Abstract: Apparatus and processes herein provide for converting hydrocarbon feeds to light olefins and other hydrocarbons. The processes and apparatus include, in some embodiments, feeding a hydrocarbon, a first catalyst and a second catalyst to a reactor, wherein the first catalyst has a smaller average particle size and is less dense than the second catalyst. A first portion of the second catalyst may be recovered as a bottoms product from the reactor, and a cracked hydrocarbon effluent, a second portion of the second catalyst, and the first catalyst may be recovered as an overhead product from the reactor. The second portion of the second catalyst may be separated from the overhead product, providing a first stream comprising the first catalyst and the hydrocarbon effluent and a second stream comprising the separated second catalyst, allowing return of the separated second catalyst in the second stream to the reactor.

Abstract: Apparatus and processes herein provide for converting hydrocarbon feeds to light olefins and other hydrocarbons. The processes and apparatus include, in some embodiments, feeding a hydrocarbon, a first catalyst and a second catalyst to a reactor, wherein the first catalyst has a smaller average particle size and is less dense than the second catalyst. A first portion of the second catalyst may be recovered as a bottoms product from the reactor, and a cracked hydrocarbon effluent, a second portion of the second catalyst, and the first catalyst may be recovered as an overhead product from the reactor. The second portion of the second catalyst may be separated from the overhead product, providing a first stream comprising the first catalyst and the hydrocarbon effluent and a second stream comprising the separated second catalyst, allowing return of the separated second catalyst in the second stream to the reactor.

Abstract: A feed injector may have a body having an outer wall and an inner wall with a first conduit formed between the outer wall and the inner wall. The first conduit is configured to receive a atomizing gas. Additionally, a second conduit may be formed by the inner wall, and the second conduit is configured to receive a liquid. The first conduit and the second conduit are separated by the inner wall. Further, a mixing chamber may be provided at an outlet of the first conduit and an outlet of the second conduit. The atomizing gas from the first conduit and the liquid from the second conduit hit and/or mix together in the mixing chamber to form liquid droplets and a mixture of the atomizing gas and the liquid. Furthermore, a flow cone may have a first end in the second conduit and a second end in the mixing chamber.

Abstract: Apparatus and processes herein provide for converting hydrocarbon feeds to light olefins and other hydrocarbons. The processes and apparatus include, in some embodiments, feeding a hydrocarbon, a first catalyst and a second catalyst to a reactor, wherein the first catalyst has a smaller average particle size and is less dense than the second catalyst. A first portion of the second catalyst may be recovered as a bottoms product from the reactor, and a cracked hydrocarbon effluent, a second portion of the second catalyst, and the first catalyst may be recovered as an overhead product from the reactor. The second portion of the second catalyst may be separated from the overhead product, providing a first stream comprising the first catalyst and the hydrocarbon effluent and a second stream comprising the separated second catalyst, allowing return of the separated second catalyst in the second stream to the reactor.

Abstract: Apparatus and processes herein provide for converting hydrocarbon feeds to light olefins and other hydrocarbons. The processes and apparatus include, in some embodiments, feeding a hydrocarbon, a first catalyst and a second catalyst to a reactor, wherein the first catalyst has a smaller average particle size and is less dense than the second catalyst. A first portion of the second catalyst may be recovered as a bottoms product from the reactor, and a cracked hydrocarbon effluent, a second portion of the second catalyst, and the first catalyst may be recovered as an overhead product from the reactor. The second portion of the second catalyst may be separated from the overhead product, providing a first stream comprising the first catalyst and the hydrocarbon effluent and a second stream comprising the separated second catalyst, allowing return of the separated second catalyst in the second stream to the reactor.

Abstract: Apparatus and processes herein provide for converting hydrocarbon feeds to light olefins and other hydrocarbons. The processes and apparatus include, in some embodiments, feeding a hydrocarbon, a first catalyst and a second catalyst to a reactor, wherein the first catalyst has a smaller average particle size and is less dense than the second catalyst. A first portion of the second catalyst may be recovered as a bottoms product from the reactor, and a cracked hydrocarbon effluent, a second portion of the second catalyst, and the first catalyst may be recovered as an overhead product from the reactor. The second portion of the second catalyst may be separated from the overhead product, providing a first stream comprising the first catalyst and the hydrocarbon effluent and a second stream comprising the separated second catalyst, allowing return of the separated second catalyst in the second stream to the reactor.

Abstract: Apparatus and processes herein provide for converting hydrocarbon feeds to light olefins and other hydrocarbons. The processes and apparatus include, in some embodiments, feeding a hydrocarbon, a first catalyst and a second catalyst to a reactor, wherein the first catalyst has a smaller average particle size and is less dense than the second catalyst. A first portion of the second catalyst may be recovered as a bottoms product from the reactor, and a cracked hydrocarbon effluent, a second portion of the second catalyst, and the first catalyst may be recovered as an overhead product from the reactor. The second portion of the second catalyst may be separated from the overhead product, providing a first stream comprising the first catalyst and the hydrocarbon effluent and a second stream comprising the separated second catalyst, allowing return of the separated second catalyst in the second stream to the reactor.

Abstract: A feed injector may have a body having an outer wall and an inner wall with a first conduit formed between the outer wall and the inner wall. The first conduit is configured to receive a atomizing gas. Additionally, a second conduit may be formed by the inner wall, and the second conduit is configured to receive a liquid. The first conduit and the second conduit are separated by the inner wall. Further, a mixing chamber may be provided at an outlet of the first conduit and an outlet of the second conduit. The atomizing gas from the first conduit and the liquid from the second conduit hit and/or mix together in the mixing chamber to form liquid droplets and a mixture of the atomizing gas and the liquid. Furthermore, a flow cone may have a first end in the second conduit and a second end in the mixing chamber.

Abstract: Systems for separating a contaminant trapping additive from a cracking catalyst may include a contaminant removal vessel having one or more fluid connections for receiving contaminated cracking catalyst, contaminated contaminant trapping additive, fresh contaminant trapping additive, and a fluidizing gas. In the contaminant removal vessel, the spent catalyst may be contacted with contaminant trapping additive, which may have an average particle size and/or density greater than the cracking catalyst. A separator may be provided for separating an overhead stream from the contaminant removal vessel into a first stream comprising cracking catalyst and lifting gas and a second stream comprising contaminant trapping additive. A recycle line may be used for transferring contaminant trapping additive recovered in the second separator to the contaminant removal vessel, allowing contaminant trapping additive to accumulate in the contaminant removal vessel.

Abstract: Apparatus and processes herein provide for converting hydrocarbon feeds to light olefins and other hydrocarbons. The processes and apparatus include, in some embodiments, feeding a hydrocarbon, a first catalyst and a second catalyst to a reactor, wherein the first catalyst has a smaller average particle size and is less dense than the second catalyst. A first portion of the second catalyst may be recovered as a bottoms product from the reactor, and a cracked hydrocarbon effluent, a second portion of the second catalyst, and the first catalyst may be recovered as an overhead product from the reactor. The second portion of the second catalyst may be separated from the overhead product, providing a first stream comprising the first catalyst and the hydrocarbon effluent and a second stream comprising the separated second catalyst, allowing return of the separated second catalyst in the second stream to the reactor.

Abstract: Apparatus and processes herein provide for converting hydrocarbon feeds to light olefins and other hydrocarbons. The processes and apparatus include, in some embodiments, feeding a hydrocarbon, a first catalyst and a second catalyst to a reactor, wherein the first catalyst has a smaller average particle size and is less dense than the second catalyst. A first portion of the second catalyst may be recovered as a bottoms product from the reactor, and a cracked hydrocarbon effluent, a second portion of the second catalyst, and the first catalyst may be recovered as an overhead product from the reactor. The second portion of the second catalyst may be separated from the overhead product, providing a first stream comprising the first catalyst and the hydrocarbon effluent and a second stream comprising the separated second catalyst, allowing return of the separated second catalyst in the second stream to the reactor.

Abstract: Apparatus and processes herein provide for converting hydrocarbon feeds to light olefins and other hydrocarbons. The processes and apparatus include, in some embodiments, feeding a hydrocarbon, a first catalyst and a second catalyst to a reactor, wherein the first catalyst has a smaller average particle size and is less dense than the second catalyst. A first portion of the second catalyst may be recovered as a bottoms product from the reactor, and a cracked hydrocarbon effluent, a second portion of the second catalyst, and the first catalyst may be recovered as an overhead product from the reactor. The second portion of the second catalyst may be separated from the overhead product, providing a first stream comprising the first catalyst and the hydrocarbon effluent and a second stream comprising the separated second catalyst, allowing return of the separated second catalyst in the second stream to the reactor.

Abstract: Apparatus and processes herein provide for converting hydrocarbon feeds to light olefins and other hydrocarbons. The processes and apparatus include, in some embodiments, feeding a hydrocarbon, a first catalyst and a second catalyst to a reactor, wherein the first catalyst has a smaller average particle size and is less dense than the second catalyst. A first portion of the second catalyst may be recovered as a bottoms product from the reactor, and a cracked hydrocarbon effluent, a second portion of the second catalyst, and the first catalyst may be recovered as an overhead product from the reactor. The second portion of the second catalyst may be separated from the overhead product, providing a first stream comprising the first catalyst and the hydrocarbon effluent and a second stream comprising the separated second catalyst, allowing return of the separated second catalyst in the second stream to the reactor.

Abstract: Apparatus and processes herein provide for converting hydrocarbon feeds to light olefins and other hydrocarbons. The processes and apparatus include, in some embodiments, feeding a hydrocarbon, a first catalyst and a second catalyst to a reactor, wherein the first catalyst has a smaller average particle size and is less dense than the second catalyst. A first portion of the second catalyst may be recovered as a bottoms product from the reactor, and a cracked hydrocarbon effluent, a second portion of the second catalyst, and the first catalyst may be recovered as an overhead product from the reactor. The second portion of the second catalyst may be separated from the overhead product, providing a first stream comprising the first catalyst and the hydrocarbon effluent and a second stream comprising the separated second catalyst, allowing return of the separated second catalyst in the second stream to the reactor.

Abstract: Systems for separating a contaminant trapping additive from a cracking catalyst may include a contaminant removal vessel having one or more fluid connections for receiving contaminated cracking catalyst, contaminated contaminant trapping additive, fresh contaminant trapping additive, and a fluidizing gas. In the contaminant removal vessel, the spent catalyst may be contacted with contaminant trapping additive, which may have an average particle size and/or density greater than the cracking catalyst. A separator may be provided for separating an overhead stream from the contaminant removal vessel into a first stream comprising cracking catalyst and lifting gas and a second stream comprising contaminant trapping additive. A recycle line may be used for transferring contaminant trapping additive recovered in the second separator to the contaminant removal vessel, allowing contaminant trapping additive to accumulate in the contaminant removal vessel.

Abstract: Apparatus and processes herein provide for converting hydrocarbon feeds to light olefins and other hydrocarbons. The processes and apparatus include, in some embodiments, feeding a hydrocarbon, a first catalyst and a second catalyst to a reactor, wherein the first catalyst has a smaller average particle size and is less dense than the second catalyst. A first portion of the second catalyst may be recovered as a bottoms product from the reactor, and a cracked hydrocarbon effluent, a second portion of the second catalyst, and the first catalyst may be recovered as an overhead product from the reactor. The second portion of the second catalyst may be separated from the overhead product, providing a first stream comprising the first catalyst and the hydrocarbon effluent and a second stream comprising the separated second catalyst, allowing return of the separated second catalyst in the second stream to the reactor.

Abstract: Apparatus and processes herein provide for converting hydrocarbon feeds to light olefins and other hydrocarbons. The processes and apparatus include, in some embodiments, feeding a hydrocarbon, a first catalyst and a second catalyst to a reactor, wherein the first catalyst has a smaller average particle size and is less dense than the second catalyst. A first portion of the second catalyst may be recovered as a bottoms product from the reactor, and a cracked hydrocarbon effluent, a second portion of the second catalyst, and the first catalyst may be recovered as an overhead product from the reactor. The second portion of the second catalyst may be separated from the overhead product, providing a first stream comprising the first catalyst and the hydrocarbon effluent and a second stream comprising the separated second catalyst, allowing return of the separated second catalyst in the second stream to the reactor.

Abstract: Systems for separating a contaminant trapping additive from a cracking catalyst may include a contaminant removal vessel having one or more fluid connections for receiving contaminated cracking catalyst, contaminated contaminant trapping additive, fresh contaminant trapping additive, and a fluidizing gas. In the contaminant removal vessel, the spent catalyst may be contacted with contaminant trapping additive, which may have an average particle size and/or density greater than the cracking catalyst. A separator may be provided for separating an overhead stream from the contaminant removal vessel into a first stream comprising cracking catalyst and lifting gas and a second stream comprising contaminant trapping additive. A recycle line may be used for transferring contaminant trapping additive recovered in the second separator to the contaminant removal vessel, allowing contaminant trapping additive to accumulate in the contaminant removal vessel.

Abstract: Apparatus and processes herein provide for converting hydrocarbon feeds to light olefins and other hydrocarbons. The processes and apparatus include, in some embodiments, feeding a hydrocarbon, a first catalyst and a second catalyst to a reactor, wherein the first catalyst has a smaller average particle size and is less dense than the second catalyst. A first portion of the second catalyst may be recovered as a bottoms product from the reactor, and a cracked hydrocarbon effluent, a second portion of the second catalyst, and the first catalyst may be recovered as an overhead product from the reactor. The second portion of the second catalyst may be separated from the overhead product, providing a first stream comprising the first catalyst and the hydrocarbon effluent and a second stream comprising the separated second catalyst, allowing return of the separated second catalyst in the second stream to the reactor.

Abstract: Systems for separating a contaminant trapping additive from a cracking catalyst may include a contaminant removal vessel having one or more fluid connections for receiving contaminated cracking catalyst, contaminated contaminant trapping additive, fresh contaminant trapping additive, and a fluidizing gas. In the contaminant removal vessel, the spent catalyst may be contacted with contaminant trapping additive, which may have an average particle size and/or density greater than the cracking catalyst. A separator may be provided for separating an overhead stream from the contaminant removal vessel into a first stream comprising cracking catalyst and lifting gas and a second stream comprising contaminant trapping additive. A recycle line may be used for transferring contaminant trapping additive recovered in the second separator to the contaminant removal vessel, allowing contaminant trapping additive to accumulate in the contaminant removal vessel.