Abstract: An integrated process is disclosed that substantially reduces the cost of producing MTBE and other alkyl tertalkyl ethers by eliminating a major portion of the equipment and operating costs associated with the downstream processing of the etherification reactor effluent. The integrated process combines the process for the etherification of iso-olefins and methanol, or other alkanols, to produce methyl tertiary alkyl ethers such as MTBE and/or TAME with the catalytic process for converting feedstock such as oxygenates, light olefins and paraffins to higher molecular weight hydrocarbons. Unconverted reactants from the etherification reaction, which may comprise unreacted alkanol and unreacted hydrocarbons or just unreacted hydrocarbons, are separated from the product ethers and passed to the catalytic conversion process reactor for conversion to gasoline boiling range hydrocarbons.

Abstract: A process for upgrading olefin feedstock containing a mixture of iso-olefin and linear olefin to produce tertiary-alkyl ether and high octane gasoline components comprising dimerized iso-olefin. Product recovery is integrated between primary and secondary reaction stages.In a preferred embodiment, a two stage etherification process employs a secondary solid acid regenerable catalyst bed to dimerize unconverted iso-butene in the debutanizer overhead stream of a conventional MTBE primary reactor stage. Both stages can utilize a regenerable acid catalyst such as ZSM-5 or Zeolite Beta for etherification and to upgrade unconverted alkenes and methanol from the primary stage.

Abstract: A process for controlled, multi-stage regeneration of FCC catalyst is disclosed. A modified high efficiency catalyst regenerator, with a fast fluidized bed coke combustor, dilute phase transport riser, and second fluidized bed regenerates the catalyst in at least two stages. The primary stage of regeneration is in the coke combustor. Second stage catalyst regeneration occurs in the second fluidized bed. The amount of combustion air added to, and conditions in, the coke combustor are controlled to limit CO combustion, while the second stage of regeneration, in the second fluidized bed, achieves complete CO combustion. Controlled multi-stage regeneration reduces steaming or deactivation of catalyst during regeneration, increase coke burning capacity, and reduces NOx emissions.

Abstract: A process and apparatus for controlled, multi-stage regeneration of FCC catalyst is disclosed. A modified high efficiency catalyst regenerator, with a fast fluidized bed coke combustor, dilute phase transport riser, and second fluidized bed regenerates the catalyst in at least two stages. The primary stage of regeneration is in the coke combustor. Second stage catalyst regeneration occurs in the second fluidized bed. The amount of combustion air added to both regeneration stages is set to maintain partial CO combustion in both stages. Controlled multi-stage regeneration reduces the steaming or deactivation of catalyst during regeneration, maximizes coke burning capacity of the regenerator, and minimizes or eliminates NOx emissions.

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 from 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.

Abstract: An oligomerization system is provided for upgrading lower olefins to distillate hydrocarbons, especially useful as high quality jet or diesel fuels. The olefinic feedstock is reacted over a shape selective acid zeolite, such as ZSM-5, to oligomerize feedstock olefins and further convert recycled hydrocarbons. Reactor effluent is fractionated to recover a light-middle distillate range product stream and to obtain gasoline and heavy hydrocarbon streams for recycle.

Abstract: A process and apparatus for fluidized catalytic cracking of heavy oils is disclosed. The long transfer line connecting the catalytic cracking reactor to the main fractionator is modified to include a cooling means, such as a quench drum or a heat exchanger. Cooling hot cracked products from the FCC reactor upstream of the main fractionator prevents thermal cracking in the transfer line, improves yields, and permits higher catalytic cracking reactor temperatures.

Abstract: A process 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: An improved reactor system reacts crude aqueous methanol feedstock with iso-olefinic hydrocarbons to produce C.sub.5.sup.+ methyl t-alkyl ethers. The system includes an extractor for contacting the aqueous methanol feedstock with a liquid hydrocarbon extraction solvent rich in C.sub.4.sup.+ isoalkene. Both an organic extract phase and an aqueous methanol raffinate phase recovered from the extractor and fed to a primary reactor. This primary reactors reacts the methanol and C.sub.4.sup.+ isoalkene from the organic extract phase under catalytic conditions to produce an ether product. The ether product is fed to an etherification effluent fractionator to separate the ether product from unreacted methanol and C.sub.4.sup.+ isoalkene. A secondary reactor then converts methanol from the aqueous methanol raffinate phase with the unreacted methanol and C.sub.4.sup.+ isolakene to produce hydrocarbons.

Abstract: An improved olefin upgrading technique and fixed-bed reactor system has been developed for increasing production of premium heavy hydrocarbons, such as distillate fuel, from lower olefinic feedstock. During recovery and recycle of intermediate range hydrocarbons products, a technique has been found for withdrawing a fraction rich in C.sub.5 -C.sub.9 gasoline range olefinic hydrocarbons from the oligomerization reactor effluent stream. By separating the reaction effluent in a multi-stage distillation system, fractionation feed can be separated into a heavier bottoms stream rich in C.sub.10 + hydrocarbons and a light hydrocarbon overhead, while withdrawing a liquid stream as an overflash fractionation stream rich in intermediate hydrocarbons. The overflash stream is combined to form a portion of the recycle stream to the reactor, thereby providing a more efficient and lower cost recovery process.

Abstract: A catalytic cracking catalyst and process are disclosed using a catalyst containing: a matrix, a large pore molecular sieve, a shape selective paraffin cracking/isomerization zeolite and a shape selective aliphatic aromatization zeolite. An exemplary catalyst comprises dealuminized zeolite Y, optionally containing rare earth elements, HZSM-5, and gallium ZSM-5 in a matrix. The matrix contains and protects the relatively fragile zeolite components and acts as a sodium and metals sink. The large pore molecular sieve cracks large hydrocarbons to lighter paraffins and olefins. The shape selective paraffin cracking/isomerization component cracks/isomerizes the paraffins produced by the large pore molecular sieve. The shape selective aliphatic aromatization catalyst converts light paraffins and olefins into aromatics. A single shape selective zeolite, e.g., ZSM-5 with a controlled amount of an aromatization component such as gallium, may promote both paraffin cracking/isomerization and aromatization.

Abstract: A catalytic cracking catalyst mixture and process are disclosed. The mixture comprises (a) a cracking catalyst containing a matrix and a large pore molecular sieve and (b) separate additive catalysts comprising at least one of a shape selective paraffin cracking/isomerization zeolite and a shape selective aliphatic aromatization zeolite. An exemplary catalyst mixture comprises dealuminized zeolite Y, optionally containing rare earth elements in an alumina-rich matrix, an additive catalyst of HZSM-5 in a matrix, and an additional additive catalyst of gallium ZSM-5 in a matrix. The alumina-rich matrix of the cracking catalyst acts a a sodium and metals sink. The large pore molecular sieve catalyst cracks large hydrocarbons to lighter paraffins and olefins. The shape selective paraffin cracking/isomerization component cracks/isomerizes the paraffins produced by the large pore moleular sieve. The shape selective aliphatic aromatization catalyst converts light paraffins and olefins into aromatics.

Abstract: Disclosed is a method and apparatus for fluid catalytic cracking (FCC). The output of a reactor riser zone is fed to a riser cyclone separator, a primary cyclone separator, and secondary cyclone separators, connected in series within a single reactor vessel. The riser cyclone separator is connected to the primary cyclone separator by a conduit, which prevents random post-riser thermal cracking of the hydrocarbons after they exit the riser cyclone separator. The conduit contains an annular port to allow strippping gas to enter the conduit to improve the separator of hydrocarbons from catalyst. Catalyst separated in the riser cyclone separator drops through a riser cyclone dipleg and passes through a dipleg seal which comprises a seal pot or catalyst held around the dipleg. The conduit is formed by two overlapping parts, one having a larger diameter than the other to form the annular port and packing or spacers may be used to align and space the overlapping parts.

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: An improved fluid-bed reaction apparatus is disclosed in which feedstock is preheated and may be at least partially converted by contacting the feedstock with spent catalyst in a preheat zone. Additional benefits include a reduction in catalyst poisons and coke production in the reaction zone. By contacting the fresh feed with hot spent catalyst, at least a portion of the coke which would otherwise form in the reactor is deposited on the spent catalyst. Temporary catalyst poisons are also sorbed onto the spent catalyst. The spent catalyst is then withdrawn from the preheat zone, stripped of entrained hydrocarbon and regenerated.

Abstract: An improved reactor system for hydrocarbon processing, employing an external catalyst cooler ("ECC") for dehydrogenating and cracking an alkane stream by contacting it with a fluid catalytic cracking ("FCC") catalyst to produce olefins. Advantageously, these olefins are then oligomerized to gasoline in a single zone of a fluid bed crystalline zeolite oligomerization catalyst, the bed operating in the turbulent regime.

Abstract: 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 dehydrogating 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 process and apparatus are disclosed 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 closed coke combustor vessel is added alongside an existing regenerator vessel, and spent catalyst is discharged into a transfer pot beneath the existing dense bed, then into the coke combustor. Catalyst is regenerated in a turbulent or fast fluidized bed, and discharged into the dilute phase region above the existing bubbling dense bed. The discharge line preferably encompasses, and is in a heat exchange relationship with, the spent catalyst standpipe. Discharge catalyst is collected in the bubbling dense bed surrounding the coke combustor, and may be given an additional stage of regeneration. Catalyst may be recycled from the dense bed to the transfer pot.

Abstract: A reactor system for increased production of olefinic gasoline incorporating the integration of olefins to gasoline conversion under moderate severity conditions in contact with medium pore catalyst with oxygenates to olefin conversion. The effluent product of the olefins to olefin conversion is passed to an olefins to gasoline and/or distillate (MOGD) conversion zone for olefin upgrading. Liquid recycle requirements, feed throughput and/or the number of MOGD fixed bed stages are reduced for the MOGD process and overall process costs are lowered. The process includes the use of common catalyst handling and regeneration steps for the integrated processes.

Abstract: Process for the continuous conversion of light olefin gas feed containing ethene, propene and butene to produce heavier hydrocarbons by contacting the light olefin feed in a fluidized bed reaction zone with a medium pore molecular sieve zeolite catalyst under oligomerization conditions to convert the light olefin feed to heavier hydrocarbons. The catalytic reaction causes the conversion of the light olefins to heavier hydrocarbons, the deposition of coke by-product on the catalyst and the absorption of hydrocarbon product on the catalyst. The deposited coke causes the partial deactivation of the catalyst. A portion of the partially deactivated catalyst containing deposited coke and absorbed hydrocarbon product is continuously withdrawn from the reaction zone and transferred to a catalyst stripping zone in which the catalyst is contacted with an inert stripping gas to remove the absorbed hydrocarbons from the catalyst.