form a carbon monoxide rich flue gas, and calcining the spent catalyst with the carbon monoxide rich flue gas.

Abstract: Apparatus and process for increasing mixing in a fluidized bed. A slide, which may be in the form of a tube or trough, transports particles from an upper zone downward to a lower zone at a different horizontal position, thereby changing the horizontal position of the particle and creating lateral mixing in the fluidized bed. Increased mixing may improve efficiency for an apparatus using a fluidized bed. For example, increased lateral mixing in a regenerator may increase temperature and oxygen mixing and reduce stagnation to improve efficiency. A slide may be relatively unobtrusive, inexpensive, and simple for a retrofit or design modification and may improve combustion efficiency at high rates by enhancing the lateral blending of spent and regenerated catalyst.