Abstract: A process for demetallizing metals contaminated FCC catalyst in an FCC regenerator. A metals getter additive, with higher settling velocity, is added to the regenerator, to remove metals from FCC catalyst by solid-solid interaction. The FCC catalyst forms a light, discrete, dense phase fluidized bed on top of a fluidized bed of additive. FCC catalyst is recycled to the cracking reactor from the top fluidized bed, while additive can be withdrawn from the lower fluidized bed for disposal or for metals recovery and recycle. Additive can be optimized for metals removal and will not dilute the cracking catalyst in the FCC reactor.

Abstract: A fluidized catalytic cracking process operates with a turbulent or fast fluidized bed (FFB) spent catalyst stripper. Higher vapor velocities in the stripper improve stripping. Preferably spent catalyst is added to the stripper via cyclone diplegs. Preferably most of the spent catalyst is added into the bed near the top of the FFB stripper is removed via the top of the stripper, to a contiguous, annular bubbling dense bed stripper surrounding the FFB stripper. Some catalyst may be removed from the base of the FFB stripper.

Abstract: A process and apparatus for achieving turbulent or fast fluidized bed regeneration of spent FCC catalyst in a bubbling bed regenerator having a stripper mounted over the regenerator and a stripped catalyst standpipe within the regenerator. A coke combustor vessel, which may be partially or totally open to the dilute phase above the bubbling bed, is added to the existing regenerator vessel Spent catalyst is discharged into the coke combustor, regenerated in a turbulent or fast fluidized bed, then discharged into the dilute phase region above the bubbling bed, either via a deflector or by simply overflowing the combustor. Regeneration of catalyst is completed in the bubbling dense bed, and/or an annular fast fluidized bed surrounding the coke combustor. Catalyst may be recycled from the dense bed to the coke combustor either by a flow line, or by adjusting relative heights of bubbling to fast fluidized bed.

Abstract: A continuous process for converting lower aliphatic alkanol and light olefinic hydrocarbon feedstock rich in tertiary olefins, such as isobutylene and other C.sub.4 isomeric hydrocarbons, to alkyl tertiary-alkyl ethers and C.sub.5 + gasoline boiling range hydrocarbons.

Abstract: A fluidized catalytic cracking process and apparatus operates with a single or multi- stage refluxed catalyst stripper. Recycle, or reflux, of stripped catalyst to the stripping zone improves stripping. Preferably, a two stage hot stripper is used. Addition of regenerated catalyst to spent catalyst from the reactor heats spent catalyst in a first stripping stage, which preferably uses stripping steam. Catalyst from the first stripping stage passes up through a second stage stripping zone with a heat removal means, e.g., a stab-in tube bundle. Steam or flue gas fluidizes catalyst, improves heat transfer and strips the catalyst. Some catalyst from the second stage stripper is preferably recycled to the inlet to the first stripping stage. Additional hot regenerated catalyst may be added downstream of the first catalyst stage to heat the second stripping stage, added to catalyst removed from the primary stripping zone which is sent to the regeneration zone.

Abstract: A process is disclosed for the production of tertiary alkyl ethers wherein linear olefins, particularly n-butene, are isomerized in the vapor phase at high temperature in contact with shape selective metallosilicate catalyst to produce iso-olefin vapor, particularly isobutene. The vaporous iso-butene is then etherified with alkanol to provide alkyl tert-alkyl ether such as MTBE. Unreacted iso-olefin and/or linear olefin and product ether are separated by fractionation and unreacted olefin components recycled. Fractionation of the vapor phase etherification product is carried out by using the fresh liquid linear olefin feedstream as a reflux stream to the fractionator.

Abstract: The present invention discloses a process for increasing the selectivity of the production of isobutylene in an admixture of C.sub.4 olefins, in a process comprising producing isobutylene, with high selectivity, comprising catalytically producing a first composition comprising at least one C.sub.4 olefin selected from the group consisting of 1-butene, cis-2-butene, trans-2-butene, admixtures thereof and 2-methylpropene admixed with at least one of said 1-butene, cis-2-butene, and trans-2-butene, by passing paraffin containing feed, which feed is free of aromatics, and in which the paraffin contains 5 to 20 carbon atoms, in the vapor phase, over a first catalyst composition, wherein the catalyst comprises ZSM-5 or ZSM-12, and increasing the isobutylene content of the first composition by producing a second composition, by contacting the first composition with a second catalyst composition comprising ZSM-23 under conditions in which the second composition is in the vapor phase, while maintaining the total C.

Abstract: The invention relates to improving the selectivity of the production of isobutylene or 2-methylpropene during fluid catalytic cracking of heavy C.sub.9 + aromatic containing feeds including resids and/or gas oils by employing two catalyst components, one of which comprises ZSM-23, ZSM-22, ZSM-35 or similarly structured catalysts and the other catalyst component being effective under the fluid catalytic cracking conditions to produce high octane gasoline.

Abstract: An improved process is disclosed for the acid catalyzed production of DIPE from propene and water feedstreams that eliminates the propene recycle stream to the olefin hydration reactor and achieves high propene conversion. The accomplishment is achieved by carrying out the hydration and etherification reactions in two stages wherein the first stage comprises a zeolite catalyzed hydration and etherification of propene employing a minimum of water feed. The second stage converts unconverted propene from the first stage reactor by hydration and etherification to DIPE in contact with an acidic catalyst, preferably acidic resin, and an excess of water. Isopropanol (IPA) from both the first and second stage reactor is recovered as an aqueous azeotrope by a combination of distillation and extraction steps and the azeotrope is recycled to the first stage reactor.

Abstract: A process and apparatus for simultaneously heating and cooling of spent FCC catalyst during regeneration in a high efficiency FCC regenerator, one using a fast fluidized bed coke combustor. The coke combustor burns coke from spent catalyst in a turbulent or fast fluidized bed, and discharges catalyst and flue gas up into a dilute phase transport riser. Catalyst is separated into flue gas and a bubbling dense bed of catalyst. The coke combustor is heated by recycling hot catalyst from the bubbling dense bed and simultaneously cooled by a backmixed heat exchanger. Catalyst flows from the combustor to the cooler and is displaced back into the combustor by adding air to the catalyst in the cooler. Heating promotes rapid coke combustion, while cooling reduces thermal and hydrothermal deactivation of the spent catalyst.

Abstract: The invention provides a substantially fail-safe HF alkylation process and reactor apparatus. The elongated reactor vessel is enclosed in a subterranean well casing and an alkylate-containing hydrocarbon layer is maintained above the hydrofluoric acid to prevent release of gaseous HF in the event of sudden depressurization. In a preferred embodiment, the hydrocarbon layer contains light hydrocarbons which vaporize upon depressurization to effect Joule-Thompson cooling of the reactor vessel.

Abstract: The invention provides a substantially fail-safe HF alkylation process and reactor apparatus. The elongated reactor vessel is enclosed in a well casing and an alkylate-containing hydrocarbon layer is maintained above the hydrofluoric acid to prevent release of gaseous HF in the event of sudden depressurization. In a preferred embodiment, the hydrocarbon layer contains light hydrocarbons which vaporize upon depressurization to effect Joule-Thompson cooling of the reactor vessel. A method for storing hazardous liquids and a penetration-resistant storage tank are also disclosed.

Abstract: A process and apparatus for fluidized catalytic cracking of heavy oils are disclosed. Quenching and cyclone separation are done in the transfer line to the main distillation column. Quenching hot vapor from the reactor, preferably with liquid recycled from the main column, improves yields, prevents coking in the transfer line and permits higher cracking reactor temperatures. Cyclone separation of quench and/or condensed liquid prevents slugging, or two phase flow, in the transfer line. Some rough-cut fractionation can be achieved in the cyclone separator. Steam stripping of cyclone liquid optimizes operation of the main column.

Abstract: A process and apparatus for fluidized catalytic cracking of heavy oils is disclosed using a modified high efficiency catalyst regenerator. A fast fluidized bed coke combustor, which is essentially free of gas/catalyst separation means, partially regenerates catalyst and discharges a steam laden flue gas and catalyst into a dilute phase transport riser. Closed cyclones separate catalyst from steam laden flue gas exiting the transport riser outlet. This flue gas is isolated from a second fluidized bed of catalyst maintained in a vessel containing the transport riser and closed cyclones. Coke combustion in the drier region of the second fluidized bed is possible. Catalyst deactivates less in the second fluidized bed because it is drier.

Abstract: A layered catalyst suited to the catalytic cracking of heavy feeds comprises a core and a shell. The shell comprises at least 5 wt % of at least 1 molecular sieve having openings of at least 8 angstroms. The core comprises at least 10 wt % of at least 1 molecular sieve having openings comprising a 12 or less-membered ring and has a reduced, if any, content of said molecular sieve having openings of at least 8 angstroms, relative to its concentration in the shell. Suitable molecular sieve materials having openings of at least 8 angstroms include MCM-41, VPI-5, MCM-9 and layered metal oxides, e.g., pillared clays. The required molecular sieve of the core can include zeolite Y, Ultrastable Y or intermediate pore size zeolites such as ZSM-5. The shell which may further contain a metals passivator can act as a metals sink, and can remove metals from the unit by attrition. The catalyst is preferably prepared by forming the core and then coating or encapsulating the core with a shell material.

Abstract: A technique for converting olefinic light hydrocarbons rich in butenes and butanes to ether-rich liquid fuels including etherification and transhydrogenation operations. The preferred process includes: reacting a mixed C4 hydrocarbon stream containing isobutene and n-butenes with lower aliphatic alcohol in an etherification zone in contact with an acidic etherification catalyst under etherification conditions whereby an effluent stream containing C5+ tertiary-alkyl ether is produced; separating the etherification effluent stream to provide a liquid stream comprising C5+ ether and an olefinic stream comprising unreacted C4 hydrocarbons; contacting at least the n-butenes from the C.sub.

Abstract: An integrated reactor system for converting methanol or the like to ether and gasoline hydrocarbons. Alcohol feedstock containing water is extracted with olefinic liquid and reacted catalytically to produce tertiary ether. Unreacted alcohol and olefin vapor separated from etherification effluent is converted along with aqueous alcoholic raffinate in a zeolite catalysis step to produce gasoline and paraffinic intermediate. By dehydrogenating the C.sub.3 -C.sub.5 paraffins, an olefinic liquid rich in isoalkenes is obtained for recycle to the extractor as solvent for alcohol feedstock.

Abstract: A multistage process for etherifying C.sub.4.sup.+ aliphatic hydrocarbon feedstock containing isoalkane including the step of contacting the hydrocarbon feedstock with dehydrogenation catalyst at elevated temperature under dehydrogenation reaction conditions to obtain C.sub.4.sup.+ isoalkene and hydrogen, and separating dehydrogenation effluent to obtain an olefinic stream rich in isoalkene and a hydrogen stream.The olefinic stream and aliphatic alcohol are contacted in an esterification stage under partial etherification conditions with a regenerable inorganic metal oxide acid solid catalyst to convert a major amount of the isoalkene to C.sub.5.sup.+ tertiary-alkyl ether.

Abstract: A process and apparatus for fluidized bed catalyst regeneration. A mixture of spent catalyst, recycled hot regenerated catalyst and regeneration gas are charged to a riser having an outlet connective with a coke combustor immersed in a fluidized bed of catalyst. The coke combustor outlet is covered by the dense phase fluidized bed. Additional combustion air may be added to the fluidized bed of catalyst covering the coke combustor outlet for additional catalyst regeneration. Indirect heat exchange may heat spent catalyst in the riser and/or the coke combustor.

Abstract: In the diisopropyl ether production process, the distallation step for the separation of aqueous IPA recovered from the DIPE extraction operations is modified to avoid carrying out the distillation under conditions that yield IPA-water azeotrope providing lower overall process cost. The determination has been made that the overhead and bottom streams form an aqueous IPA fractionation process operated under off-azeotrope conditions in DIPE production can be recycled, respectively, to the DIPE reactor and extractor operations. Recycling the water and IPA overhead mixture eliminates the requirement for adding fresh water to the DIPE reactor. Returning the water and IPA bottom stream to the extractor reduces the requirement for distilled water addition to the extraction step. As a consequence, a less complex and costly aqueous IPA separation process is implemented.