Abstract: Catalyst and hydrocarbon vapors are separated in a cyclone zone attached to the discharge of a riser cracking operation. Vortex stabilizing means separating the cyclone zone from a stripping zone allows stripping gas from said stripping zone to be passed upwardly into said cyclone zone countercurrent to the downward flow of catalyst, thereby improving the separation and stripping of gaseous hydrocarbons from separated catalyst. The combined cyclone-stripping zone reduces catalyst hydrocarbon contact time, thereby improving gasoline yield and olefin content, decreasing gas make, and reducing coke deposits.

Abstract: A process is disclosed for the conversion of high boiling oil feeds having a significant level of Conradson carbon components and metals to form lighter oil products by contacting the feed under catalytic conversion conditions with a catalyst containing one of a select group of metal additives to catalyze the endothermic removal of carbon with CO.sub.2. Conversion conditions are such that hydrocarbonaceous material and metals are deposited to deactivate the catalyst in the conversion zone. Deactivated catalyst is partially regenerated in the presence of carbon dioxide containing gas before or after oxygen regeneration at a temperature below 1600.degree. F. to provide a regenerated catalyst which is recycled to the conversion zone for further contact with fresh feed. The metal additive is present on the catalyst in an amount sufficient to catalyze the endothermic removal of carbonaceous material in the presence of a carbon dioxide rich gas at regeneration temperature below 1500.degree. F.

Abstract: A system is described for control of sulfur oxides in emissions to the atmosphere from regenerators of cyclic Fluid Catalytic Cracking Units (FCC). By the disclosed system, hot regenerator flue gas is cooled, air (oxygen) is injected into the cooled flue gas unless oxygen is already present, and then the cooled flue gas is contacted with a solid particulate material which has the capability of associating with and binding sulfur oxides in the flue gas to form a stable solid material which is separated from the gases.

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 method as described in the title comprising deflecting the gas from the distributor through nozzles therein through an angle in the range of 30.degree. to 75.degree. for decreased erosion in the nozzles by solids drawn therein and for reduced required power consumption. A new gas distributor with nozzles mounted therein is disclosed.

Abstract: Emissions of sulfur oxides from the regenerator of a fluidized catalytic cracking unit are reduced by selectively removing a portion of the sulfur from sulfur-containing coke deposits on deactivated cracking catalyst. This is accomplished by reaction of these deposits with limited amounts of molecular oxygen in a stripping zone at a temperature in the range from about 550.degree. to about 700.degree. C. Effluent gas from the striping zone is combined with the cracked hydrocarbon products.

Abstract: A process for the direct catalytic conversion of hydrocarbon oil is disclosed wherein the hydrocarbon feedstock, hydrogen and hot solid catalyst particles are contacted at a temperature from about 600.degree. F. to about 995.degree. F. to form a suspension in a riser reactor thereby producing lower boiling hydrocarbon components.

Abstract: A process and associated apparatus for the cooling of hot fluidized solid particles. The particles flow from a first dense phase fluidized bed into the shell side of a vertically oriented shell and tube heat exchanger where cooling occurs via indirect heat exchange with a cooling medium circulating in the tubes. The extent of cooling is controlled by the varying of the heat transfer coefficient between the tubes and particles in the heat exchanger which are maintained as a second dense phase fluidized bed. The coefficient is varied by varying the quantity of fluidizing gas to the fluidized bed in the heat exchanger. The particles flow freely to and from the first and second dense phase fluidized beds through which the particles recirculate and are backmixed. The process has particular applicability to a combustive regeneration process and most particular applicability to the FCC process.

Abstract: A catalyst regeneration process and apparatus for the oxidative removal of coke from a coke contaminated fluid catalyst. The process comprises a high temperature coke combustion zone, a catalyst disengagement zone and an external heat removal zone comprising a shell and tube heat exchanger. Catalyst is cooled by passing it through the shell side of the heat exchanger with a cooling medium through the tube side. A mixture of coke contaminated catalyst, oxygen containing gas, and cool regenerated catalyst from the heat removal zone are contacted in the high temperature combustion zone, the temperature of which is controlled by adjusting the rate at which catalyst is passed through the heat exchanger. This rate is adjusted by adjusting the difference in catalyst head between the catalyst inlet and outlet of the heat exchanger and thus the hydraulic driving force which effects catalyst circulation through the heat exchanger.

Abstract: Emissions of sulfur oxides from the regenerator of a catalytic cracking unit are reduced by selectively removing a portion of the sulfur from sulfur-containing coke deposits on deactivated cracking catalyst. This is accomplished by reaction of these deposits with limited amounts of molecular oxygen in a stripping zone at a temperature in the range from about 550.degree. to about 700.degree. C. Hot regenerated catalyst and/or hot effluent gas from the catalyst regeneration zone is passed to the stripping zone in an amount which is effective to maintain the temperature in said stripping zone within the range from about 550.degree. to about 700.degree. C.

Abstract: A process and associated apparatus for the cooling of hot fluidized solid particles. The particles flow from a dense phase fluidized bed into the shell side of a vertically oriented shell and tube heat exchanger where cooling occurs via indirect heat exchange with a cooling media circulating in the tubes. The extent of cooling is controlled by the varying of the heat transfer coefficient between the tubes and particles in the heat exchanger which are maintained as a dense phase fluidized bed. The coefficient is varied by varying a combination of the variables comprising the quantity of fluidizing gas to the fluidized bed in the heat exchanger and the quantity of particle flow through that bed. The process has particular applicability to a combustive regeneration process and most particular applicability to the FCC process.

Abstract: A method is disclosed for cracking a carbo-metallic oil feed containing high amounts of coke forming carbonaceous materials as characterized by a Conradson carbon value of more than 1 and containing a level of nickel and/or vanadium of greater than 5 ppm. The method includes contacting the feed with catalyst particles and liquid water containing hydrogen sulfide. At least a portion of the water may be recycled water from prior catalytic cracking of an oil feed containing sulfur.

Abstract: An apparatus for regenerating coke-contaminated fluid catalyst is disclosed which comprises a vertical combustion chamber, an inlet to said chamber for spent catalyst and regeneration gas, a heat removal chamber located superadjacent to the combustion chamber and in communication therewith, heat removal means disposed within the heat removal chamber, a catalyst withdrawal conduit connected at one end to the heat removal chamber for withdrawing regenerated fluid catalyst from the heat removal chamber, and a catalyst recycle conduit connecting the withdrawal conduit with the lower portion of the combustion chamber, such that regenerated fluid catalyst can pass from the heat removal chamber to the combustion chamber. There may also be a means and control system for manipulating the extent of immersion of the heat removal means.

Abstract: A method and apparatus for regeneration of coked catalyst resulting from a hydrocarbon conversion reaction in which catalyst regeneration is carried out in a plurality of superposed regeneration zones comprising the combination of a first dense phase fluidized bed regeneration zone, an entrained catalyst dilute phase regeneration zone superposed on said first regeneration zone, and a second dense phase fluid bed regeneration zone superposed on said dilute phase regeneration zone. Catalyst is regenerated by combustion of coke from the surface of the catalyst at an elevated temperature in the range of 675.degree. to 800.degree. C. with an excess of oxygen supplied by an oxygen-containing regeneration gas part of which is introduced into the first fluidized bed regeneration zone and part into said dilute phase regeneration zone, including a novel means of control of the rate of catalyst recirculated from said second dense phase regeneration zone to said first regeneration zone.

Abstract: A catalyst regeneration process and apparatus for the oxidative removal of coke from a coke contaminated fluid catalyst. The process comprises a high temperature coke combustion zone, a catalyst disengagement zone and an external heat removal zone. A mixture of coke contaminated catalyst, oxygen containing gas, hot regenerated catalyst and cool regenerated catalyst from the heat removal zone are contacted in the high temperature combustion zone, the temperature of which is controlled by adjusting the rate at which catalyst is recycled from the heat removal zone. The temperature of the catalyst-gas mixture is controlled by adjusting the rate at which hot catalyst is recycled from the disengagement zone.

Abstract: A process for economically converting carbo-metallic oils to lighter products. The carbo-metallic oils contain 650.degree. F.+ material which is characterized by a carbon residue on pyrolysis of at least about 1 and a Nickel Equivalents of heavy metals content of at least about 4 parts per million. This process comprises flowing the carbo-metallic oil together with particulate cracking catalyst through a progressive flow type reactor having an elongated reaction chamber, which is at least in part vertical or inclined, for a predetermined vapor riser residence time in the range of about 0.5 to about 10 seconds, at a temperature of about 900.degree. to about 1400.degree. F., and under a pressure of about 10 to about 50 pounds per square inch absolute sufficient for causing a conversion per pass in the range of about 40% to 90% while producing coke in amounts in the range of about 6 to about 14% by weight based on fresh feed, and laying down coke on the catalyst in amounts in the range of about 0.

Abstract: A catalyst regeneration process and apparatus for the oxidative removal of coke from a coke contaminated fluid catalyst. The process comprises a high temperature coke combustion zone, a catalyst disengagement zone and an external heat removal zone comprising a shell and tube heat exchanger. Catalyst is cooled by passing it through the shell side of the heat exchanger with a cooling medium through the tube side. A mixture of coke contaminated catalyst, oxygen containing gas, and cool regenerated catalyst from the heat removal zone are contacted in the high temperature combustion zone, the temperature of which is controlled by adjusting the rate at which fluidizing gas is passed to the bottom portion of the shell of the heat exchanger which varies the degree of turbulence of the fluidized bed in the shell side and thus the heat transfer coefficient at the outside surface of the tubes which in turn varies the quantity of heat transferred to the cooling medium in the tubes.

Abstract: A fluid catalytic cracking process and apparatus in which a plurality of hydrocarbon feedstocks including at least one normally gaseous paraffinic hydrocarbon feedstock and at least one normally liquid hydrocarbon feedstock are subjected to cracking reaction conditions in a common transport type reaction zone in the presence of a zeolite cracking catalyst. Fresh hot regenerated catalyst is first contacted with a normally gaseous paraffinic hydrocarbon under dehydrogenation reaction conditions effecting conversion to normally gaseous olefins, and fresh normally liquid cracking charge stock is contacted in the reaction zone under cracking reaction conditions with the gaseous paraffinic and olefinic hydrocarbons.

Abstract: An apparatus for regenerating coke-contaminated fluid catalyst which comprises a vertical combustion chamber, an inlet to said chamber for spent catalyst and regeneration gas, a disengagement chamber above and in communication with the combustion chamber, a heat removal chamber below the combustion chamber in which may be maintained a dense phase catalyst bed, heat removal means positioned within the heat removal chamber such that it will be immersed in the catalyst bed, a recycle conduit for passing catalyst from the disengagement chamber to the heat removal chamber, a vertical cooled catalyst inlet conduit connecting the heat removal chamber with the lower portion of the combustion chamber so that catalyst can pass from the former to the latter, and a regeneration gas inlet line connecting with a lower part of the cooled catalyst inlet conduit to enable the flow of cooled catalyst up into the combustion chamber, wherein a control system senses the catalyst level in the heat removal zone, formulates an outpu

Abstract: A method and apparatus for catalytic conversion of hydrocarbon feedstocks and regeneration of coked catalyst resulting from the hydrocarbon conversion reaction in which the catalyst regeneration is carried out in a combination of dense phase fluidized bed, an entrained phase regeneration zone and a second dense phase fluidized bed and the hydrocarbon conversion reaction is carried out in a high velocity short contact time dilute phase reaction zone wherein the reaction time and temperature and the regenerator temperature may be separately varied to provide and maintain optimum conversion conditions.

Abstract: A method is disclosed for cracking a carbo-metallic oil feed containing high amounts of coke forming carbonaceous materials as characterized by a carbon residue on pyrolysis of at least about 1 and by a level of heavy metal(s) of at least about 5.5 ppm by weight of Nickel Equivalents. The method includes contacting the feed with cracking catalyst bearing an accumulation of at least about 3,000 ppm by weight of Nickel Equivalents of heavy metal(s) and with additional material including water. The resultant stream flows through a progressive flow type reactor for a vapor residence time of about 0.5 to about 6 seconds at conditions sufficient for causing a conversion per pass of about 60% to about 90%. The additional material is added in a weight ratio relative to feed of up to about 0.4 and includes water in a weight ratio relative to feed of at least about 0.04. The water may be introduced as steam and/or liquid water.

Abstract: A process for economically converting carbo-metallic oils to lighter products. This process comprises flowing the carbo-metallic oil together with particulate cracking catalyst through a progressive flow type reactor having an elongated reaction chamber, which is at least in part vertical or inclined, for a predetermined vapor riser residence time in the range of about 0.5 to about 10 seconds, at a temperature of about 900 to about 1400.degree. F., and under a pressure of about 10 to about 50 pounds per square inch absolute sufficient for causing a conversion per pass in the range of about 50% to about 90% while producing coke in amounts in the range of about 6 to about 14% by weight based on fresh feed, and laying down coke on the catalyst in amounts in the range of about 0.3 to about 3% by weight.

Abstract: Conversion of a hydrocarbon feed containing a catalyst-deactivating component in a riser FCC cracking system can be increased by employing a baffle in the lower part of the riser to exclude a portion of the upwardly flowing catalyst from initial contact with feed hydrocarbons containing the catalyst-deactivating component. Part of the catalyst flowing upwardly through the riser thereby is excluded from contact with the catalyst-deactivating component until the catalyst-deactivating component has been at least partially removed from the resulting hydrocarbonaceous vapor by deposition on another portion of the upwardly flowing catalyst.

Abstract: In a fluid catalytic cracking (FCC) process and apparatus, the heat balance between the reactor and the regenerator of the FCC operation is partially uncoupled by transferring at least a portion of thermal energy from the reactor vessel downflow riser to the regenerator vessel. The transfer of thermal energy results in a higher regenerating temperature. The thermal energy is recirculated to the upstream section of the downflow reactor riser through a regenerated catalyst having higher temperature. Consequently, the outlet of the reactor vessel is maintained at a substantially constant temperature (e.g., 1000.degree. F.) and the rate of conversion of the oil feed and the octane number of gasoline produced in the process are increased.

Abstract: A multi-zone fluidized bed hydrocarbon conversion process and apparatus for producing gas and distillable liquid products from heavy hydrocarbon feedstocks. The feedstock is introduced into an upper fluidized bed primary cracking zone maintained at temperature of 850.degree.-1400.degree. F. for cracking reactions therein, and resulting tars and coke are deposited on and within a particulate carrier material contained therein. The carrier material containing said tars and coke descends successively through a stripping zone to remove tars and an interim controlled temperature zone for secondary cracking against an upflowing hot reducing gas, then descends into a lower fluidized bed gasification zone. The gasification zone is maintained at temperature of 1600.degree.-1900.degree. F. by oxygen-containing gas and steam introduced therein to gasify the coke deposits and produce the reducing gas.

Abstract: A process for economically converting carbo-metallic oils to lighter products. The carbo-metallic oils contain 650.degree. F..sup.+ material, at least a portion of said 650.degree. F..sup.+ material containing components which will not boil before about 1025.degree. F., said 650.degree. F..sup.+ material further being characterized by a carbon residue on pyrolysis of at least about 1 and a Nickel Equivalents of heavy metals content of at least about 4 parts per million. This process comprises providing a cracking catalyst having an average pore volume of at least about 0.2 cc per gram and an average particle diameter in the range of about 20 microns to about 150 microns, flowing the carbo-metallic oil together with the cranking catalyst through a progressive flow type reactor having an elongated reaction chamber, which is at least in part vertical or inclined, for a predetermined vapor riser residence time in the range of about 0.5 to about 10 seconds, at a temperature of about 900.degree. to about 1400.

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 catalyst regeneration process and apparatus for the oxidative removal of coke from a coke contaminated fluid catalyst for use of the catalyst in a catalytic cracking reaction zone. The process comprises a high temperature coke combustion zone, a catalyst disengagement zone and an external heat removal zone comprising a shell and tube heat exchanger. A mixture of coke contaminated catalyst, and oxygen containing gas are contacted in the high temperature combustion zone. Catalyst is cooled by passing it through the shell side of the heat exchanger with a cooling medium through the tube side. The cooled catalyst is passed to the reaction zone. The catalyst is maintained in the cooling zone as a dense phase fluidized bed by passing a fluidizing gas into the bottom of the shell side. Steam is the preferred fluidizing gas.

Abstract: A particular aspect of the invention concepts disclosed and described is directed to the use of a vented cup ballistic separation device and method of use for achieving rapid separation of a suspension of fluidized solid particulate and gasiform material. The vented cup ballistic separation apparatus is particularly discussed in conjunction with separating a suspension of catalyst particles from vaporous hydrocarbon reaction products of catalytic cracking discharged from a riser cracking operation. The vented cup ballistic separation apparatus particularly comprises an annular chamber about the upper periphery of an open ended riser conduit. The annular chamber is open in the upper end and one or more open end conduits extend outwardly from the annular chamber comprising means for attachment to cyclone separation means. The riser with vented cup or annular chamber terminates within a larger diameter chamber.

Abstract: A process is disclosed for the production of high octane gasoline and/or other valuable lower molecular weight products from carbo-metallic oils. Examples include crude oil, topped crude, reduced crude, residua, the extract from solvent de-asphalting and other heavy hydrocarbon fractions. These carbo-metallic oils contain quantities of coke precursors and heavy metal catalyst poisons substantially in excess of what is normally considered acceptable for FCC processing (fluid catalytic cracking) and substantial amounts of sulfur, nitrogen and other troublesome components may also be present. Such carbo-metallic oils are converted to the desired products in a catalytic conversion process. Named "RCC" (Reduced Crude Conversion) after a particularly common or useful carbo-metallic feed, the present process is by no means restricted to reduced crude or to oils of petroleum origin, having utility in the processing of oils from coal, shale and other sources.

Abstract: Process and apparatus suitable for the regeneration of catalytic cracking catalyst particles and for the heating and partial conversion of coke particles from a coking process are described. The particles are heated in two successive zones, for example formed by two fluidized beds, conditions being controlled so that (1) only partial regeneration of catalyst particles or conversion of coke particles occurs in the first zone, and (2) there is no major evolution of heat from either zone.

Abstract: A catalyst regeneration process and apparatus for the oxidative removal of coke from a coke-contaminated fluid catalyst. The process utilizes a high temperature coke combustion zone and a catalyst disengagement zone. A mixture of coke-contaminated catalyst, and oxygen-containing gas are contacted in the combustion zone and from there, the regenerated catalyst and flue gas mixture passes to the catalyst disengagement zone. There are one or more diplegs through which regenerated catalyst flows from the disengagement zone to the combustion zone. The diplegs are sized so as to ensure a low maximum accumulation of catalyst in the disengagement zone. The temperature at a lower locus of the combustion zone may be controlled by control of the catalyst inventory in the reactor-regenerator system.

Abstract: A fluid catalytic cracking (FCC) process and apparatus using a riser and a reactor for cracking of petroleum feeds in the presence of a catalyst and a regenerator for regenerating the spent catalyst are improved by providing a downflow riser. The downflow riser assures uniform distribution of the catalyst throughout the feed, decreases contact time of the catalyst with the feed and decreases the amount of coke made in the process.

Abstract: The invention relates to an improvement in an integrated, two stage coking and steam cracking process for the production of unsaturated light hydrocarbons. A heavy hydrocarbonaceous oil is first coked in a fluid coking zone. High temperature cracking in the presence of steam is carried out on the vaporous coker conversion product by injecting into the vapors a stream of hot coke particles at a sufficient temperature and in sufficient amount to raise the coker vapors to steam cracking temperature and supply the endothermic heat of reaction. Solids are separated from gas in a gas-solids separation zone such as one or more cyclones and sent to the fluid coking zone and the gas is quenched to stop olefin degradation reactions. According to the improvement, a portion of the separated solids is diverted from entering the fluid coking zone so that the amount of separated solids it receives is only sufficient to satisfy its heat requirement. Solids may be diverted via the cyclone dipleg.

Abstract: Modifying a heat balanced operating fluid catalytic cracking (FCC) system to utilize a platinum group metal modified cracking catalyst, whereby increasing the heat generated in the exothermic regeneration of coked catalyst, and to provide a regenerated catalyst heat exchange cooler to permit adjustment of cracking conditions independent of the extra heat produced in the regeneration of catalyst.

Abstract: A catalyst, having a specified amount of rare earth metal content and a specified amount of alkali metal content, suitable for conversion of hydrocarbon oils to lower boiling products comprises a crystalline aluminosilicate zeolite, such as zeolite Y, an inorganic oxide matrix and, optionally discrete particles of alumina dispersed in the matrix. The zeolite prior to being composited with the matrix has a unit cell size above about 24.5 Angstroms. A cracking process utilizing the catalyst is also provided.

Abstract: A catalyst regeneration process and apparatus for the oxidative removal of coke from a coke contaminated fluid catalyst. The process comprises a high temperature coke combustion zone, a catalyst disengagement zone and an external heat removal zone. A mixture of coke contaminated catalyst, oxygen containing gas, hot regenerated catalyst and cool regenerated catalyst from the heat removal zone are contacted in the high temperature combustion zone, the temperature of which is controlled by adjusting the rate at which catalyst is recycled from the heat removal zone. The temperature of the catalyst-gas mixture is controlled by adjusting the rate at which hot catalyst is recycled from the disengagement zone.

Abstract: A process for economically converting carbo-metallic oils to lighter products. The carbo-metallic oils contain 650.degree. F.+ material which is characterized by containing material which will not boil below about 1025.degree. F., a carbon residue on pyrolysis of at least about 1 and a Nickel equivalents of heavy metals content of at least about 4 parts per million. This process comprises flowing the carbo-metallic oil together with particulate cracking catalyst through a progressive flow type reactor having an elongated reaction chamber, which is at least in part vertical or inclined, for a predetermined vapor riser residence time in the range of about 0.5 to about 10 seconds, at a temperature of about 900.degree. to about 1400.degree. F.

Abstract: A catalyst regeneration process and apparatus for the oxidative removal of coke from a coke-contaminated fluid catalyst. The process comprises of high temperature coke combustion zone, a lower temperature heat removal zone and an upper disengagement zone. Coke-contaminated catalyst, oxygen-containing gas and cooled regenerated catalyst from the heat removal zone are contacted in the high temperature combustion zone, the temperature of which is controlled by adjusting the rate at which catalyst is recycled to the heat removal zone. The heat removal zone contains a relatively dense-phase fluid catalyst bed in which is immersed heat removal means such as cooling coils. The level of this fluid catalyst bed, and thus the extent of immersion of the heat removal means in the bed, is maintained by controlling the quantity of regeneration gas passed into the transfer line that carries catalyst upward from the heat removal zone to the combustion zone.

Abstract: In a fluid catalytic cracking process, the regeneration temperature can be eliminated as an operating constraint, catalyst losses can be held constant or reduced, carbon on regenerated catalyst can be reduced and the coke burning capacity of the regenerator can be increased by the combination of cooling the hot regenerated catalyst and increasing the oxygen content of the inlet regeneration air.

Abstract: A catalyst regeneration process and apparatus for the oxidative removal of coke from a coke contaminated fluid catalyst. The process comprises a high temperature coke combustion zone, a catalyst disengagement zone and an external heat removal zone comprising a shell and tube heat exchanger. Catalyst is cooled by passing it through the shell side of the heat exchanger with a cooling medium through the tube side. A mixture of coke contaminated catalyst, oxygen containing gas, and cool regenerated catalyst from the heat removal zone are contacted in the high temperature combustion zone, the temperature of which is controlled by adjusting the rate at which catalyst is passed through the heat exchanger. This rate is adjusted by adjusting the difference in catalyst head between the catalyst inlet and outlet of the heat exchanger and thus the hydraulic driving force which effects catalyst circulation through the heat exchanger.

Abstract: In a fluid catalytic cracking (FCC) process and apparatus, the heat balance between the reactor and the regenerator of the FCC operation is partially uncoupled by transferring at least a portion of thermal energy from the reactor vessel riser to the regenerator vessel. The transfer of thermal energy results in a higher regenerating temperature. The thermal energy is recirculated to the bottom section of the reaction riser through a regenerated catalyst having higher temperature. Consequently, the outlet of the reaction vessel is maintained at a substantially constant temperature (e.g., 100.degree. F.) and the rate of conversion of the oil feed and the octane number of gasoline produced in the process are increased.

Abstract: A process is disclosed for the production of high octane gasoline and/or other valuable lower molecular weight products from carbo-metallic oils. Examples include crude oil, topped crude, reduced crude, residua, the extract from solvent de-asphalting and other heavy hydrocarbon fractions. These carbo-metallic oils contain quantities of coke precursors and heavy metal catalyst poisons substantially in excess of what is normally considered acceptable for FCC processing (fluid catalytic cracking) and substantial amounts of sulfur, nitrogen and other troublesome components may also be present. Such carbo-metallic oils are converted to the desired products in a catalytic conversion process. Named "RCC" (Reduced Crude Conversion) after a particularly common or useful carbo-metallic feed, the present process is by no means restricted to reduced crude or to oils of petroleum origin, having utility in the processing of oils from coal, shale and other sources.

Abstract: A regenerator control system is disclosed which is particularly useful in connection with combustion promoted cracking catalysts. The air flow is controlled responsive to the temperature in the dilute phase, first in a direct mode when the amount of combustibles on the catalyst is at or above a set point and second in accordance with a reverse mode when the amount of combustibles is below such a set point. This versatile control system allows the safe operation of a regenerator under a variety of conditions.

Abstract: A catalyst regeneration process and apparatus for the oxidative removal of coke from a coke contaminated fluid catalyst. The process comprises a high temperature coke combustion zone, a catalyst disengagement zone and an external heat removal zone comprising a shell and tube heat exchanger. Catalyst is cooled by passing it through the shell side of the heat exchanger with a cooling medium through the tube side. A mixture of coke contaminated catalyst, oxygen containing gas, and cool regenerated catalyst from the heat removal zone are contacted in the high temperature combustion zone, the temperature of which is controlled by adjusting the rate at which fluidizing gas is passed to the bottom portion of the shell of the heat exchanger which varies the degree of turbulence of the fluidized bed in the shell side and thus the heat transfer coefficient at the outside surface of the tubes which in turn varies the quantity of heat transferred to the cooling medium in the tubes.

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: A fluid catalytic cracking unit (FCCU) is controlled in such a manner that load is automatically shifted from the wet gas compressor to the air blower for the catalyst regenerator if the loading on the wet gas compressor becomes a limiting factor on the yield of a desired product from the FCCU. Also, the preheat temperature for the feed flowing to the reactor is automatically increased if the desired temperature in the reactor cannot be maintained by increasing catalyst flow to the reactor without exceeding an air blower limitation. This automatic load shifting provides for a substantially maximum production of a desired product without exceeding a process limitation.

Abstract: Cracking catalyst fines from a slurry oil are introduced into a cracking-regeneration loop not together with the highly aromatic, refractory hydrocarbon of the slurry oil but rather with a desirable hydrocarbon, such as a virgin gas oil. The invention has the advantage that the desirable catalyst fines are introduced into the cracking-regeneration loop whereas the highly aromatic oil of this slurry is not or not to a substantial extent introduced into the cracking zone.

Abstract: A side by side hydrocarbon conversion-two staged stacked catalyst regeneration arrangement is provided wherein the first stage of catalyst regeneration is temperature restricted to achieve incomplete removal of carbon deposits and a second higher temperature regeneration is accomplished in an upflowing catalyst contact system under conditions to accomplish removal of residual carbon on the catalyst and produce a CO.sub.2 -rich flue gas. A special external cyclone separator arrangement may be attached to either of the second stage regeneration operation or the riser hydrocarbon conversion operation to effect separation of catalyst particles from gasiform material.

Abstract: A process is disclosed for the production of high octane gasoline and/or other valuable lower molecular weight products from carbo-metallic oils. Examples include crude oil, topped crude, reduced crude, residua, the extract from solvent de-asphalting and other heavy hydrocarbon fractions. These carbo-metallic oils containing quantities of coke precursors and heavy metal catalyst poisons substantially in excess of what is normally considered acceptable for FCC processing (fluid catalytic cracking) and substantial amounts of sulfur, nitrogen and other troublesome components may also be present. Such carbo-metallic oils are converted to the desired products in a catalytic conversion process. Named "RCC" (Reduced Crude Conversion) after a particularyly common or useful carbo-metallic feed, the present process is by no means restricted to reduced crude or to oils of petroleum origin, having utility in the processing of oils from coal, shale and other sources.