Abstract: Thermal cracking in a riser cracking, closed cyclone, fluidized catalytic cracking process is reduced. A snorkel or flow conduit having an inlet just above the catalyst stripper moves stripper vapor into the closed cyclone. The system preferably operates without a stripper cap, relying on fluid dynamics to isolate stripper vapor from upper parts of the vessel containing the riser outlet. Preferably the snorkel is at least partially supported by, and ideally is inside, the primary cyclone dipleg. Reduced residence time of stripper vapor in the vessel containing the stripper and the closed cyclone system reduces thermal cracking of stripper vapor.

Abstract: Thermal cracking in a riser cracking, closed cyclone, fluidized catalytic cracking process is reduced. A snorkel or flow conduit having an inlet just above the catalyst stripper moves stripper vapor into the closed cyclone. The system preferably operates without a stripper cap, relying on fluid dynamics to isolate stripper vapor from upper parts of the vessel containing the riser outlet. Preferably the snorkel is at least partially supported by, and ideally is inside, the primary cyclone dipleg. Reduced residence time of stripper vapor in the vessel containing the stripper and the closed cyclone system reduces thermal cracking of stripper vapor.

Abstract: Thermal cracking in a riser cracking, closed cyclone, fluidized catalytic cracking process is reduced. A snorkel or flow conduit having an inlet just above the catalyst stripper moves stripper vapor into the closed cyclone. The system preferably operates without a stripper cap, relying on fluid dynamics to isolate stripper vapor from upper parts of the vessel containing the riser outlet. Preferably the snorkel is at least partially supported by, and ideally is inside, the primary cyclone dipleg. Reduced residence time of stripper vapor in the vessel containing the stripper and the closed cyclone system reduces thermal cracking of stripper vapor.

Abstract: A nozzle, and hydrocarbon conversion process using the nozzle for atomizing heavy feed to conversion zone, are disclosed. A liquid feed stream is atomized by radial out-to-in impingement of atomizing vapor, discharged onto an imperforate central region of a perforated plate in one end of a nozzle barrel, then sprayed through an outlet in the other end of the nozzle barrel. Preferably two perforate plates are used, a first at one end of the nozzle barrel and a second between the first plate and the outlet, which is preferably an elliptical orifice.

Abstract: Crystalline materials having increased mechanical strength and improved chemical properties are provided by incorporating carbonate by contact treatment with carbon dioxide (CO.sub.2) to modify the alkaline earth oxide morphology. Alkaline earth-containing particulate solids are stabilized in the crystalline oxide structure, preferrably with dense phase or supercritical CO.sub.2. Typical industrial applications include particulate contact solids, catalysts, binders and monolithic structures.

Abstract: A nozzle, and hydrocarbon conversion process using the nozzle for atomizing heavy feed to conversion zone, are disclosed. A liquid feed stream is atomized by radial out-to-in impingement of atomizing vapor, discharged onto an imperforate central region of a perforated plate in one end of a nozzle barrel, then sprayed through an outlet in the other end of the nozzle barrel. Preferably two perforate plates are used, a first at one end of the nozzle barrel and a second between the first plate and the outlet, which is preferably an elliptical orifice.

Abstract: An apparatus for multistage, hot stripping of spent FCC catalyst in a regenerator having a stripper supported by the regenerator is disclosed. A secondary stripper, under the conventional primary stripper, is heated indirectly by immersion in a dense bed of hot regenerated catalyst, or heat exchange with a dilute phase transport riser encompassing the primary stripper standpipe and secondary stripper, or by direct contact heat exchange with added hot regenerated catalyst. Vapor from the secondary stripper passes through the primary stripper without contacting spent catalyst in the primary stripper.

Abstract: A low sulfur gasoline of relatively high octane number is produced from a catalytically cracked, sulfur-containing naphtha by hydrodesulfurization followed by octane enhancing treatment in a fluidized bed catalytic process, in the presence of an aromatics-rich feedstream. The process converts the hydrodesulfurized intermediate and the aromatics-rich feedstream to a gasoline boiling range fraction of high octane number. The fluidized bed catalytic process is carried out over zeolite catalyst particles in a turbulent reactor bed at a temperature of about 600.degree. to 800.degree. F. (316.degree. to 427.degree. C.) and pressure of about 100 to 250 psig (790 to 825 kPa. The catalyst has an apparent particle density of about 0.9 to 1.6 g/cm.sup.3 and a size range of about 1 to 150 microns, and average catalyst particle size of about 20 to 100 microns containing about 10 to 25 weight percent of fine particles having a particle size less than 32 microns.

Abstract: A method and system for cracking hydrocarbons and regeneration of the catalyst is described with particular emphasis directed to partially restoring the activity of the catalyst after an initial hydrocarbon conversion use by heat soaking the catalyst at an elevated temperature before use in a second hydrocarbon conversion zone.This case is a division of application Ser. No. 595,833, filed Jul. 14, 1975.

Abstract: An inertial/filtering separator in a single vessel and FCC process using same as a third stage separator are disclosed. Gas and fines are added tangentially to an annulus formed by a cylindrical insert in a vessel. Gas flows over the insert and down to filters in the vessel. Solids are withdrawn from the base of the annulus and periodically from the filter. Three types of solids collection--inertial, gravity settling and filtration--are practiced in a single vessel.

Abstract: A process for multi-stage catalytic cracking is disclosed. A first stage cracks a first feed at atmospheric to 100 psig over a shape selective zeolite to convert from 10 to 90%, by volume, to lighter products rich in iso-compounds which may be used to make ethers. A second feed, which may include 700.degree. F.+ liquid from the selective cracking reaction, is cracked in a catalytic cracking (FCC) unit. Preferably all or some of the products from the shape selective cracking reactor are fractionated in the FCC main column.

Abstract: Low sulfur gasoline of relatively high octane number is produced from a catalytically cracked, sulfur-containing naphtha and benzene-rich fraction by hydrodesulfurization in a first reaction zone and treatment over an acidic catalyst, preferably an intermediate pore size zeolite such as ZSM-5 in a second reaction zone to reduce the octane loss which takes place as a result of the hydrodesulfurization. The benzene-rich fraction can be cofed to the first reaction zone or the second reaction zone. The benzene-rich fraction is preferably a heart-cut reformate.

Abstract: A process and apparatus for low cracking or recracking of liquid hydrocarbons with FCC catalyst containing 0.2 to 1.5 wt % coke is disclosed. FCC naphtha, or a thermally or hydrocracked naphtha, contacts spent FCC catalyst in a naphtha recracking reactor for limited conversion to lighter products and an increase in octane number. Spent catalyst from the recracking reactor can be recycled to the FCC reactor without stripping or regeneration. Naphtha recracking products are preferably cooled, then used as an absorbent to recover gasoline boiling range products from the FCC main column overhead vapor. Use of spent catalyst and controlled conversion conditions minimizes overcracking of the light liquid and minimizes formation of heavy ends.

Abstract: A multistage catalytic reactor system for preparing ethers such as methyl t-butyl (MTBE) and t-amyl methyl ether (TAME) from iso-olefin and methanol, comprising a first reactor for contacting the iso-olefin and alcohol with a solid regenerable catalyst, such as medium-pore zeolite conversion catalyst for partial conversion of the iso-olefin and methanol to an unsymmetrical ether, operatively connected for feeding effluent from the first reactor to a second etherification reaction zone containing sensitive catalyst, such as macroreticular polystyrenesulfonic acid resin. In a preferred embodiment, the second reaction zone comprises an inlet means for receiving withdrawn intermediate product, a catalytic distillation column containing solid acid resin etherification catalyst in a plurality of fixed bed catalysis-distillation zones, and outlet means for withdrawing a final etherification product.

Abstract: A process and apparatus for regeneration of spent FCC catalyst in a bubbling bed regenerator having a stripper mounted over the regenerator. Spent catalyst is regenerated in a fast fluidized bed coke combustor heated by direct contact heat exchange with catalyst recycled to the coke combustor via an internal "trough" trap. Catalyst recycle flow to the combustor is controlled by varying gas flow in the trough trap.

Abstract: A process is disclosed for upgrading reformate and/or light FCC gasoline by substantially reducing the amount of benzene in the gasoline product while simultaneously reducing the gasoline ASTM distillation End Point. The process comprises the fractionation of reformate to recover that fraction, C.sub.7 -C.sub.8 hydrocarbons, directly useful in gasoline without further conversion. A heavy bottom fraction comprising C.sub.9 + aromatic and non-aromatic hydrocarbons is recovered and a C.sub.6 fraction rich in benzene. The total C.sub.6 fraction and a portion of the C.sub.9 + fraction are converted by alkylation, transalkylation and cracking in contact with acidic metallosilicate catalyst particles to gasoline boiling range materials rich in alkylaromatics. Following debutanization or depentanization of the conversion product, the fraction containing unconverted benzene is recycled to the reformate fractionator.

Abstract: A process and apparatus for increasing the coke burning capacity of FCC catalyst regenerators is disclosed. An auxiliary regenerator receives spent catalyst from an FCC stripper and burns some of the coke at turbulent or fast fluidized bed conditions. Partially regenerated catalyst and flue gas enter a low pressure drop cyclone discharging more than 90% of the partially regenerated catalyst down into a bubbling or fast fluidized bed in the primary regenerator. Flue gas from the auxiliary regenerator is discharged into the dilute phase above the bed in the primary regenerator. Catalyst entrainment from the fluidized bed in the primary regenerator may be reduced because less combustion air is needed as a result of partial regeneration in the auxiliary regenerator. Reduced NOx and dust emissions, and/or increased coke burning capacity, may be achieved, especially when a bubbling dense bed primary catalyst regenerator is used.

Abstract: A process is disclosed for enhancing the alkylation conversion rate of a benzene-rich gasoline boiling range hydrocarbon feedstream alkylated with C.sub.2 -C.sub.5 olefins. The process comprises contacting the benzene-rich stream and olefins sequentially in decreasing order of olefin oligomerization activity comprising a first contact with C.sub.3 -C.sub.5 olefins followed by contact with C.sub.2 olefin, preferably at different points of an alkylation zone containing solid, shape selective aluminosilicate catalyst particles under benzene alkylation conditions. Gasoline is produced having a reduced benzene content.

Abstract: A process for multistage regeneration of spent FCC catalyst in an "Orthoflow" or stacked FCC unit having a stripper mounted over the regenerator. Spent catalyst is discharged into a fast fluidized bed coke combustor heated by direct contact heat exchange with catalyst and large particles or beads of CO combustion promoter. The large particle CO combustion promoter is trapped in the coke combustor, to permit complete CO combustion, with limited coke combustion.

Abstract: A layered catalyst contains a core of at least one, and preferably three, molecular sieve components within a shell layer of reduced molecular sieve content. A preferred catalyst consists of a core of a large pore molecular sieve, preferably a dealuminized Y-type zeolite, a shape selective paraffin cracking/isomerization component, preferably HZSM-5, and a shape selective aliphatic aromatization component, preferably gallium ZSM-5, within a shell of an alumina-rich, matrix. The shell can capture metals from the feeds being processed, it can act as a metals sink, and can remove metals form the unit by attrition. The catalyst is preferably prepared by forming the core and then coating or encapsulating the core with a shell having a reduced molecular sieve content. The shell may contain a pillared clay or other very large pore cracking component. The shell may be an attritable coating of an amorphous rare earth oxide, aluminum oxide and aluminum phosphate composite, which traps metals.