Abstract: A process for producing olefins and gasoline from residual oil by thermally cracking a side cut fraction from a fractionation tower, quenching the cracked product with residual oil, producing coke from a portion of the quenched product and using a portion of the coke to provide reaction heat for the thermal cracking.

Abstract: The invention concerns a process for withdrawing catalyst, particularly from a moving bed.The device is characterized in that fins (4) (see FIG. 1A), shaped as corner-plates, are arranged, on a plate (6) which supports the catalyst bed radially around each vertical duct for catalyst withdrawal, so that the flow of catalyst particles converges towards the withdrawing ducts.The apparatus is useful for example in hydroconversion reactions, particularly in hydrotreatments of heavy oil cuts.

Abstract: An apparatus for fluid catalytic cracking (FCC) wherein 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 stripping gas to enter the conduit to improve the separation 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: Disclosed is a method and apparatus for feeding catalyst, oil and steam into a fluid catalytic cracking (FCC) riser. Oil passes through respective oil lines into a multiplicity of upwardly extending nozzles located at a lower portion of the riser, while steam passes through respective steam lines into the nozzles where it blends with the oil, with the combined oil and steam mixture being fed through the nozzles into the riser. Each oil line and steam line is provided with a valve to separately control oil and steam flow rates, respectively, in each of the nozzles to obtain a substantially constant catalyst to oil ratio across a horizontal cross-section of the riser. The substantially constant catalyst to oil ratio is represented by a substantially isothermal temperature profile across the horizontal riser cross-section, which is detected by measuring the temperature at various points along the horizontal cross-section.

Abstract: A method and apparatus for improving the flow of catalyst particles from a riser conversion zone to a separator in a fluidized catalytic cracking (FCC) unit. The exit of the riser conversion zone is equipped with a deflector mounted so as to redirect catalyst particle and gas suspension movement toward a separator inlet, thus preventing rebound back into the riser conversion zone. The catalyst deflector, in other embodiments, can be combined with one or more of a short contact time stripper, a stripper mount in or adjacent the exhaust barrel of a separator, and/or a catalyst seal pot, all serving to reduce "residence" time of hydrocarbons with catalyst particles.

Abstract: A method and apparatus for improving the separation of a catalyst phase from a gas suspension phase in a fluidized catalytic cracking (FCC) unit. In a vertical separation embodiment, a cyclone separator inlet is located in the upper portion of a riser conversion zone and draws off gaseous hydrocarbon materials, while catalyst particles continue vertically to the end of the riser conversion zone, and pass through a catalyst conduit to a catalyst storage area. In a horizontal separation embodiment, the catalyst/hydrocarbon mixture is transported horizontally from the end of the riser conversion zone past a cyclone separator inlet towards a catalyst conduit. The cyclone inlet draws off gaseous hydrocarbon materials, while the catalyst particles pass through the catalyst conduit to a catalyst storage area.

Abstract: A method and apparatus for improving the stripping of hydrocarbons from catalyst particles in a fluidized catalytic cracking (FCC) unit. A stripper vessel has catalyst particles entering at one end and stripped catalyst particles exiting at another end. While passing through the stripper, the catalyst particles are exposed to a stripping gas, in a preferred embodiment steam, at each stage. A baffle and conduit system is provided, such that after exposure to only a portion of catalyst contained above the steam injection location in the stripper, the stripping gas and any stripped hydrocarbons are removed from any further substantial catalyst contact. The short contact time (SCT) stripper, in other embodiments, can be combined with one or more of a riser conversion zone deflector, a stripper mount in or adjacent the exhaust barrel of a separator, and/or a catalyst seal pot, all serving to reduce "residence" time of hydrocarbons with catalyst particles.

Abstract: A process is described for converting residual oil with fluid catalyst particles which comprises passing an upflowing suspension of fluid catalyst particles at an elevated temperature upwardy through a riser reaction zone/atomizing a residual oil feed to be converted to a particle size commensurate with the particle size of the catalyst particles in the upflowing suspension; discharging the atomized residual oil at a velocity in excess of 300 ft./sec. for contact with said upflowing catalyst particle suspension; maintaining the temperature of contact between said catalyst particles and said atomized residual oil feed suspension sufficiently elevated to obtain up to 50 percent thermal conversion of the atomized oil feed and catalytic conversion thereof by an order of magnitude greater than obtainable with a less atomized oil feed; and separating the suspension vaporous products of the previous step from catalyst particles in a time frame less than two seconds.

Abstract: A vapor recovery shroud of relatively small size is positioned in a large diameter catalyst disengaging vessel of a fluid catalytic cracking system so that vapor released directly from the riser reactor pipe must execute a reversal of flow direction to enter the vapor recovery shroud. At the same time catalyst and vapors from the stripper are separated by gravity and inertia in the large diameter separation vessel so that stripper vapors may also vent through the vapor recovery shroud. Vapor is vented from the vapor recovery shroud through cyclone means confined within the disengaging vessel. Preferably, the inlet to the vapor recovery shroud is located adjacent to the riser reactor outlet because this location is the most rarefied in catalyst density and provides the shortest path for hydrocarbon vapors to exit the hot separation vessel and enter a distillation system.

Abstract: A fluid coking process is provided in which the fluidizing and stripping gas is introduced as a plurality of streams in the proximity of flow deflecting means positioned in the stripping portion of the coking reactor such as to provide a specified superficial gas velocity in the stripping portion.

Abstract: An improved Fluid Catalytic Cracking (FCC) Process wherein vaporization of oil feed is optimized prior to catalytic cracking. A draft tube mixer placed in the lower reactor riser splits the hot regenerated catalyst flow into two streams resulting in improved riser mixing of catalyst and oil.

Abstract: An apparatus and method for mixing a fluidized solid and a fluid wherein the fluidized solid flows in a space defined between an outer member and an inner member positioned within the outer member. A body means is provided in the space between the members to occupy a predetermined volume in the space. A stream of solid particles flows around the body, and is directed across the upper end of the inner member. Fluid is released at the upper end of the inner member which mixes with the fluidized solid.

Abstract: The invention provides an improved method and apparatus for operating a fluidized bed chemical processing unit of the type having steam generating coils, so as to reduce the occurrence of thermally-induced stresses in the coils and thereby extend the useful life of the coils.The invention involves causing the tube wall temperature of a coil being brought into service to be lowered from bed temperature prior to initiating water flow in the coil, so as to decrease the thermal shock temperature gradient and thereby reduce the magnitude of thermally-induced stress in the coil.The invention utilizes a base coil in addition to the steam generating coil that is being cycled, and a pair of steam drums which operate at a pressure differential. The method involves generating saturated steam in the base coil and superheating the saturated steam in the coil being brought on line. Steam is directed from one drum to the other in a predetermined manner so as to provide proper temperature control of the coil being cycled.

Abstract: A process for converting normally liquid hydrocarbons with an active fluid catalytic cracking catalyst which comprises:(a) passing a suspension of hot regenerated active fluid catalytic cracking catalyst in a lift gas comprising hydrocarbons including not more than 10 mole % C.sub.3 and heavier hydrocarbons through a horizontally oriented lower portion of a riser conversion zone at a velocity of from about 1.8 to less than 12.2 meters per second, and for a residence time from about 0.5 to about 15 seconds, the ratio of catalyst to hydrocarbon in said lift gas being greater than 80; and(b) introducing the normally liquid hydrocarbons into the upflowing suspension at a vertically orientated locus in the riser conversion zone downstream of the lower portion to form a catalyst-hydrocarbon mixture wherein the temperature and residence time are sufficient to effect the desired conversion.The process is particularly useful for the treatment of a heavy residual feedstock.

Abstract: A fast fluidized bed regenerator of an FCC apparatus is improved by incorporating into the regenerator an internal riser, for more complete combustion of coke, and by providing a means of preventing catalyst flow reversals between the spent and regenerated beds of the catalyst.

Abstract: A process for converting a charge stock comprising normally liquid hydrocarbons in a riser conversion zone with an active fluid catalytic cracking catalyst wherein a suspension of hot regenerated active fluid catalytic cracking catalyst in a lift gas comprising hydrocarbons including not more than 10 mole % C.sub.3 and heavier hydrocarbons (calculated on a water-free basis) is passed through a first treatment section of the riser conversion zone at conditions selected to treat the catalyst prior to any contact with the charge stock while simultaneously accelerating the catalyst to a velocity sufficient to provide turbulent dilute flow at the point of contact with the charge stock; thereafter a charge stock is introduced into the suspension of treated particles in the riser conversion zone downstream of the treatment section to form a mixture of catalyst, charge stock and lift gas having the catalyst relatively uniformly distributed therethrough.

Abstract: A hydrocarbon feed injection method is provided in which concentric inlet conduits carry hydrocarbon liquid and steam. Small nozzles located on the outer steam-carrying conduit discharge steam in the direction of the inner wall of the transfer line reactor to protect the inner wall from carbonaceous deposits. The hydrocarbon feed nozzles are staged along a line parallel to the longitudinal axis of the transfer line.

Abstract: A method for improving fluidization of a particulate material flowing through a fluid conductor is provided by controlling the rate of addition of fluid, such as aerating gas or steam at a plurality of spaced apart locations along the conduit. The composition and rate of flow of the fluidized particles, is controlled by positioning a source of penetrative radiation such as neutrons, gamma rays, or X-rays at any location along the conduit so that the radiation traverses the fluidized particulate material flowing therein. A radiation detector is positioned opposite the source so that radiation absorbed in the conduit by the fluidized mixture may be measured as an electrical quantity. This electrical quantity may represent the total number of gamma rays of a preselected energy interacting with a detector in a given time interval or the average number of all gamma rays generating electrical pulses by interaction with the radiation detector.

Abstract: In a fluid catalytic cracking process comprising admixing a hydrocarbon oil feed with hot regenerated catalyst in the bottom section of a reactor riser, passing the mixture of the hydrocarbon oil feed and the catalyst through the riser, thereby at least partially volatilizing the oil feed and effecting cracking thereof at the process temperature under endothermic process conditions and deactivating the catalyst by deposition of carbonaceous deposits thereon, separating the deactivated catalyst from the cracked hydrocarbonaceous feed, passing the deactivated catalyst to a regenerator vessel wherein the carbonaceous deposits are removed from the deactivated catalyst under exothermic process conditions by means of a regenerating medium introduced into the regenerator vessel, and passing the regenerated hot catalyst substantially above process cracking temperature to the bottom section of the reactor riser; the improvement comprisingcontinuously injecting liquid oil feed into a primary mixing zone in a venturi tu

Abstract: The present invention relates to a baffle arrangement that improves separation of gaseous hydrocarbon reaction products from catalyst within the reactor vessel of a fluidized catalytic cracker unit. The catalytic reactor vessel includes an outer generally cylindrical shell having a stripping zone arranged at the lower end of the vessel. An inlet riser conduit forming a primary reaction zone extends generally within the shell from the lower end of the vessel to a location near the top of the vessel. A shroud surrounds the upper end of the riser conduit and forms an annular outlet for downwardly discharging a mixture of hydrocarbon and catalyst. According to the present invention, an annular catalyst disengaging riser baffle for deflecting the mixture from the outlet toward the wall of the vessel is arranged on the outside of the riser conduit below the annular outlet and above the stripping zone.

Abstract: A process and related apparatus for separating particulate solids from a stream comprising vapors and particulate solids passed in admixture through an elongated contacting zone. The stream is discharged downwardly at an angle to the vertical along the inside wall of a cylindrical disengagement zone and at an angle to the horizontal of greater than 0.degree. and less than 45.degree.. The solids separate due to centripetal acceleration and fall to the bottom of the disengagement zone.

Abstract: A process for converting normally liquid hydrocarbons with an active fluid catalytic cracking catalyst which comprises:(a) passing an upflowing suspension of hot regenerated active fluid catalytic cracking catalyst in a lift gas comprising hydrocarbons including not more than 10 mole % C.sub.3 and heavier hydrocarbons through a lower portion of a vertically orientated riser conversion zone at a velocity of from about 1.8 to less than 12.2 meters per second, and for a residence time from about 0.5 to about 15 seconds, the ratio of catalyst to hydrocarbon in said lift gas being greater than 80; and(b) introducing the normally liquid hydrocarbons into the upflowing suspension at a locus in the riser conversion zone downstream of the lower portion to form a catalyst-hydrocarbon mixture wherein the temperature and residence time are sufficient to effect the desired conversion.The process is particularly useful for the treatment of a heavy residual feedstock.

Abstract: The hydrotreatment of hydrocarbons in the liquid phase is effected in a column containing a catalyst bed supported by a grid, wherethrough passes an ascending stream of the charge admixed with hydrogen which expands the catalyst bed, the perforations of the grid being small enough to prevent passage of the catalyst particles but large enough to permit passage of the hydrogen-charge mixture, the reaction effluent being withdrawn from the top of the column.

Abstract: A process is disclosed for cracking a carbo-metallic oil feed containing 650.degree. F. material which is characterized by a carbon residue on pyrolysis of at least about 1 and by a level of heavy metal(s) of at least about 4.0 ppm by weight of Nickel Equivalents. The process includes contacting the feed with cracking catalyst bearing an accumulation of substantially more than 600 ppm by weight of Nickel Equivalents of heavy metal(s). The resultant stream flows through a progressive flow type reactor for a vapor residence time of about 0.5 to about 10 seconds at conditions sufficient for causing a conversion per pass of about 50% to about 90% while producing coke in amounts of at least about 6% by weight based on fresh feed and laying down coke on the catalyst in amounts of at least about 0.3% by weight based on catalyst.

Abstract: A process for quenching and cooling the reactor effluent in a thermal regenerative cracking (TRC) system is disclosed. The process for quenching the reactor effluent includes the steps of introducing particulate solids into the reactor effluent stream, passing the composite stream of reactor effluent and particulate solids in indirect heat exchange relationship with a coolant, separating the solids and quenched effluent and returning the separated solids to quench effluent.

Abstract: The invention described is directed to the fluid catalytic conversion of hydrocarbons and is concerned particularly with the method and means for obtaining atomized-vaporized contact of residual oils and reduced crudes with high temperature dispersed phase fluid catalyst particles. More particularly, one embodiment of the invention is directed to atomizing an oil-water emulsion thereafter discharged into up-flowing dispersed phase catalyst particles at velocities up to sonic velocities to form a suspension under hydrocarbon conversion conditions.

Abstract: The invention described is concerned with atomizing an oil fraction of crude oil to provide a fog of oil droplets in diluent gaseous material which is sprayed into an upwardly flowing annular dense mass of catalyst particles to form a high temperature suspension therewith and conveyed through a riser conversion zone under selected hydrocarbon conversion conditions suitable for cracking the oil droplets to gasoline and light cycle oil boiling range products. The oil feed preparation and distribution arrangement to form a suspension with catalyst particles of desired elevated temperature is employed in combination with a two-stage catalyst regeneration operation designed and operated to achieve catalyst temperatures at least equal to the pseudo-critical temperature of the oil feed and at least above the end boiling point of gas oil boiling range material and resid product of vacuum distillation.

Abstract: The present invention relates generally to fluidized catalytic cracking. More particularly, the present invention relates to a baffle arrangement that improves separation of gaseous hydrocarbon reaction products from catalyst within the reactor vessel of a fluidized catalytic cracker unit. The catalytic reactor vessel includes an outer generally cylindrical shell having a stripping zone arranged at the lower end of the vessel. An inlet riser conduit forming a primary reaction zone extends generally external to and generally parallel with the shell to a location near the top of the vessel. The upper end of the riser conduit then turns through 180.degree., preferably through two right angle turns of 90.degree. each, so that the riser conduit enters the vessel either on a horizontal run into the side of the vessel and then turns downwardly, or on a downward run through the top of vessel, into the center of the vessel to form an outlet, discharging downwardly the mixture of hydrocarbon and catalyst.

Abstract: A method and apparatus for regulating the intensity of the catalytic conversion of hydrocarbons in a conversion system employing a transfer line reactor are disclosed.

Abstract: A process and an apparatus for the fluidized catalytic cracking of hydrocarbons are disclosed. A small vent conduit extends upward out of the flow diversion device mounted on the top of the riser reactor. This vent conduit preferably carries between about 2 and 10 percent of the vapor and catalyst leaving the top of the riser upward into the upper portion of the receiving vessel. This reduces coke deposits in the upper portion of the vessel. The remainder of the vapors and catalyst are preferably directed downward upon leaving the top of the riser.

Abstract: Method to improve mixing water-and charge in a hydrocarbon conversion unit comprising foaming the charge with a foaming agent e.g. selected from the group consisting of sulfonates or polymer resins (preferably some oil soluble, some water soluble).

Abstract: A suspension of catalyst and gasiform material is separated by a catalyst particle concentrating means which discharges the catalyst into a steam stripping zone and transmits the separated gasiform material to a cyclone separator by means of a restricted passageway which minimizes the time the gasiform material is exposed to the catalytic reaction product temperature.

Abstract: A process and related apparatus for separating particulate solids from a stream comprising vapors and particulate solids passed in admixture through an elongated contacting zone. The stream is discharged at an angle to the vertical along the inside wall of a cylindrical disengagement zone. The solids separate due to centripetal acceleration and fall to the bottom of the disengagement zone.

Abstract: An apparatus for the fluidized catalytic cracking of a hydrocarbon feedstock comprises a riser reactor and a collar positioned along the same axis as the downstream end of the riser reactor. The collar is further positioned in close proximity to, but not in contact with, the riser reactor such that an annular space is defined between the riser reactor and the collar. The collar has a diameter greater than the diameter of the riser reactor at its downstream end and communicates directly and laterally with the inlets of the cyclone separation system. The riser reactor may or may not include a flow reversal cap to redirect the flow of the hydrocarbons and the catalyst.

Abstract: In a fluid catalytic cracking process in the case of a catalyst load dump the catalyst-laden gas is prevented from passing through the power recover expander. This is achieved by establishing a tangential, low pressure bypass flow path in the supply line to the expander which causes the catalyst to be bypassed. An optical sensor senses the catalyst load dump and causes the actuation of the valve necessary to establish the low pressure bypass flow path.

Abstract: The present invention is an apparatus continuously feeding particulate solids to a TRC reaction chamber or zone at a controlled rate of flow, and for admixing the solids with fluid simultaneously introduced to the reaction zone. This invention utilized one or more conduits, preferably tubular, to transfer the solids from a solids reservoir chamber to the reaction chamber at a controlled rate of flow, the conduits being in open communication with both the reservoir chamber and with the reaction chamber. The conduits are in the nature of orifices, and are symmetrically located across the reactor cross section, said orifices or conduits also being specially oriented with respect to the fluid reactant inlet to promote rapid and intimate mixing of the two phases.

Abstract: In a TRC process and system, an improved process and system for regulating the rate of solids added continuously to a solids-fluid reaction system, the solids participating in the reaction as a reactant, catalyst, or inert heat supply medium.

Abstract: In a cracking process wherein used catalyst is regenerated, contacted with reducing gas to counter effects of contaminating metals, and recycled to the cracking zone, the improvement comprising using a gas seal to assure that a major portion of the unconsumed reducing gas is also passed into the cracking zone.

Abstract: An apparatus and process for delivering fluidization gas to a bed of particulate solids to selectively locally fluidize the solids above a delivery conduit in communication with a reaction chamber. Also an apparatus and process for intimately mixing hydrocarbon feed with the particulate solids at the end of the delivery conduit in the reaction chamber.

Abstract: A burner vessel or regenerator vessel is disclosed which has an elliptical bottom head which supports a particulate refractory fill which in turn supports and stabilizes an air distributor inlet manifold. The manifold is supported at radially arranged distribution pipes so that the main air header floats freely for expansion and contraction. A fluidized bed of particulate is combusted above the refractory fill layer. Other appropriate operation apparatus for the vessel are also disclosed. The burner vessel is used in a fluid coker apparatus and the regenerator vessel is used in a fluid catalytic cracking unit.

Abstract: In a transfer line catalytic cracking reaction system having a riser-reactor provided with a vertical section and a horizontal section, the improvement for minimizing erosion in the system which comprises cracking with a high velocity of reactant and catalyst in the vertical portion of the riser and a lower velocity in the lateral or horizontal section of the reactor prior to introduction of reactant effluent into catalyst separation zone(s).

Abstract: An apparatus for the catalytic cracking of hydrocarbons having two independent transfer line reactors, each of which is associated with an independent cyclone separation system and wherein the cyclone separation systems are located within a common separator vessel. More particularly, the improved apparatus can be used for the simultaneous fluidized catalytic cracking of a hydrocarbon feedstock and the recracking of a selected fraction of the products from said cracking without commingling the feedstock and the selected fraction to be recracked.

Abstract: A method and apparatus for the fluid catalytic cracking of petroleum hydrocarbons wherein an ascending cocurrent stream of vaporous hydrocarbon and entrained catalyst particulates is effected in a tubular reaction zone the method including the following steps: (1) altering the direction of flow of said stream of hydrocarbons and particulates to a downward direction by conducting the stream into a flow reversing zone, (2) accelerating the rate of downward flow of the particulates by gravitational force augmenting fluid flow drag forces to impart momentum thereto, (3) withdrawing cracked hydrocarbons laterally from the downwardly flowing particulates, and (4) contacting the downwardly flowing particulates with inert stripping gas, the momentum of said particulates preventing their passage laterally with the cracked hydrocarbons and permitting their passage counter current to the upward movement of stripping steam.

Abstract: An improved fluid catalytic cracking process providing improved product yield and selectivity and reduced catalyst deactivation which employs a split flow of catalyst to the reactor riser.

Abstract: Residual fractions from distillation of petroleum are rendered suitable for charge to catalytic cracking by high temperature, short time contact in a decarbonizing zone with a fluidizable solid particles of essentially inert character and low surface area to deposit high boiling components of the crude and metals on the fluidizable solid particles whereby Conradson Carbon values and metal content of the hydrocarbon feedstock are reduced to levels tolerable in catalytic cracking and carbon laid down on the inert fluidizable particles is burned in a burning zone separate from the decarbonizing zone. Heated inert particles are recycled at least in part to the decarbonizing zone and then to the burning zone.

Abstract: An improved fluid catalytic cracking process providing improved product yield and selectivity which employs a split flow of recycled, regenerated catalyst to the reactor riser. Process operating temperatures control the flow rates of the recycled, regeneration catalyst.

Abstract: The thermal cracking of retort oil vapors in an elongated reactor is improved by passing the effluent oil vapors and gases from a retort to a thermal cracking unit before the temperature of the retort effluent falls below 680.degree. F. This encourages the more desirable cracking reactions, increases the thermal efficiency of the process, and avoids preheater coking.

Abstract: A riser cracking-catalyst regeneration operation is described wherein a suspension discharged from a riser operation is separated by catalyst particle concentrating means which discharge a concentrated stream of catalyst separated from gasiform material into a downcomer zone and out of further contact with discharged gasiform material in the suspension. A stripping gas is used to particularly aid the separation of catalyst and hydrocarbon vapors.

Abstract: In a reactant-fluid catalyst suspension system, an arrangement of apparatus is provided contiguous with a riser discharge which centrifugally initially separates the suspension into a solids phase and a gasiform material phase prior to discharge from the riser. The catalyst may be further stripped if desired in equipment above and about the riser discharge. The arrangement contributes substantially to the efficiency and economics of the separation of catalyst from gasiform products including products of hydrocarbon conversion and combustion products of catalyst regeneration.

Abstract: A method of injecting a hydrocarbon feed into a catalytic conversion zone whereby wall temperatures within the conversion zone are reduced and overcracking of the hydrocarbon feed is minimized.