Abstract: A process for reducing pressure of a flue gas stream comprising passing a pressurized flue gas stream from a catalyst regenerator to an orifice chamber through an inlet. The pressurized flue gas stream is longitudinally passed through orifices in a plurality of plates in the chamber to reduce the pressure of the flue gas stream and passed from the chamber at a lower pressure than at the inlet. The plurality of orifice plates in the chamber may be spaced apart along a height of the chamber in an apparatus embodiment. Each one of the orifice plates may comprise an array of orifice strips. The strips may be sized to be inserted and removed from the chamber through a manway for installation and replacement. The process and apparatus May enable rapid replacement of eroded plates.

Abstract: A process for regenerating catalyst from an MTO process is disclosed. The process comprises providing an oxygen stream and a preheated carbon dioxide recycle stream and mixing the oxygen stream and the preheated carbon dioxide recycle stream to provide a carbon dioxide rich oxidation stream. The carbon dioxide rich oxidation stream is passed to a regenerator unit to provide a carbon dioxide rich flue gas stream. The carbon dioxide rich flue gas stream is filtered to remove the catalyst fines to produce a filtered flue gas stream. A carbon dioxide recycle stream is taken from the filtered flue gas stream.

Abstract: A process for preventing hazardous conditions at startup and shutdown of a reactor by sending an inert gas such as nitrogen to strip entrained oxygen from the catalyst when reactor temperatures are below about 240° C. During normal operation the entrained oxygen reacts with hydrocarbons to produce oxides but at the lower temperatures that are present at startup or shutdown these reactions do not occur sufficiently leaving oxygen that can cause hazardous conditions as temperatures increase upon startup. When the temperature is in the safe operating zone above 240° C., the nitrogen gas is stripped by air or other oxygen containing gas.

Abstract: A fluidized catalytic reactor system cycles from 0.05-5% of catalyst at a time through a rejuvenation unit to be heated in the presence of oxygen to maintain catalyst activity. The use of the rejuvenation unit that may be 2% of the size of the main catalyst regeneration unit allows for reduction in equipment size and in catalyst inventory. The catalyst that is sent to the rejuvenation unit may be spent catalyst but may be partially or fully regenerated catalyst. The rejuvenation unit may be heated by combusting fuel or by hot flue gas.

Abstract: A process and apparatus for indirect heating of catalyst in the regeneration zone is disclosed. A hot flue gas flows within a heating tube and the catalyst to be heated flows outside the heating tube. The hot flue gas is generated by igniting a fuel stream. The hot flue gas is generated directly in the heating tube or is generated in a separate burner outside the heating tube.

Abstract: A process and reactor for contacting a feed stream with a catalyst stream comprises a reaction chamber comprising two spent catalyst inlets for delivering two spent catalyst streams to the reaction chamber and at least one regenerated catalyst inlet for delivering a regenerated catalyst stream to the reaction chamber. The reaction chamber may also include a second regenerated catalyst inlet for delivering a second regenerated catalyst stream to the reaction chamber. The second spent catalyst inlet enables thorough mixing of catalyst streams.

Abstract: A process for recovering catalyst from a fluidized catalytic reactor effluent is disclosed comprising reacting a reactant stream by contact with a stream of fluidized catalyst to provide a vaporous reactor effluent stream comprising catalyst and products. The vaporous reactor effluent stream is contacted with a liquid coolant stream to cool it and transfer the catalyst into the liquid coolant stream. A catalyst lean vaporous reactor effluent stream is separated from a catalyst rich liquid coolant stream. A return catalyst stream is separated from the catalyst rich liquid coolant stream to provide a catalyst lean liquid coolant stream, and the return catalyst stream is transported back to said reacting step.

Abstract: A fluidized catalytic reactor connected to a start-up heater is provided. The start-up heater provides sufficient heat to a catalyst containing stream to gradually increase the feed temperature. This allows for a critical volumetric flow rate to be achieved so that catalyst can be recovered from product instead of being entrained in product.

Abstract: A process for preventing hazardous conditions at startup and shutdown of a reactor by sending an inert gas such as nitrogen to strip entrained oxygen from the catalyst when reactor temperatures are below about 240° C. During normal operation the entrained oxygen reacts with hydrocarbons to produce oxides but at the lower temperatures that are present at startup or shutdown these reactions do not occur sufficiently leaving oxygen that can cause hazardous conditions as temperatures increase upon startup. When the temperature is in the safe operating zone above 240° C., the nitrogen gas is stripped by air or other oxygen containing gas.

Abstract: A process and apparatus comprise a reaction chamber that includes an aspect ratio between about 0.7 and 1.3 for establishing a dense catalyst bed in the reaction chamber while minimizing hot residence time of the product gas in a range that will not deteriorate product selectivity. We have found the dense catalyst bed is necessary to ensure sufficient contact between catalyst and feed gas.

Abstract: A process and reactor for contacting a feed stream with a catalyst stream comprises a reaction chamber comprising two spent catalyst inlets for delivering two spent catalyst streams to the reaction chamber and at least one regenerated catalyst inlet for delivering a regenerated catalyst stream to the reaction chamber. The reaction chamber may also include a second regenerated catalyst inlet for delivering a second regenerated catalyst stream to the reaction chamber. The second spent catalyst inlet enables thorough mixing of catalyst streams.

Abstract: Processes involving the use of a dry sorbent injection (DSI) unit or slurry reagent injection (SRI) unit to remove sulfur compounds form flue gas are described. Flue gas from an FCC regenerator, for example, is used to make superheated steam and saturated steam. The flue gas is then sent to a DSI unit to remove the sulfur compounds, and then to an economizer (or heat exchanger) to heat boiler feed water or combustion air. Because the temperature is not reduced as much as with a wet scrubber process, additional energy can be recovered in the economizer.

Abstract: Processes involving the use of a dry sorbent injection (DSI) unit or slurry reagent injection (SRI) unit to remove sulfur compounds form flue gas are described. Flue gas from an FCC regenerator, for example, is used to make superheated steam and saturated steam. The flue gas is then sent to a DSI unit to remove the sulfur compounds, and then to an economizer (or heat exchanger) to heat boiler feed water or combustion air. Because the temperature is not reduced as much as with a wet scrubber process, additional energy can be recovered in the economizer.

Abstract: A fluidized catalytic reactor decouples the catalyst regenerator temperature from the catalyst reactor residence time. Regenerated catalyst is cooled before it contacts reactant feed. The regenerated catalyst may be cooled by heat exchange with oxygen supply gas, spent catalyst or other materials. The process and apparatus are especially useful for fluidized endothermic catalytic reactions.

Abstract: A process and apparatus for indirect heating of catalyst in the regeneration zone is disclosed. A hot flue gas flows within a heating tube and the catalyst to be heated flows outside the heating tube. The hot flue gas is generated by igniting a fuel stream. The hot flue gas is generated directly in the heating tube or is generated in a separate burner outside the heating tube.

Abstract: A process for recovering catalyst from a fluidized catalytic reactor effluent is disclosed comprising reacting a reactant stream by contact with a stream of fluidized catalyst to provide a vaporous reactor effluent stream comprising catalyst and products. The vaporous reactor effluent stream is contacted with a liquid coolant stream to cool it and transfer the catalyst into the liquid coolant stream. A catalyst lean vaporous reactor effluent stream is separated from a catalyst rich liquid coolant stream. A return catalyst stream is separated from the catalyst rich liquid coolant stream to provide a catalyst lean liquid coolant stream, and the return catalyst stream is transported back to said reacting step.

Abstract: Vent gases from a catalyst cooler are directed downstream or outside of the catalyst regenerator to avoid sending air to a location where after burn may occur. Vent gases contain oxygen that when contacted with carbon monoxide in regenerator flue gas can cause after burn to occur at a location which lacks sufficient catalyst density to serve as a heat sink. Locating the cooling media supply in the top of the catalyst cooler enables cooled catalyst to drain from the bottom of the catalyst cooler and fitting more cooler tubes in the catalyst cooler.

Abstract: A fluidized catalytic reactor system cycles from 0.05-5% of catalyst at a time through a rejuvenation unit to be heated in the presence of oxygen to maintain catalyst activity. The use of the rejuvenation unit that may be 2% of the size of the main catalyst regeneration unit allows for reduction in equipment size and in catalyst inventory. The catalyst that is sent to the rejuvenation unit may be spent catalyst but may be partially or fully regenerated catalyst. The rejuvenation unit may be heated by combusting fuel or by hot flue gas.

Abstract: A process for regenerating spent catalyst by combusting coke and fuel gas together in the presence of enriched oxygen restores activity to the catalyst to bring back to adequate activity level while reducing or obviating the need for the oxygen treatment step. The oxygen concentration in the oxygen supply gas should be greater than 21 vol %.

Abstract: A dehydrogenation process and apparatus contact a paraffinic stream with dehydrogenation catalyst to product olefinic product gases. The olefinic product gases are separated from spent dehydrogenation catalyst and contained in a confined space that has a smaller volume than the reactor particularly at the same elevation. The containment of the olefinic product gases facilitates quenching the olefinic product gases to terminate reaction and improve selectivity to propylene.