Abstract: One exemplary embodiment can be a process for regenerating catalyst in a fluid catalytic cracking unit. Generally, the process includes providing a feed to a riser of a reaction vessel, and providing a stream to a distributor positioned within a void proximate to an inlet receiving unregenerated catalyst in a regenerator. The feed can include at least one of a gas oil, a vacuum gas oil, an atmospheric gas oil, a coker gas oil, a hydrotreated gas oil, a hydrocracker unconverted oil, and an atmospheric residue.

Abstract: Pyrolysis methods and apparatuses that allow effective heat removal, for example when necessary to achieve a desired throughput or process a desired type of biomass, are disclosed. According to representative methods, the use of a quench medium (e.g., water), either as a primary or a secondary type of heat removal, allows greater control of process temperatures, particularly in the reheater where char, as a solid byproduct of pyrolysis, is combusted. Quench medium may be distributed to one or more locations within the reheater vessel, such as above and/or within a dense phase bed of fluidized particles of a solid heat carrier (e.g., sand) to better control heat removal.

Abstract: Char-handling processes for controlling overall heat balance, ash accumulation, and afterburn in a reheater are provided. Carbonaceous biomass feedstock is pyrolyzed using a heat transfer medium forming pyrolysis products and a spent heat transfer medium. The spent heat transfer medium is separated into segregated char and char-depleted spent heat transfer medium. The char-depleted spent heat transfer medium is introduced into a dense bed of heat transfer medium fluidized by a stream of oxygen-containing regeneration gas. All or a portion of the segregated char is combusted in the dense bed using the stream of oxygen-containing regeneration gas. A portion of the segregated char may be exported out of the pyrolysis system to control the overall heat balance and ash accumulation.

Abstract: A process and apparatus described is for distributing fluidizing gas to a riser. Fluidizing gas is delivered to a plenum below the riser. A first stream of fluidizing gas is distributed from the plenum into a chamber in a riser and a second stream of fluidizing gas is distributed from the plenum into the riser outside of the chamber. First nozzles in the plenum have a first outlet in the chamber and second nozzles in the plenum have a second outlet outside of the chamber. Streams of regenerated catalyst and carbonized catalyst may be passed to the riser and mixed around the chamber in a lower section of a riser.

Abstract: A process and apparatus for mixing streams of regenerated and carbonized catalyst utilizes a ramp or bend provided on only one of the catalyst conduits to provide mixing advantages.

Abstract: One exemplary embodiment can be a process for transferring catalyst in a fluid catalytic cracking apparatus. The process can include passing the catalyst through a conveyor wherein the conveyor contains a screw for transporting the catalyst.

Abstract: A process and apparatus for heating catalyst is presented. Cooler catalyst is removed from a reactor and heated with a hot gas in a riser, heated in a heating tube or heated in a heating chamber. Heated catalyst is disengaged from the hot gas if necessary and returned to the reactor. The process and apparatus can be used for producing light olefins. The hot gas may be a flue gas from an FCC regenerator or a combustion gas from a heater.

Abstract: A process and apparatus for heating catalyst is presented. Cooler catalyst is removed from a reactor and heated with a hot gas in a riser, heated in a heating tube or heated in a heating chamber. Heated catalyst is disengaged from the hot gas if necessary and returned to the reactor. The process and apparatus can be used for producing light olefins. The hot gas may be a flue gas from an FCC regenerator or a combustion gas from a heater.

Abstract: A catalyst cooler for cooling regenerated catalyst in a regenerator associated with a fluid catalytic cracking unit. The catalyst cooler includes a first passage for transporting hot regenerated catalyst away from the regenerator and a second passage for returning cooled regenerated catalyst to the regenerator. The catalyst cooler also includes at least one heat exchanger. The second passage may be disposed within the first passage, or the first and second passage may each occupy a portion of a horizontal cross section of the catalyst cooler.

Abstract: A process and apparatus for heating catalyst is presented. Cooler catalyst is removed from a reactor and heated with a hot gas in a riser, heated in a heating tube or heated in a heating chamber. Heated catalyst is disengaged from the hot gas if necessary and returned to the reactor. The process and apparatus can be used for producing light olefins. The hot gas may be a flue gas from an FCC regenerator or a combustion gas from a heater.

Abstract: A stripping vessel for removing hydrocarbons from a catalyst and a process for removing hydrocarbons from a catalyst. In an FCC unit, the stripping vessel includes first and second stripping sections. The first stripping section includes at least one grid having a plurality of interesting members and openings therebetween. The second stripping section includes structured packing such as a plurality of ribbons. The one or more grids are spaced from the structured packing, and from each other, so as to minimize the accumulation of catalyst within the stripping vessel, preferably between about 0.91 m (3 ft) to about 1.5 m (5 ft).

Abstract: Embodiments of methods and apparatuses for rapid thermal processing of carbonaceous material are provided herein. The method comprises the step of contacting a carbonaceous feedstock with heated inorganic heat carrier particles at reaction conditions effective to rapidly pyrolyze the carbonaceous feedstock to form a product stream comprising pygas, pyrolysis oil, and solids. The solids comprise char and cooled inorganic heat carrier particles. The reaction conditions include a reactor pressure of about 70 kPa gauge or greater.

Abstract: Methods and FCC apparatuses are provided for cracking hydrocarbons. An FCC apparatus includes a riser with a riser outlet positioned within a reactor catalyst collection area. A stripper is coupled to the reactor catalyst collection area, where the riser extends through the stripper, and where the stripper includes a stripper exterior wall. A sleeve is positioned within the stripper between the riser and the stripper exterior wall.

Abstract: Methods and apparatuses for regenerating catalysts and methods of inhibiting corrosion in catalyst regenerating apparatuses are provided. An exemplary apparatus includes: a metal vessel configured to receive a spent catalyst stream and contact at least a portion of the spent catalyst stream with an oxygen containing environment at a sufficiently high temperature to burn coke present in the spent catalyst stream; a refractory material overlying at least a portion of an inner surface of the metal vessel; and a corrosion inhibiting material in contact with at least a portion of the inner surface of the metal vessel and disposed between the inner surface and at least a portion of the refractory material, wherein the corrosion inhibiting material is heat stable at a temperature of at least up to about 400° F. (about 204° C.) and inhibits contact of an acid environment with the inner surface of the metal vessel.

Abstract: An FCC process may include a distributor disposed in a recess in a wall of the riser for distributing gaseous hydrocarbon feed to a riser. The distributor may be shielded from upwardly flowing catalyst by a shield. An array of nozzles from the distributor may extend through openings in the shield.

Abstract: A process for increasing the yields of propylene is presented. The process is an FCC process for producing light olefins, and utilizes a smaller secondary reactor that uses the same catalyst, or a different catalyst as in the FCC reactor. The FCC effluent is separated, and C4 and C5 olefins are recovered. The C4 and C5 olefins are passed to the secondary reactor for cracking to generate increased light olefin yields.

Abstract: Catalyst regenerators and methods of their use are provided. A catalyst regenerator includes a combustion chamber with a combustion chamber diameter and a combustion chamber bottom. A mixing chamber is fluidly coupled to the combustion chamber at the combustion chamber bottom, where the mixing chamber has an exterior wall and a mixing chamber diameter less than the combustion chamber diameter. A first and second catalyst inlet are fluidly coupled to the mixing chamber, and a mixing cylinder is within the mixing chamber. The mixing cylinder and the exterior wall define an annular space there-between, and the mixing cylinder includes a cylinder opening.

Abstract: Catalyst regenerators and methods of their use are provided. A catalyst regenerator includes a combustion chamber with a combustion chamber diameter and a combustion chamber bottom. A mixing chamber is fluidly coupled to the combustion chamber at the combustion chamber bottom, where the mixing chamber has an exterior wall and a mixing chamber diameter less than the combustion chamber diameter. A first and second catalyst inlet are fluidly coupled to the mixing chamber, and a mixing cylinder is within the mixing chamber. The mixing cylinder and the exterior wall define an annular space there-between, and the mixing cylinder includes a cylinder opening.

Abstract: Apparatuses and processes are provided for stripping gaseous hydrocarbons from particulate material. One process comprises the step of contacting particles that contain hydrocarbons with a stripping vapor in countercurrent flow to remove at least a portion of the hydrocarbons with the stripping vapor to form stripped particles. Contacting the particles includes advancing the particles down a sloping element of a structured packing toward a reinforcing rod that is disposed adjacent to a lower section of the sloping element. The particles are advanced down through an opening formed in the sloping element proximate the reinforcing rod. The particles are contacted with the stripping vapor that is rising up through the opening.

Abstract: An apparatus and process is disclosed for mitigating coking in an FCC reactor plenum. The apparatus and process utilize a baffle to create a inner volume for the product vapors to prevent contact with a relatively cool plenum. The baffle also limits the amount of the time the product vapors spend in the plenum minimizing time for coke formation and limit product vapors from entering low fluidization zones.