Abstract: An FCC process and apparatus operates with closed reactor cyclones and a catalyst stripper using H2 or recycled stripper vapor for stripping gas. Preferably stripper vapor is removed, cooled and condensed, and some vapor recycled to the stripper. Isolation of the stripper from the cracked product vapors permits use of large amounts of stripping steam, or stripping gases such as hydrogen.

Abstract: In fluid catalytic cracking of oils, the feedstock oil is atomized so that its average particle size relative to the average catalyst particle size is such that most oil particles contacting a catalyst particle will form a film having a thickness substantially less than the boundary layer thickness of the thermal conduction interface between the feedstock oil and the catalyst. A nozzle suitable for producing such atomisation is disclosed. To compensate for reduced formation of coke from the feedstock, and permit riser temperatures to be maintained without overcracking, decant oil or other oil residues containing uncrackable hydrocarbons may be added to the feedstock so as to obtain gasoline fractions having increased octane numbers.

Abstract: A fluidized catalytic cracking (FCC) process and apparatus uses a catalyst stripper with slant trays or shed trays having "downcomers". Downcomers, vertical catalyst/gas contacting elements, provide a vertical, countercurrent region for catalyst/stripping vapor contact. The downcomers improve stripping effectiveness.

Abstract: This invention is a vented riser arrangement for multiple cyclones having an open inlet configuration that reduces the space requirements of the cyclone and eliminates the extended inlet conduit. The inlet configuration extends the outer cylindrical wall of the cyclone in a semicircular path that extends past the interior of the cyclone by a distance that cuts off the path of solids by-passing into the cyclone. The configuration eliminates the need for a cyclone inlet conduit that enlarged the required transverse area necessary to house the riser and the cyclones.

Abstract: A cyclone and process for fluidized catalytic cracking of heavy oils is disclosed. Gas and entrained solids are added tangentially around a vapor outlet tube in a cylindrical tube cyclone body. Solids and some gas is withdrawn via a plurality of openings radially and longitudinally distributed in the cylindrical sidewall of the cyclone body. Distributed withdrawal replaces or reduces conventional underflow of solids from an end of cyclone outlet and reduces solids reentrainment. 0-5 micron particle removal is enhanced by reducing eddy formation and particle bouncing near the cyclone sidewall. The device may be used as an FCC regenerator third stage separator.

Abstract: A process wherein a fluidized particulate solid is contacted with a hydrocarbon feedstock in a vertically extending contacting zone, which process comprises introducing a stream of the particulate solid into the contacting zone and introducing a plurality of streams of liquid hydrocarbon feedstock into the contacting zone to intimately contact the particulate solid therein, the plurality of streams each being introduced into the contacting zone from one of a plurality of nozzles spaced apart in the contacting zone, and each stream having a flow path extending into the contacting zone and a flow pattern having a thickness which is substantially constant and a width which diverges from the point of introduction into the contacting zone.

Abstract: An improvement has been discovered in an ebullated bed process. A residual hydrocarbon oil feedstock is hydrocracked to yield a product oil. The amount of sediment in the product oil is controlled by adjusting hydrogen partial pressure according to an algorithm. A change in temperature and residence time is avoided.

Abstract: In an ebullated bed process for hydrotreating a distillate hydrocarbon feedstock it has been found that a catalyst addition slurry is made up with catalyst and feedstock. A control system provides for a constant distillate feedstock rate during intermittent catalyst addition.

Abstract: The invention is a method for mixing feedstock with fluidized catalyst in a fluid catalytic cracking (FCC) riser reactor. A dispersed catalyst suspension is passed upwardly at a velocity of 0.5 to 4 ft/sec. Atomized feedstock is injected downwardly at a velocity of -30 to -1000 ft./sec to produce a turbulently mixed reaction suspension. Vaporizing feedstock rapidly accelerates the reaction suspension in approximately plug flow. The slip factor between catalyst and hydrocarbon in the reaction suspension defining the departure from ideal plug flow is thereby reduced.

Abstract: In an ebullated bed process the feedstock conduit is provided with at least 50 psi (4.4 atm) head in excess of a liquid-vapor separation pressure. The excess head is used in combination with an eductor to recycle a reactor effluent liquid. The expanded catalyst bed is thereby maintained at 110 vol % to vol % of a settled catalyst volume. A separate pump to expand (ebullate) the catalyst bed is not required.

Abstract: A catalytic cracking process and apparatus wherein hot regenerated catalyst particles from the dense phase of the regenerator are passed through a heat exchanger in indirect heat exchange with stripped catalyst particles whereby the former are cooled and the latter are heated. The regenerated catalyst which contacts the feed is thus cooler than it would otherwise be, and there is a reduction in thermal cracking. The stripped catalyst entering the regenerator is hotter than it would otherwise be thereby improving the efficacy of the regeneration step.

Abstract: A process for fluidized catalytic cracking of heavy feed using a low H.sub.2 S content lift gas in the base of a riser reactor. The lift gas is a recycled, ethylene rich stream obtained by removing H.sub.2 S from a compressed vapor stream intermediate the FCC main column receiver and the gas plant associated with the FCC unit. The low H.sub.2 S lift gas does not increase SO.sub.x emissions from the regenerator as much as a recycled vapor from the FCC main column. As the lift gas is not purified in the gas plant it does not overload it.

Abstract: A separator apparatus and method for a hydrocarbon fluidized catalytic cracking process are disclosed. The apparatus comprises a main plenum in a disengagement vessel which connects a plurality of riser cyclones in a riser catalyst separation stage to a plurality of secondary cyclones in a secondary catalyst separation stage. The cyclones in the second and each succeeding stage receive a substantially equal amount of gas from the plenum. The effluent gas is substantially prevented from leaking into the interior space of the disengagement vessel. Also disclosed is a method for retrofitting an existing plant with the plenum design to provide a more compact arrangement of the catalyst separation equipment in the disengagement vessel.

Abstract: Disclosed is a system for fluid catalytic cracking. The system includes a method and means for decreasing and increasing the slip velocity of a hydrocarbon reaction stream to further enhance catalytic cracking of the hydrocarbon within the reaction stream. The system also allows for control of residence time within both a riser and a collection and velocity reducing means to provide for more complete cracking of the hydrocarbon without leading to additional coking of the catalytic cracking catalyst.

Abstract: An FCC process and apparatus is arranged to provide a low volume dilute disengagement zone in a reactor vessel. A vented riser that provides an open discharge of catalyst and gaseous products is directly discharged into a reactor vessel. The interior of the reactor vessel is arranged such that the outlet of the reactor riser is located close to and directed at the top of the reactor vessel. The reactor vessel operates with a dense bed of catalyst having an upper bed level that is only a short distance below the outlet of the reactor riser. The cyclone separators are located to the outside of the reactor riser and circulate catalyst directly back to the reactor riser or directly to an independent stripping vessel that returns the catalyst to the regenerator.

Abstract: An open-bottomed cyclone separator with gas inlet tube is disclosed which minimizes the entrainment of separated solids in a process gas entering the separator. In some embodiments, the gas inlet tube directs the process gas into a solids-depleted region within a cyclonic separation chamber. In other embodiments, a gas inlet tube directs the process gas into a stream of solids-depleted gas withdrawn from the chamber. Methods for practicing the invention are also disclosed.

Abstract: In a fluid catalytic cracking (FCC) process coked catalyst is partially regenerated by contacting with high temperature steam in the absence of oxygen. About 10 to 30% of the coke is converted to a steam reformed gas comprising hydrogen, methane and carbon dioxide. The off-gas may be subjected to cryogenic separation to yield a hydrogen-rich gas.

Abstract: In a fluidized catalytic cracking (FLC) type unit for contacting of a hydrocarbon feedstock with hot solid particles in a fluidized bed in an upright tubular-type upflow hydrocarbon conversion reactor, there is provided, between the means for fluidization and the means for injection of the feedstock, a means for causing the fluidized phase at the periphery of the reactor to rotate about the axis of the reactor.

Abstract: A process and apparatus for regeneration of spent FCC catalyst in a bubbling bed regenerator having a stripper mounted over the regenerator. Spent catalyst is regenerated in a fast fluidized bed coke combustor heated by direct contact heat exchange with catalyst recycled to the coke combustor via an internal "trough" trap. Catalyst recycle flow to the combustor is controlled by varying gas flow in the trough trap.

Abstract: The invention relates to a downflow fluid cracking process and apparatus. More specifically, sampling takes place of the at least partly regenerated catalyst, which must be recycled to the reactor 1 from a dense phase 17a, contained in a regenerator 17 and the stage of introducing the catalyst into the upper part 3 of the reactor 1 takes place under conditions such that the density of the thus formed gas-solid suspension is between 80 and 500 kg/m.sup.3 prior to its contacting with the charge, which is introduced by the injectors 5.

Abstract: A process for the substantial homogenization of the mixture of hot solid particles and of the hydrocarbon vapors to be treated within a tubular reactor (preferably an FCC unit) for the cracking of hydrocarbons in a fluidized bed of hot solid particles. Directly downstream of the zone of injection, in the reaction zone of the feedstock to be or being treated, usually where at least 75 percent of the droplets of the feedstock are vaporized, there is injected into the reactor a fluid in the gaseous state at one or more points on the interior surface of the side wall of the reactor.

Abstract: A process and apparatus for increasing the coke burning capacity of FCC catalyst regenerators is disclosed. An auxiliary regenerator receives spent catalyst from an FCC stripper and burns some of the coke at turbulent or fast fluidized bed conditions. Partially regenerated catalyst and flue gas enter a low pressure drop cyclone discharging more than 90% of the partially regenerated catalyst down into a bubbling or fast fluidized bed in the primary regenerator. Flue gas from the auxiliary regenerator is discharged into the dilute phase above the bed in the primary regenerator. Catalyst entrainment from the fluidized bed in the primary regenerator may be reduced because less combustion air is needed as a result of partial regeneration in the auxiliary regenerator. Reduced NOx and dust emissions, and/or increased coke burning capacity, may be achieved, especially when a bubbling dense bed primary catalyst regenerator is used.

Abstract: A fluidized solid process for upgrading or converting a hydrocarbon feedstock wherein carbonaceous deposits accumulate on a particulate fluidized solid and are burned in a regenerator to regenerate the solid, the regenerated solid and entrained combustion products are introduced into a vertical lift pipe, a fluid lift medium is introduced into the lift pipe and the regenerated solid is separated from the lift medium and combustion products to improve the quality of the regenerated solid contacted with the hydrocarbon feedstock.

Abstract: A process for multistage regeneration of spent FCC catalyst in an "Orthoflow" or stacked FCC unit having a stripper mounted over the regenerator. Spent catalyst is discharged into a fast fluidized bed coke combustor heated by direct contact heat exchange with catalyst and large particles or beads of CO combustion promoter. The large particle CO combustion promoter is trapped in the coke combustor, to permit complete CO combustion, with limited coke combustion.

Abstract: An FCC process uses a tube sheet arrangement and a multiplicity of centrifugal separation devices in an FCC reactor to reduce the volume of the reactor vessel thereby minimizing uncontrolled reaction of feed hydrocarbons and the production of riser by-products. The separation arrangement encloses an upwardly directed outlet end of a ballistic separation device in a low volume disengaging vessel that transfers dilute catalyst and product vapors to a tube sheet arrangement of swirl tubes that removes catalyst and directs it downwardly into a stripper arrangement.

Abstract: In a steam generator for recovering heat in a hot fluidized bed of solid particles, wherein coils of the steam generator make a 180.degree. U-bend, the U-bend portion of the coils are protected from overheating by installing an open top insulating box around the U-bend portion of the coil. In use solid particles from the circulating fluidized bed accumulate in the insulating box thus providing a non-moving layer of solid particles surrounding the U-bend which thermally insulates the U-bend portion of the coil from the higher temperature encountered in the moving fluidized bed.

Abstract: A process and apparatus for fluidized catalytic cracking of heavy oil feed using a plurality of feed nozzles. Flow through each nozzle is controlled based on distribution of feed, steam or catalyst in the reactor, as determined by a scanner such as a rotating gamma ray source and detector. More uniform contact of catalyst and feed improves conversion.

Abstract: FCC process uses an open reactor vessel to house cyclones or other separation devices that reduce the carry through of product gases with the catalyst into the reactor vessel to less than 10 wt. % so that the catalyst in the reactor vessel provides a secondary dealkylation zone. By using a highly efficient separation device to remove product from the catalyst, the environment in the reactor vessel receives a low volume of cracked hydrocarbons from the riser conversion zone and provides a convenient secondary reaction zone that receives a recycled heavy gasoline fraction separated from the riser product stream. Dealkylation in the secondary reaction zone provides additional light gasoline to satisfy T90 requirements.

Abstract: A resid refining reactor has an ebullated catalyst bed. Hydrogen gas is released into the catalyst bed at a point which is far enough above a distributor plate at the bottom of the catalyst bed to form a gas updraft in a committed zone through the bed. This committed updraft causes a reduction in gas holdup which increases the residence time of a liquid phase in the catalyst bed.

Abstract: A nozzle, and FCC process using the nozzle for atomizing heavy feed to a riser reactor, are disclosed. A liquid feed stream is atomized by radial out-to-in impingement of atomizing vapor, discharged onto an impingement plug in an annular expansion region, then sprayed through an outlet. Baffles at the expansion region outlet, and an orifice outlet improve feed atomization and feed/FCC catalyst contact in a riser reactor. The nozzle may be used to distribute liquid over other reactor beds, or to add liquid to distillation columns.

Abstract: An FCC process and apparatus is arranged to provide a low volume dilute disengagement zone in a reactor vessel and a quench zone immediately downstream of the reactor vessel. A vented riser that provides an open discharge of catalyst and gaseous products is directly discharged into a reactor vessel. The interior of the reactor vessel is arranged such that the outlet of the reactor riser is located close to and directed at the top of the reactor vessel. The reactor vessel operates with a dense bed of catalyst having an upper bed level that is only a short distance below the outlet of the reactor riser. The cyclone separators are located to the outside of the reactor riser and circulate catalyst back to the dense bed of the reactor section. The quenching takes place downstream of the cyclone separators.

Abstract: In ebullated bed hydroprocessing of a distillate hydrocarbon feedstock, it has been found that high pressure and low pressure heat exchange can be separated. Both the high pressure heat exchange and the fired heater fuel consumption are reduced. A control system provides for a constant distillate feedstock temperature in cooperation with heat integration.

Abstract: A process for short contact time cracking of heavy feed. A falling, annular curtain of hot regenerated FCC catalyst, or hot inert solids, is formed over a cone shaped plug valve. Hydrocarbons pass from under the cone, or via a hollow stem, in radial in to out flow to contact the falling curtain of solids. After 0.01 to 1.0 seconds of contact time, solids and cracked vapor are separated, preferably in a bell separator beneath the reaction zone. Downflow of reactants into a contiguous upflowing stripper minimizes attrition.

Abstract: An FCC process and apparatus is arranged to provide a low volume dilute disengagement zone in a reactor vessel. A vented riser that provides an open discharge of catalyst and gaseous products is directly discharged into a reactor vessel. The interior of the reactor vessel is arranged such that the outlet of the reactor riser is located close to and directed at the top of the reactor vessel. The reactor vessel operates with a dense bed of catalyst having an upper bed level that is only a short distance below the outlet of the reactor riser. The cyclone separators are located to the outside of the reactor riser and circulate catalyst back to the dense bed of the reactor section.

Abstract: A process and apparatus for dense phase, at least partially co-current, fluidized bed regeneration of FCC catalyst are disclosed. Catalyst regeneration occurs in a dense phase fluidized bed, with catalyst flowing laterally from a spent catalyst inlet to a regenerated catalyst outlet. Regeneration air flows up through the dense bed into a dilute phase region defined at the base by the dense phase bed and at the top by a horizontal baffle. The plate has openings or baffles forcing the dilute phase, consisting of entrained catalyst and flue gas, to flow horizontally in the same direction as the lateral flow of catalyst in the dense bed. Concurrent flow of at least the dilute phase material and the dense bed material improves regeneration and can reduce NOx emissions.

Abstract: Open-ended cyclone separators are disclosed which employ catalyst separation tubes to prevent separated solids discharged through an open cyclone end from being entrained in a countercurrently moving flow of process gas entering the separator through the open end. In several preferred embodiments, generally conical tubes are axially located within the cyclone open bottom. Methods for practicing the invention also are disclosed.

Abstract: This invention provides an improved apparatus for stripping hydrocarbons from spent catalyst which offers ready access to stripper baffles for inspection and maintenance. The inner baffles move upwardly or downwardly on a conduit that slides over the central riser.

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: This invention provides a method of reducing the sulfur oxide emissions from the regenerator of an FCC process that cracks a sulfur containing feedstream. The sulfur oxide emissions are reduced by using an essentially sulfur free lift gas stream to shift the sulfur concentration equilibrium between the product stream from the reaction zone and the flue gas stream from the regeneration zone. Sulfur compounds present in the FCC feed leave the reaction zone as volatile sulfurous gases in the product vapor stream or as adsorbed sulfur compounds on the catalyst. Sulfurous gas in the product vapors is mainly H.sub.2 S. By lowering the concentration of H.sub.2 S that enters the riser with the lift gas the equilibrium reaction of sulfur with hydrogen in the riser is favorably shifted to increase the production of H.sub.2 S and decrease the lay down of sulfur compounds in the coke that forms on the catalyst.

Abstract: Methods and apparatus are disclosed for separating solids from a mixture of solids and gases. An in-line cyclone separator cyclonically swirls the mixture as it exits a conduit concentrically located within a radially symmetric separation chamber. In some embodiments, stripping gas apertures direct stripping gas into the chamber to help maintain the angular momentum of the solids cyclonically swirling within the chamber.

Abstract: The invention is a process and apparatus for rapidly and efficiently separating a fluidized catalytic cracking mixture into cracking catalysts and hydrocarbon vapor. The invention decreases the production of unwanted hydrocarbon byproducts by decreasing the contact time between the separated hydrocarbon vapor and the cracking catalyst.

Abstract: Coke formation/deposition within and downstream of catalytic cracking reactors is suppressed by adding a coke suppressing additive to the cracking reactor and/or cracked product vapor. Free radical inhibitors, such as oxygenates, are preferred. The additive addition rate is preferably controlled based on temperature of regenerated catalyst, or a direct or indirect measurement of coke accumulation on the transfer line between the cracking reactor and the main fractionator.

Abstract: A riser cyclone separator for rapidly separating catalyst from cracked hydrocarbon vapors in a fluid catalytic cracking process. The riser cyclone is provided with an annular port for drawing stripping gas into the riser cyclone to separate entrained catalyst and vent stripper gas from the regenerator vessel. The cyclone is inherently negative pressure to the reactor vessel.

Abstract: A coking process wherein a heavy hydrocarbonaceous chargestock is mixed with a minor amount of coal and preheated to a temperature from about 500.degree. F. up to, but not including, coking temperatures. The pretreated mixture is then reacted in a coking zone at coking conditions.

Abstract: In a fluid catalytic cracking (FCC) process riser reactor effluent is rapidly separated into spent catalyst and hydrocarbon product. The separated hydrocarbon product is immediately quenched to an unreactive temperature in the absence of quenching spent catalyst. An increase in debutanized naphtha yield is achieved. By avoiding catalyst quenching, heat duty is saved in the catalyst regenerator.

Abstract: In an ebullated bed process, a nominal 1000.degree. F.+ boiling point vacuum residuum is hydrotreated at a first temperature of 750.degree. F. to 875.degree. F. and total pressure of 1900 psig to 3000 psig. Hydrogen partial pressure is controlled by changing total reactor pressure in the range of 1700 psig to 2300 psig to achieve a selected yield of 650.degree. F.- boiling material.

Abstract: The invention is directed to a process and apparatus for controlling reactor temperature and/or carbon and heat balance in a fluid hydrocarbon conversion and cracking unit. In particular, the invention is directed to a process wherein the introduction of feed into a conversion and cracking zone is effected by a feed injector which optimizes the atomization of the feed in order to achieve reactor temperature and/or carbon and heat balance control objectives. This invention is applicable to fluid coking, fluid coking with gasification, asphaltene residuum treating (ART), and other petroleum industry processes.

Abstract: An FCC process uses an open reactor vessel to house cyclones or other separation devices that reduce the carry though of product gases with the catalyst into the reactor vessel to less than 5 wt. % so that the catalyst in the reactor vessel can contact a secondary feedstock. By using a highly efficient separation device to remove product from the catalyst the environment in the reactor vessel receives a low volume of feed hydrocarbons and riser by-products. These by products comprise mainly C.sub.2 and lighter gases which are inert to a variety of other feedstreams. Possible secondary feedstreams include hydrotreated heavy naphtha, hydrotreated light cycle oil, light reformate and olefins. It is highly useful to use the secondary feedstream to heat the catalyst in the reactor vessel to facilitate hot stripping of the catalyst. Heat may be introduced in this manner by heating the secondary feedstream or using a feedstream that produces an exothermic reaction in the reactor vessel.

Abstract: A method for introducing a heavy oil feedstock into a catalytic cracking unit is disclosed which comprises forming the oil feed into a sheet of flowing fluid and breaking down the sheet of oil by mixing the oil with a sheet of atomizing gas flowing normally to the sheet of oil.

Abstract: This invention is directed to a feed injector for a fluid catalytic cracking reaction zone, which feed injector provides improved oil atomization and dispersion. The injector comprises a straight-pass conduit section, in which a feed oil and steam are premixed, and a terminal section, where the oil is atomized and dispersed by a generally fan-shaped distributor. The feed injector produces a substantially flat spray pattern across the direction of catalyst flow in the catalyst/oil contacting section of the catalytic cracking reaction zone. Improved product yield and lower coke and light gas yields are obtained.