PROCESS FOR REGENERATING CATALYST IN A FLUID CATALYTIC CRACKING UNIT

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

FCC spent catalyst distributor

An distributor arrangement introduces spent FCC catalyst more uniformly across the dense bed of the regenerator to provide more even contact with regeneration gas in order to avoid hot spots and zones of incomplete combustion. The invention forms a fluidized hopper to collect spent catalyst and a horizontally extended header with multiple horizontally extended outlet arms to place catalyst into the regenerator. The invention may use an aeration means to fluidize the header to further assist catalyst flow. Furthermore, the spent catalyst delivered to the top of the regenerator dense reduces NOx emissions in the flue gas.

External second stage cyclones in olefin production process

The present invention comprises a process and apparatus for producing olefins from oxygenates in a reactor. This process comprises these oxygenates with a catalyst to produce a gaseous mixture comprising light olefins and by-products, sending the mixture to a single stage cyclone within said reactor to separate said catalyst from said gaseous mixture and then sending said the to a second stage cyclone. The second stage cyclone is located outside of said reactor and it functions to remove the catalyst from the mixture. Then the catalyst can be returned to the reactor after having been treated in a regeneration zone to remove carbonaceous deposits from the catalyst.

Char-handling processes in a pyrolysis system

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

Catalyst cooler for regenerated catalyst

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

Design for Drying Regenerated Catalyst in Route to a Propane Dehydrogenation Reactor

An apparatus and process are presented for drying a catalyst in a reactor-regenerator system. The process includes a continuous operating system with catalyst circulating between a reactor and regenerator, and the catalyst is dried before returning the catalyst to the reactor. The process uses air that is split between the drying stage and the combustion stage without adding equipment outside of the regenerator, minimizing energy, capital cost, and space requirements.

For drying regenerated catalyst in route to a propane dehydrogenation reactor

An apparatus and process are presented for drying a catalyst in a reactor-regenerator system. The process includes a continuous operating system with catalyst circulating between a reactor and regenerator, and the catalyst is dried before returning the catalyst to the reactor. The process uses air that is split between the drying stage and the combustion stage without adding equipment outside of the regenerator, minimizing energy, capital cost, and space requirements.

Method for drying regenerated catalyst in route to a propane dehydrogenation reactor

An apparatus and process are presented for drying a catalyst in a reactor-regenerator system. The process includes a continuous operating system with catalyst circulating between a reactor and regenerator, and the catalyst is dried before returning the catalyst to the reactor. The process uses air that is split between the drying stage and the combustion stage without adding equipment outside of the regenerator, minimizing energy, capital cost, and space requirements.

Method for Drying Regenerated Catalyst in Route to a Propane Dehydrogenation Reactor

An apparatus and process are presented for drying a catalyst in a reactor-regenerator system. The process includes a continuous operating system with catalyst circulating between a reactor and regenerator, and the catalyst is dried before returning the catalyst to the reactor. The process uses air that is split between the drying stage and the combustion stage without adding equipment outside of the regenerator, minimizing energy, capital cost, and space requirements.

PROPANE DEHYDROGENATION PROCESS UTILIZING FLUIDIZED CATALYST SYSTEM

A process for the production of propylene from a propane rich hydrocarbon source is presented. The process converts a propane rich stream and uses less equipment and energy for the separation and production of propylene. The process uses a non-noble metal catalyst and utilizes a continuous reactor-regeneration system to keep the process on line for longer periods between maintenance.

Process for feed preheating with flue gas cooler

Hydrocarbon feed to a catalytic reactor can be heat exchanged with flue gas from a catalyst regenerator. This innovation enables recovery of more energy from flue gas thus resulting in a lower flue gas discharge temperature. As a result, other hot hydrocarbon streams conventionally used to preheat hydrocarbon feed can now be used to generate more high pressure steam.

SLURRY COLUMN GASOLINE ALKYLATION USING GAS PHASE OLEFIN INJECTION

Alkylation systems and processes are provided herein that include a slurry reactor. The slurry reactor receives a reactor feed slurry including catalyst and liquid isobutane, a olefin feed, and a circulating reactor vapor stream, where the slurry reactor produces a reactor liquid effluent stream, the reactor liquid effluent stream including catalyst, isobutane, and a liquid alkylate product. The catalyst in the reactor feed slurry can be regenerated catalyst from a catalyst regenerator. The catalyst can be regenerated after being removed from the liquid alkylate product and isobutane in the reactor liquid effluent stream.

SLURRY COLUMN GASOLINE ALKYLATION USING GAS PHASE OLEFIN INJECTION

Alkylation systems and processes are provided herein that include a slurry reactor. The slurry reactor receives a reactor feed slurry including catalyst and liquid isobutane, a olefin feed, and a circulating reactor vapor stream, where the slurry reactor produces a reactor liquid effluent stream, the reactor liquid effluent stream including catalyst, isobutane, and a liquid alkylate product. The catalyst in the reactor feed slurry can be regenerated catalyst from a catalyst regenerator. The catalyst can be regenerated after being removed from the liquid alkylate product and isobutane in the reactor liquid effluent stream.

APPARATUSES FOR CONTROLLING HEAT FOR RAPID THERMAL PROCESSING OF CARBONACEOUS MATERIAL AND METHODS FOR THE SAME

Embodiments of apparatuses and methods for controlling heat for rapid thermal processing of carbonaceous material are provided herein. The apparatus comprises a reactor, a reheater for forming a fluidized bubbling bed comprising an oxygen-containing gas, inorganic heat carrier particles, and char and for burning the char into ash to form heated inorganic particles. An inorganic particle cooler is in fluid communication with the reheater. The inorganic particle cooler comprises a shell portion and a tube portion. The inorganic particle cooler is configured such that the shell portion receives a portion of the heated inorganic particles and the tube portion receives a cooling medium for indirect heat exchange with the portion of the heated inorganic particles to form partially-cooled heated inorganic particles. 1. An apparatus for controlling heat for rapid thermal processing of carbonaceous material , the apparatus comprising:a reactor;a reheater in fluid communication with the reactor to receive inorganic heat carrier particles and char, wherein the reheater is configured to form a fluidized bubbling bed that comprises an oxygen-containing gas, the inorganic heat carrier particles, and the char and to operate at combustion conditions effective to burn the char into ash and heat the inorganic heat carrier particles to form heated inorganic particles; andan inorganic particle cooler in fluid communication with the reheater and comprising a shell portion and a tube portion that is disposed in the shell portion, wherein the inorganic particle cooler is configured such that the shell portion receives a portion of the heated inorganic particles and the tube portion receives a cooling medium for indirect heat exchange with the portion of the heated inorganic particles to form partially-cooled heated inorganic particles that are fluidly communicated to the reheater.2. The apparatus according to claim 1 , wherein the tube portion comprises a plurality of tubes each having an ...

Direct return of oxygenate recycle stream in olefin production process

The invention is a process and the corresponding apparatus for producing light olefins from oxygenates in an OTO reactor comprising sending an oxygenate feed stream through a feed stream distributor into an OTO reactor, contacting the oxygenates with a catalyst to produce a mixture comprising light olefins, diolefins, unreacted oxygenate and other by-products; separating the unreacted oxygenate and diolefins from said light olefins and said by-products; and returning the unreacted oxygenate and diolefins to the OTO reactor. The unreacted oxygenate and diolefins are sent through at least one feed nozzle into said reactor at a point separate from the oxygenate feed stream.

Process for regenerating catalyst in a fluid catalytic cracking unit

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

Process for the production of propylene

A process for catalyst regeneration is presented. The process regenerates a catalyst in a paraffin dehydrogenation process, where the reaction is endothermic. The regeneration process provides the heat for the process through heating the catalyst and removes the need for a charge heater to the dehydrogenation reactor, which in turn eliminates high temperature thermal residence time which eliminates thermal cracking of the feed and improves the overall product selectivity. In addition, plot area, equipment costs and operating complexity are reduced.

FCC DUAL ELEVATION RISER FEED DISTRIBUTORS FOR GASOLINE AND LIGHT OLEFIN MODES OF OPERATION

A fluid catalytic cracking process includes feeding hydrocarbon into a riser in the presence of a catalyst, cracking the hydrocarbon in the riser in the presence of the catalyst to form a cracked stream, and separating the catalyst from the cracked stream. When in a gasoline mode, the hydrocarbon is fed through a first distributor into the riser, and when in a light olefin mode, the hydrocarbon is fed through a second distributor into the riser. The second distributor is positioned at a higher elevation than the first distributor.

Separation process and apparatus

An apparatus and process is disclosed for the separation of solids from gases in a mixture which is most particularly applicable to an FCC apparatus. The mixture of solids and gases are passed through a conduit and exit through a swirl arm that imparts a swirl motion having a first annular direction to centripetally separate the heavier solids from the lighter gases. The mixture then enters a cyclone which has a curved outer wall and imparts a second swirling angular direction to the mixture. The second angular direction is counter to the first angular direction. The apparatus and method assures that a greater proportion of the mixture entering the cyclone is incorporated into the vortex to further enhance separation between the solids and gases.

Apparatuses for controlling heat for rapid thermal processing of carbonaceous material and methods for the same

Embodiments of apparatuses and methods for controlling heat for rapid thermal processing of carbonaceous material are provided herein. The apparatus comprises a reactor, a reheater for forming a fluidized bubbling bed comprising an oxygen-containing gas, inorganic heat carrier particles, and char and for burning the char into ash to form heated inorganic particles. An inorganic particle cooler is in fluid communication with the reheater. The inorganic particle cooler comprises a shell portion and a tube portion. The inorganic particle cooler is configured such that the shell portion receives a portion of the heated inorganic particles and the tube portion receives a cooling medium for indirect heat exchange with the portion of the heated inorganic particles to form partially-cooled heated inorganic particles.

APPARATUS FOR VENTING A CATALYST COOLER

The apparatus herein provide a catalyst cooler with a vent that communicates fluidizing gas to a lower chamber of a regenerator. Air that is used as fluidizing gas can then be consumed in the regenerator without promoting after burn in the upper chamber.

Advanced elevated feed distribution system for very large diameter RCC reactor risers

An FCC process and apparatus may include injecting hydrocarbon feedstock at different radial positions inside a riser. Multiple distributors may be used to position the openings for injecting feedstock at multiple radial positions. In addition, the openings may be away from riser peripheral wall and at different elevations along the riser wall or extending up from the riser bottom. The different opening positions introduce the feedstock across a larger area of the cross-section of the riser, which may improve the feedstock dispersion and mixing with catalyst. Improved mixing may increase conversion of the feedstock. Larger FCC units generally have greater riser diameters that may cause problems for feedstock dispersion and decrease the ability for the feedstock to mix with catalyst. Injecting the feedstock at multiple radial positions may improve feedstock dispersion in larger FCC units and increase mixing.

CHAR-HANDLING PROCESSES IN A PYROLYSIS SYSTEM

Char-handling processes for controlling overall heat balance, ash accumulation, and afterburn in a reheater are provided. Carbonaceous biomass feedstock is pyrolyzed using a heat transfer medium forming pyrolysis products and a spent heat transfer medium. The spent heat transfer medium is separated into segregated char and char-depleted spent heat transfer medium. The char-depleted spent heat transfer medium is introduced into a dense bed of heat transfer medium fluidized by a stream of oxygen-containing regeneration gas. All or a portion of the segregated char is combusted in the dense bed using the stream of oxygen-containing regeneration gas. A portion of the segregated char may be exported out of the pyrolysis system to control the overall heat balance and ash accumulation. 1. A process for pyrolysis of a carbonaceous biomass feedstock in a pyrolysis system , the process comprising:pyrolyzing carbonaceous biomass feedstock using a heat transfer medium forming pyrolysis products and a spent heat transfer medium;separating the spent heat transfer medium into segregated char and char-depleted spent heat transfer medium; andintroducing the char-depleted spent heat transfer medium into a dense bed of heat transfer medium fluidized by a stream of oxygen-containing regeneration gas.2. The process of claim 1 , further comprising the step of combusting all or a portion of the segregated char in the dense bed using the stream of oxygen-containing regeneration gas.3. The process of claim 2 , further comprising the step of additionally combusting the segregated char outside of the reheater in the stream of oxygen-containing regeneration gas before introduction of the segregated char into the dense bed.4. The process of claim 3 , wherein the step of additionally combusting the segregated char comprises mixing in an inlet riser the heat transfer medium from the dense bed with the segregated char in the stream of oxygen-containing regeneration gas.5. The process of claim 1 , ...

Dual riser catalytic cracker for increased light olefin yield

A process for improving the yield of ethylene and propylene from a light naphtha feedstock includes obtaining light naphtha feedstock from a primary cracking zone having a cracking catalyst. The light naphtha feedstock is contacted with an olefin catalyst in an olefin producing zone to produce an ethylene- and propylene-rich stream. After reacting with the olefin catalyst, the ethylene- and propylene-rich stream is separated from the olefin catalyst from in a separator zone. At least a portion of the olefin catalyst is regenerated by combusting coke deposited on a surface of the olefin catalyst in an oxygen-containing environment, and at least a portion of the olefin catalyst is heated. These portions could be the same one or they could be different. In some embodiments, at least a portion of the olefin catalyst could be neither regenerated nor heated. The olefin catalyst is returned to the olefin producing zone.

Distribution apparatus for contact of hydrocarbon compounds with particles

Disclosed is an apparatus for injecting a plurality of uniform jets into an extended dispersion of moving catalyst particles within a reactor vessel. The apparatus comprises a plurality of outer conduits each for carrying atomizing fluid. A plurality of tips in the outer conduits each include a plurality of orifices for spraying a mixture of feed and atomizing fluid. Inner conduits with outlets within the outer conduits delivers feed to the tips of the outer conduits.

Apparatus for Feed Preheating with Flue Gas Cooler

Hydrocarbon feed to a catalytic reactor can be heat exchanged with flue gas from a catalyst regenerator. This innovation enables recovery of more energy from flue gas thus resulting in a lower flue gas discharge temperature. As a result, other hot hydrocarbon streams conventionally used to preheat hydrocarbon feed can now be used to generate more high pressure steam.

Process for regenerating catalyst in a fluid catalytic cracking unit

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

FCC spent catalyst distributor

An distributor arrangement introduces spent FCC catalyst more uniformly across the dense bed of the regenerator to provide more even contact with regeneration gas in order to avoid hot spots and zones of incomplete combustion. The invention forms a fluidized hopper to collect spent catalyst and a horizontally extended header with multiple horizontally extended outlet arms to place catalyst into the regenerator. The invention may use an aeration means to fluidize the header to further assist catalyst flow. Furthermore, the spent catalyst delivered to the top of the regenerator dense reduces NO_x emissions in the flue gas.

Apparatuses for controlling heat for rapid thermal processing of carbonaceous material and methods for the same

A rapid thermal processing system includes an inorganic heat carrier particles reheater coupled to an inorganic particle cooler. For example. inorganic heat carrier particles may be cooled in a shell and tube inorganic particle cooler by indirect heat exchange with a cooling medium. The cooled inorganic heat carrier particles may then be supplied to a reactor to transfer heat to carbonaceous material.

Process for Feed Preheating with Flue Gas Cooler

Hydrocarbon feed to a catalytic reactor can be heat exchanged with flue gas from a catalyst regenerator. This innovation enables recovery of more energy from flue gas thus resulting in a lower flue gas discharge temperature. As a result, other hot hydrocarbon streams conventionally used to preheat hydrocarbon feed can now be used to generate more high pressure steam.

Apparatuses for Controlling Heat for Rapid Thermal Processing of Carbonaceous Material and Methods for the Same

Embodiments of apparatuses and methods for controlling heat for rapid thermal processing of carbonaceous material are provided herein. The apparatus comprises a reactor, a reheater for forming a fluidized bubbling bed comprising an oxygen-containing gas, inorganic heat carrier particles, and char and for burning the char into ash to form heated inorganic particles. An inorganic particle cooler is in fluid communication with the reheater. The inorganic particle cooler comprises a shell portion and a tube portion. The inorganic particle cooler is configured such that the shell portion receives a portion of the heated inorganic particles and the tube portion receives a cooling medium for indirect heat exchange with the portion of the heated inorganic particles to form partially-cooled heated inorganic particles. 1. An apparatus for controlling heat for rapid thermal processing of carbonaceous material , the apparatus comprising:a reactor;a reheater in fluid communication with the reactor to receive inorganic heat carrier particles and char, wherein the reheater is configured to form a fluidized bubbling bed that comprises an oxygen-containing gas, the inorganic heat carrier particles, and the char and to operate at combustion conditions effective to burn the char into ash and heat the inorganic heat carrier particles to form heated inorganic particles; andan inorganic particle cooler in fluid communication with the reheater and comprising a shell portion and a tube portion that is disposed in the shell portion, wherein the inorganic particle cooler is configured such that the shell portion receives a portion of the heated inorganic particles and the tube portion receives a cooling medium for indirect heat exchange with the portion of the heated inorganic particles to form partially-cooled heated inorganic particles that are fluidly communicated to the reheater.2. The apparatus according to claim 1 , wherein the tube portion comprises a plurality of tubes each having an ...

Apparatus for feed preheating with flue gas cooler

Hydrocarbon feed to a catalytic reactor can be heat exchanged with flue gas from a catalyst regenerator. This innovation enables recovery of more energy from flue gas thus resulting in a lower flue gas discharge temperature. As a result, other hot hydrocarbon streams conventionally used to preheat hydrocarbon feed can now be used to generate more high pressure steam.

Purge Gas Streams to Stagnant Zones within Oxygenate-to-Olefin Reactor

The present invention comprises a process for conversion of oxygenates to olefins comprising contacting within a reactor the oxygenates with a catalyst to produce light olefins and wherein the reactor comprises at least two zones, a first zone wherein gas circulates at a faster rate than a second zone wherein a gas circulates at a slower rate; and inserting a quantity of inert gas into the second zone to increase circulation of any materials located in said second zone. The invention prevents accumulation of undesirable by-products within stagnant zones within the reactor and reduces the amount of coke deposited on catalyst or on surfaces within these zones.

Once through regeneration for an olefin cracking reactor

A regeneration process for olefin cracking reactor is presented. The process utilizes the nitrogen waste stream from an air separation plant and the partially combusted effluent stream from the olefin cracking reactor is used to heat the nitrogen waste stream. The control of the heating of the nitrogen waste stream can be achieved through redirection of a portion of the heat from combustion to generate steam.

Apparatus and process for minimizing catalyst residence time in a reactor vessel

A reactor conduit discharges into a disengaging chamber that is directly connected to a separator. A dipleg of the separator is directly connected to the disengaging chamber or to an intermediate chamber which is in direct communication with the disengaging chamber.

Apparatus for venting a catalyst cooler

The apparatus herein provide a catalyst cooler with a vent that communicates fluidizing gas to a lower chamber of a regenerator. Air that is used as fluidizing gas can then be consumed in the regenerator without promoting after burn in the upper chamber.

Propane dehydrogenation process utilizing fluidized catalyst system

A process for the production of propylene from a propane rich hydrocarbon source is presented. The process converts a propane rich stream and uses less equipment and energy for the separation and production of propylene. The process uses a non-noble metal catalyst and utilizes a continuous reactor-regeneration system to keep the process on line for longer periods between maintenance.

PROCESS FOR VENTING A CATALYST COOLER

The process herein provide a catalyst cooler with a vent that communicates fluidizing gas to a lower chamber of a regenerator. Air that is used as fluidizing gas can then be consumed in the regenerator without promoting after burn in the upper chamber. 2. The process of wherein air is vented from said catalyst cooler above said hot catalyst inlet.3. The process of wherein said cooled catalyst is withdrawn from below said hot catalyst inlet.4. The process of wherein said hot catalyst is withdrawn from said disengaging chamber for transport to said hot catalyst inlet.5. The process of wherein said air is vented to said combustor chamber separately from said cooled catalyst and said hot catalyst inlet.6. The process of wherein said vented air is directed downwardly after venting from said vent and before entering said combustor chamber.7. The process of wherein said vented air is consumed in the combustion of coke from catalyst in the combustor chamber.8. The process of wherein cooled catalyst withdrawn from said catalyst cooler is transported in a riser to said combustor chamber.10. The process of wherein air is vented from said catalyst cooler above said hot catalyst inlet.11. The process of wherein said cooled catalyst is withdrawn from below said hot catalyst inlet.12. The process of wherein said vented air is directed downwardly after venting from said vent and before entering said combustor chamber.13. The process of wherein said vented air is consumed in the combustion of coke on catalyst in the combustor chamber.14. The process of wherein cooled catalyst withdrawn from said catalyst cooler is transported in a riser to said combustor chamber.16. The process of wherein air is vented from said catalyst cooler above said hot catalyst inlet.17. The process of wherein said hot catalyst is withdrawn from said disengaging chamber for transport to said hot catalyst inlet.18. The process of wherein said vented air is directed downwardly after venting from said vent and ...

PROCESS FOR REGENERATING CATALYST IN A FLUID CATALYTIC CRACKING UNIT

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

Heat removal and recovery in biomass pyrolysis

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

Char-handling processes in a pyrolysis system

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

Process for regenerating catalyst in a fluid catalytic cracking unit

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

OTO QUENCH TOWER CATALYST RECOVERY SYSTEM UTILIZING A LOW TEMPERATURE FLUIDIZED DRYING CHAMBER

Systems and methods for recovering catalyst in an oxygenate to olefin process are provided that include removing a quench tower bottoms stream containing catalyst from a quench tower and passing the catalyst containing stream to a drying chamber, where the catalyst containing stream is dried to produce substantially dried catalyst.

Heat Removal and Recovery in Biomass Pyrolysis

Pyrolysis methods and apparatuses that allow effective heat removal, for example when necessary to achieve a desired throughput or process a desired type of biomass, are disclosed. According to representative methods, the use of a quench medium (e.g., water), either as a primary or a secondary type of heat removal, allows greater control of process temperatures, particularly in the reheater where char, as a solid byproduct of pyrolysis, is combusted. Quench medium may be distributed to one or more locations within the reheater vessel, such as above and/or within a dense phase bed of fluidized particles of a solid heat carrier (e.g., sand) to better control heat removal. 120-. (canceled)21. An apparatus for pyrolysis of a biomass feedstock , comprising:ii) a pyrolysis reactor;ii) a solid-gas cyclone separator in fluid communication with the pyrolysis reactor;iii) a reheater having a lower section and an upper section, said reheater in fluid communication with the cyclone separator; andiv) a quench liquid distribution system having a first quench liquid distributor in the lower section.22. The apparatus of claim 21 , wherein the first quench liquid distributor is proximate the bottom of the lower section.23. The apparatus of claim 21 , wherein the first quench liquid distributor is configured to inject quench liquid into a dense phase contained in the reheater.24. The apparatus of claim 21 , wherein the reheater further comprises an inlet port in fluid communication with the cyclone separator claim 21 , said inlet port positioned above the first quench liquid distributor.25. The apparatus of claim 21 , wherein the quench liquid distribution system has a second quench liquid distributor claim 21 , said second quench liquid distributor positioned in the upper section.26. The apparatus of claim 21 , wherein the quench liquid distribution system has a second quench liquid distributor configured to inject quench liquid into a dilute phase contained in the reheater.27. The ...

PROCESS FOR REGENERATING CATALYST IN A FLUID CATALYTIC CRACKING UNIT

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

Purge gas streams to stagnant zones within oxygenate-to-olefin reactor

The present invention comprises a process for conversion of oxygenates to olefins comprising contacting within a reactor the oxygenates with a catalyst to produce light olefins and wherein the reactor comprises at least two zones, a first zone wherein gas circulates at a faster rate than a second zone wherein a gas circulates at a slower rate; and inserting a quantity of inert gas into the second zone to increase circulation of any materials located in said second zone. The invention prevents accumulation of undesirable by-products within stagnant zones within the reactor and reduces the amount of coke deposited on catalyst or on surfaces within these zones.

Process for the Production of Propylene

A process for catalyst regeneration is presented. The process regenerates a catalyst in a paraffin dehydrogenation process, where the reaction is endothermic. The regeneration process provides the heat for the process through heating the catalyst and removes the need for a charge heater to the dehydrogenation reactor, which in turn eliminates high temperature thermal residence time which eliminates thermal cracking of the feed and improves the overall product selectivity. In addition, plot area, equipment costs and operating complexity are reduced.

Once Through Regeneration for an Olefin Cracking Reactor

A regeneration process for olefin cracking reactor is presented. The process utilizes the nitrogen waste stream from an air separation plant and the partially combusted effluent stream from the olefin cracking reactor is used to heat the nitrogen waste stream. The control of the heating of the nitrogen waste stream can be achieved through redirection of a portion of the heat from combustion to generate steam.

Purge gas streams to stagnant zones within oxygenate-to-olefin reactor

The present invention comprises a process for conversion of oxygenates to olefins comprising contacting within a reactor the oxygenates with a catalyst to produce light olefins and wherein the reactor comprises at least two zones, a first zone wherein gas circulates at a faster rate than a second zone wherein a gas circulates at a slower rate; and inserting a quantity of inert gas into the second zone to increase circulation of any materials located in said second zone. The invention prevents accumulation of undesirable by-products within stagnant zones within the reactor and reduces the amount of coke deposited on catalyst or on surfaces within these zones.

Char-Handling Processes in a Pyrolysis System

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

DUAL RISER CATALYTIC CRACKER FOR INCREASED LIGHT OLEFIN YIELD

A process for improving the yield of ethylene and propylene from a light naphtha feedstock includes obtaining light naphtha feedstock from a primary cracking zone having a cracking catalyst. The light naphtha feedstock is contacted with an olefin catalyst in an olefin producing zone to produce an ethylene- and propylene-rich stream. After reacting with the olefin catalyst, the ethylene- and propylene-rich stream is separated from the olefin catalyst from in a separator zone. At least a portion of the olefin catalyst is regenerated by combusting coke deposited on a surface of the olefin catalyst in an oxygen-containing environment, and at least a portion of the olefin catalyst is heated. These portions could be the same one or they could be different. In some embodiments, at least a portion of the olefin catalyst could be neither regenerated nor heated. The olefin catalyst is returned to the olefin producing zone. 1. A process for improving the yield of ethylene and propylene from a light naphtha feedstock , comprising:obtaining light naphtha feedstock from a primary cracking zone comprising a cracking catalyst;contacting the light naphtha feedstock with an olefin catalyst in an olefin producing zone to produce an ethylene- and propylene-rich stream;separating the olefin catalyst from the ethylene- and propylene-rich stream in a separator zone;regenerating at least a portion of the olefin catalyst by combusting coke deposited on a surface of the olefin catalyst in an oxygen-containing environment;heating at least a portion of the olefin catalyst with a stream of hot combustion gas; andreturning the olefin catalyst to the olefin producing zone.2. The process of wherein the primary cracking zone is a fluidized bed catalytic cracking zone claim 1 , a resid fluidized bed catalytic cracking zone or a fluidized bed catalytic cracking zone optimized to produce olefins.3. The process of wherein at least a portion of the hot combustion gas is flue gas from a catalyst ...

CATALYST COOLER FOR REGENERATED CATALYST

A catalyst cooler for cooling regenerated catalyst in a regenerator associated with a fluid catalytic cracking unit. The catalyst cooler includes a first passage for transporting hot regenerated catalyst away from the regenerator and a second passage for returning cooled regenerated catalyst to the regenerator. The catalyst cooler also includes at least one heat exchanger. The second passage may be disposed within the first passage, or the first and second passage may each occupy a portion of a horizontal cross section of the catalyst cooler. 1. A regenerator for regenerating spent catalyst particles , the regenerator comprising:an inlet for spent catalyst particles;an outlet for regenerated catalyst particles;a gas distributor disposed below a bed of catalyst particles configured to supply combustion gas into the regenerator for combusting coke on the spent catalyst particles to provide the regenerated catalyst particles; and,a cooling zone for removing heat from regenerated catalyst, the cooling zone comprising a first passage for receiving regenerated catalyst, a second passage for returning cooled regenerated catalyst to the regenerator, and at least one heat exchanger for removing heat from the regenerated catalyst, wherein each heat exchanger in the cooling zone is disposed in at least one of the first passage and the second passage.2. The regenerator of wherein the first passage comprises a conduit disposed within the second passage.3. The regenerator of wherein the second passage comprises a conduit disposed within the first passage.4. The regenerator of wherein the first passage and the second passage each comprise a portion of a single shell.5. The regenerator of wherein each heat exchanger includes a longitudinal axis claim 1 , and wherein the longitudinal axis of each heat exchanger is generally parallel to a flow path of the regenerated catalyst through the first passage.6. The regenerator of claim 1 , wherein the catalyst cooler further comprises an ...

Multiple stage separator vessel

A novel multiple stage separator (MSS) vessel is disclosed wherein the vessel includes at least first and second stages or decks of separation cyclones, the stages arranged for operation in series. Each stage or deck includes an upper and lower tube sheet on which a plurality of cyclones are installed, solid particles in the gas stream being separated from the stream and dispensed between the tube sheets as the stream passes through each stage. The vessel has an inlet to receive a gas stream containing the particulates, and the flow travels typically downwardly, first passing through the first stage, then passing through at least a second stage. When implemented downstream of a fluid catalytic cracking (FCC) unit, the MSS has been found to remove a surprisingly increased amount of particulates over a conventional third stage separator (TSS), which contains a single stage separator.

HEAT REMOVAL AND RECOVERY IN BIOMASS PYROLYSIS

Pyrolysis methods and apparatuses that allow effective heat removal, for example when necessary to achieve a desired throughput or process a desired type of biomass, are disclosed. According to representative methods, the use of a quench medium (e.g., water), either as a primary or a secondary type of heat removal, allows greater control of process temperatures, particularly in the reheater where char, as a solid byproduct of pyrolysis, is combusted. Quench medium may be distributed to one or more locations within the reheater vessel, such as above and/or within a dense phase bed of fluidized particles of a solid heat carrier (e.g., sand) to better control heat removal. 1. A pyrolysis method comprising:(a) combining biomass and a solid heat carrier to provide a pyrolysis reaction mixture;(b) subjecting the pyrolysis reaction mixture to pyrolysis conditions to provide a pyrolysis effluent;(c) separating, from the pyrolysis effluent, (1) a solids-enriched fraction comprising solid char and a recycled portion of the solid heat carrier and (2) a solids-depleted fraction comprising gaseous and liquid pyrolysis products;(d) contacting the solids-enriched fraction with (1) an oxygen-containing combustion medium to combust at least a portion of the solid char and reheat the recycled portion of the solid heat carrier and (2) a quench medium to limit the temperature of the recycled portion of the solid heat carrier.2. The pyrolysis method of claim 1 , wherein the biomass selected from the group consisting of hardwood claim 1 , softwood claim 1 , hardwood bark claim 1 , softwood bark claim 1 , corn fiber claim 1 , corn stover claim 1 , sugar cane bagasse claim 1 , switchgrass claim 1 , miscanthus claim 1 , algae claim 1 , waste paper claim 1 , construction waste claim 1 , demolition waste claim 1 , municipal waste claim 1 , and mixtures thereof.3. The pyrolysis method of claim 1 , wherein the pyrolysis conditions include a temperature from about 400° C. (752° F.) to about 700° ...

Distribution apparatus and method for patterned feed injection

An arrangement for the controlled production of an essentially linear array of hydrocarbon feed injection jets maintains stable and reliable jets by passing individual piping for each jet through a support shroud that is located in a contacting vessel. Controlled atomization is provided by independently injecting a uniform quantity of gas medium into each of the plurality of uniformly created feed injection streams upstream of a discharge nozzle that separately discharges each mixed stream of hydrocarbons and gas medium into a stream of catalyst particles at or about the inner end of the support shroud. The feed injection jets are suitable for positioning in an inner location of a large contacting vessel. Uniformity of distribution is obtained by dividing the hydrocarbons streams from an oil chamber into an individual oil conduit for each spray injection nozzle. The individual oil conduits receive separate streams of a gas phase fluid that mixes with feed to pass the mixture to a spray nozzle. Each spray nozzle discharges a discrete jet of the gas and oil mixture into the vessel. An individual restrictor controls at least one of the fluid flow to each spray nozzle. A distributor shroud positions and guides the individual conduits supplying the mixture to the jets to permit extension of the jets into the interior of the vessel where the contacting occurs.

Heat removal and recovery in biomass pyrolysis

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

Apparatus and process for minimizing catalyst residence time in a reactor vessel

We have discovered a way to minimize the time that catalyst and gaseous products are in contact after exiting the discharge opening (22) of a reactor conduit (10). The reactor conduit discharges into a disengaging chamber (24) that is directly connected to a separator (32). A dipleg (34) of the separator is directly connected to the disengaging chamber or to an intermediate chamber (64) which is in direct communication with the disengaging chamber. Accordingly, catalyst never gets a chance to become entrained in the large open volume of the reactor vessel. Consequently, catalyst which makes it out of the disengaging chamber is quickly returned back to the disengaging chamber, thereby minimizing the time that catalyst and product gases are in contact after being discharged from the reactor conduit.

Heat removal and recovery in biomass pyrolysis

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

Heat removal and recovery in biomass pyrolysis

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

Apparatus and process for minimizing catalyst residence time in a reactor vessel

Purge gas streams to stagnant zones within oxygenate-to-olefin reactor

The present invention comprises a process for conversion of oxygenates to olefins comprising contacting within a reactor (2) the oxygenates with a catalyst to produce light olefins and wherein the reactor comprises at least two zones, a first zone wherein gas circulates at a faster rate than a second zone wherein a gas circulates at a slower rate; and inserting a quantity of inert gas into the second zone to increase circulation of any materials located in said second zone. The invention prevents accumulation of undesirable by-products within stagnant zones within the reactor and reduces the amount of coke deposited on catalyst or on surfaces within these zones.

Purge gas streams to stagnant zones within oxygenate-to-olefin reactor

The present invention comprises a process for conversion of oxygenates to olefins comprising contacting within a reactor (2) the oxygenates with a catalyst to produce light olefins and wherein the reactor comprises at least two zones, a first zone wherein gas circulates at a faster rate than a second zone wherein a gas circulates at a slower rate; and inserting a quantity of inert gas into the second zone to increase circulation of any materials located in said second zone. The invention prevents accumulation of undesirable by-products within stagnant zones within the reactor and reduces the amount of coke deposited on catalyst or on surfaces within these zones.

External second stage cyclones in olefin production process

The present invention comprises a process and apparatus for producing olefins from oxygenates in a reactor (2). This process comprises these oxygenates with a catalyst to produce a gaseous mixture comprising light olefins and by-products, sending the mixture to a single stage cyclone (14) within said reactor to separate said catalyst from said gaseous mixture and then sending said the to a second stage cyclone (18). The second stage cyclone is located outside of said reactor and it functions to remove the catalyst from the mixture. Then the catalyst can be returned to the reactor (2) after having been treated in a regeneration zone (22) to remove carbonaceous deposits from the catalyst.

Oto quench tower catalyst recovery system utilizing a low temperature fluidized drying chamber

Systems and methods for recovering catalyst in an oxygenate to olefin process are provided that include removing a quench tower bottoms stream containing catalyst from a quench tower and passing the catalyst containing stream to a drying chamber, where the catalyst containing stream is dried to produce substantially dried catalyst.

Partial CO combustion with staged regeneration of catalyst

FCC catalyst is regenerated in a process providing increased coke-burning capacity without additional heat evolution or air consumption. The process uses a two-stage regeneration arrangement providing initial coke combustion in a low catalyst density-high efficiency contact zone followed by substantial separation of catalyst and regeneration gas and complete regeneration of catalyst particles in a dense bed regeneration zone. Catalyst and gas flow cocurrent prior to this separation but flow countercurrent after the separation. An effective control scheme for regulating oxygen addition to the final zone is also disclosed. This process is applicable to FCC operations for conventional and residual feedstocks.

Process and apparatus for feed preheating with flue gas cooler

Hydrocarbon feed to a catalytic reactor can be heat exchanged with flue gas from a catalyst regenerator. This innovation enables recovery of more energy from flue gas thus resulting in a lower flue gas discharge temperature. As a result, other hot hydrocarbon streams conventionally used to preheat hydrocarbon feed can now be used to generate more high pressure steam.

METHOD AND DEVICE FOR THE SIMULTANEOUS RENEWAL AND COOLING OF SWITCHED PARTICLES

FCC catalyst regeneration by introducing a first stream of oxygen-contg. combustion gas and the fluidised catalyst particles into a combustion zone to produce hot fluidised particles; passing these upward into a second zone above the combustion zone and collecting a dense phase bed of hot solid particles in a collection section at the bottom of the second zone; transferring a stream of particles downward through a particle flow means and a vertical transfer conduit into the upper end of a backmixed particle cooling chamber; cooling the particles in a lower portion of the cooling chamber using a heat exchanger entirely within the lower part of the cooling chamber; fluidising the dense phase particle bed by the passage of a controlled flow of a second oxygen-contg. combustion gas, and discharging the second stream of combustion gas into the combustion zone through a conduit above the heat exchanger.

Heat removal and recovery in biomass pyrolysis

Railway tie and fastener

Process and apparatus for the separation of the catalyst using a cyclone in a fcc process

Railway-tie and rail-fastener.