Engelhard Minerals & Chemicals Corporation

Other

Engelhard Corporation

Bar-co Processes Joint Venture

Uop Lcc

Englehard Corporation

New Life Catalyst, Inc.

Engelard Corporation

Davis, Robert E.

Bartholic, David B.

David B Bartholic

Dwight F Barger

William J Reagan

John W Byrne

Robert E Davis

Robert L Flanders

Regis B Lippert

Andrew S Moore

Don S Chin

A method for preparing a mixture of FCC catalyst components for use in an FCCU, which comprises: performing an analysis of an FCCU operation; determining the catalyst requirements for the FCCU, based on said analysis; determining the catalytic properties of at least two FCC catalyst components selected from the group consisting of untreated equilibrium FCC catalyst, reactivated equilibrium FCC catalyst, demetallized equilibrium FCC catalyst, reactivated and demetallized equilibrium FCC catalyst and fresh high activity FCC catalyst containing a zeolite component; and blending said at least two components in proportions, based on the determined properties of said at least two components and the determined catalyst requirements, to form a mixture of the components suitable for addition to the FCCU.

Method for preparing a substitute for fresh fluid catalytic cracking catalyst

A process for increasing the activity of a zeolite-containing particulate solid containing contaminants which block the pores of the zeolite and adversely affect the activity thereof wherein the contaminated zeolitic material is slurried with a liquid containing an acid, detergent or surfactant, the slurry is agitated to liberate the pore-blocking contaminants from the zeolite pores so that they are suspended in the liquid, a portion of the liquid is withdrawn from the slurry and filtered to remove the suspended contaminants, the resulting liquid is returned to the slurry, and the treated zeolite-containing particulate solid is liquid from the solution and recovered.

Process for increasing the activity of zeolite containing particulate

A spent zeolite-containing hydrocarbon cracking catalyst is treated by regenerating it to remove carboneous deposits. A portion of the regenerated catalyst is withdrawn from the circulating catalyst inventory of a hydrocarbon processing unit and slurried with a liquid containing an activating agent to solubilize and/or dislodge contaminants which block the pores of the zeolite and adversely affect the activity of the catalyst. The slurry is agitated to dissolve or dislodge the contaminants from the zeolite pores, and the agitated slurry, without being permitted to settle, is transferred to a fluidized drying zone where the liquid and solubilized and/or dislodged contaminants are removed from the treated catalyst which has a level of cracking activity higher than that of the catalyst in the circulating catalyst inventory. The treated catalyst is then recycled to the unit and contacted with a hydrocarbon feedstock under cracking conditions.

Process for zeolitic catalyst reactivation

A fluidized process which comprises contacting a hydrocarbon feedstock with a fluidized particulate solid in a contacting zone wherein carbonaceous deposits accumulate on the solid and the solid becomes spent and wherein the carbonaceous deposits are burned from the spent solid to produce a regenerated solid; removing a stream of the fluidized spent solid and entrained hydrocarbons from the contacting zone; introducing the fluidized spent solid/entrained hydrocarbon stream and a stream of hot regenerated solid into a lower portion of a zone; introducing a stream of a fluid stripping medium, e.g, water and/or steam into the lower portion of the stripping zone to contact the spent solid therein; passing a stream of the spent solid mixed with the stripping medium and the hot regenerated solid upwardly in the stripping zone to an upper portion thereof under dilute phase stripping conditions; separating the spent solid from the hydrocarbons and stripping medium in a separation zone connected to the upper portion of the stripping zone; passing a fluidized stream of separated solid from the separation zone to the regeneration zone wherein said carbonaceous deposits are burned therefrom to produce a regenerated solid for return to the reaction zone; removing a stream containing vaporized separated hydrocarbons and stripping medium from the separation zone; separating the vaporized separated stripping medium from the hydrocarbons; recycling the separated stripping medium to the stripping zone. The process also contemplates introducing the medium into a lower portion of a dilute phase zone to cool the solid.

Fluidized process for improved stripping and/or cooling of particulate

A process wherein a fluidized particulate solid is contacted with a hydrocarbon feedstock in a vertically extending contacting zone, which process comprises introducing a stream of the particulate solid into the contacting zone and introducing a plurality of streams of liquid hydrocarbon feedstock into the contacting zone to intimately contact the particulate solid therein, the plurality of streams each being introduced into the contacting zone from one of a plurality of nozzles spaced apart in the contacting zone, and each stream having a flow path extending into the contacting zone and a flow pattern having a thickness which is substantially constant and a width which diverges from the point of introduction into the contacting zone. The nozzles each comprise a tubular member having an inlet end, an outlet end, and a flow channel extending through the member from the inlet to the outlet end, the outlet end having an oval concave surface therein and a circular opening centered in the concave surface and in flow communication with the flow channel.

Process for improved contacting of hydrocarbon feedstock and particulate

The method of controlling the flow of a fluidizable particulate solid, e.g., FCC catalyst, which comprises: (a) passing a fluidized stream of the particulate solid downwardly from a source of the particulate solid, e.g., an FCC regenerator, in a first conduit to a junction with a second conduit where the solid particulate is mixed with a stream of a fluid transport medium from a third conduit; (b) passing a stream of the resulting mixed solid particulate/transport medium upwardly in the second conduit at an angle less than 90.degree. from the first conduit for a distance at least as great as the diameter of the first conduit at the junction into a fourth conduit; (c) transporting the particulate solid/fluid transport medium stream in the fourth conduit to a desired location; and (d) controlling the mass flow of the particulate solid in the fourth conduit by setting the flow rate of the transport medium in the third conduit. By determining the temperatures of the particulate solid in the first conduit, the transport medium in the third conduit and the particulate solid transport medium mixture, the mass flow of the particulate solid in the fourth conduit may be controlled by setting the flow rate of the transport medium in the third conduit. Apparatus for carrying out the method is also included.

Process and apparatus for controlling and metering the pneumatic

The disclosed method and apparatus provides for providing addition of micro-spheroidal ('MS') Fluid Catalytic Cracking ('FCC') catalyst additives and/or bulk catalyst to an in situ circulating, active catalyst inventory of a fluid catalytic cracking unit at times and rates precisely controlled to sustain an effective additive concentration. In a preferred version of this invention, each of a series of such apparatus comprising one such device for each catalyst additive, is operated on a basic cycle time length during a portion of which the unit is engaged in active addition while in the remainder of the time it is passive.

Method and apparatus for controlling introduction of catalysts into FCC

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

Fluidized process for improving the quality of a particulate regenerated

Apparatus for separating particulate solids from a process gas stream which includes one or more primary separation chambers, preferably ballistic separation chambers, for removing a major portion of the solids entrained in the gas stream. One or more secondary separator chambers containing multi-cyclones are employed for removing substantially all of the remaining solids from the gas discharged from the primary separator chamber. The ballistic separation chamber has an inlet portion and a larger diameter outlet portion, and it may have an arcuate shape to aid in the separation. In one preferred embodiment a plurality of horizontally extending ballistic separation chambers are connected to a top portion of a transport riser, a plurality of the secondary separation chambers having off-gas outlets connected to a cup-shaped off-gas collector housing are positioned above the gas outlets of the ballistic separation chambers and a conical catalyst outlet vessel connected to the solids outlets of the secondary chamber extends downwardly into the transport riser for returning separated solids to a source vessel.

Solids-gas separation apparatus and method

A fluid catalytic cracking process wherein a hydrocarbon charge-stock is atomized and injected, in a contactor/reactor, into a vertical curtain of hot regenerated catalyst to vaporize and crack hydrocarbons in the charge-stock, wherein the catalyst preferably contains at least 40% by weight of a zeolitic cracking component and the contact time of the hydrocarbon vapors and the catalyst in the contactor/reactor is ultra-short, preferably not greater than 0.5 second.

Ultra-short contact time fluidized catalytic cracking process

Apparatus for the treatment of a liquid hydrocarbon charge containing solids or solids-forming contaminants, e.g., inorganic solids, metals and asphaltenes, which includes a contactor vessel having a liquid charge inlet, a vaporizing media inlet above the charge inlet and a vapor-solids outlet. An atomizer is positioned in the charge inlet for forming small particles of the liquid charge and directing the particles of liquid in a substantially horizontal flat pattern into the contactor vessel. A premix downcomer having a dispersion grid positioned therein is located in the vaporizing media inlet for introducing a fluidized mixture of a gas dispersion media and hot circulating solid particles into the contactor vessel in a substantially vertical flat pattern to traverse the path of the liquid particles and intimately contact the liquid particles. The vapor-solids-outlet is positioned in the contactor vessel substantially opposite the liquid charge inlet to receive product vapors and entrain solid particles and rapidly pass the same into cyclones connected to the vapor-solids-outlet for separating solid particles from product vapors. A stripper vessel is located beneath the contactor vessel for receiving heavy solid particles and stripping hydrocarbons therefrom.

Apparatus for upgrading liquid hydrocarbons

An improved continuous cyclic process for removing oxides of sulfur from a waste gas with a regenerable particulate adsorbent in which hot adsorbent particles pick up SOx in a first fluid transport riser, followed by separation of clean gas from sulfur-contained particles which are then recycled to a desorber in which they are contacted at elevated temperature with a mixture of reducing gas and water vapor for release of sulfur as hydrogen sulfide. The adsorbent particles are then recycled in the process. Means are provided for removing particulates in the waste gas.

Gas/solid contact method for removing sulfur oxides from gases

A continuous fluidized process for upgrading a heavy liquid hydrocarbon charge-stock containing solid or solid-forming contaminants, e.g., inorganic solids, metals and asphaltenes. The charge is atomized to provide a stream of liquid particles introduced horizontally into a horizontal contacting zone to contact a vertical curtain of fluidized hot solid particles so as to vaporize hydrocarbons in the charge without substantial cracking, the solid particles being solely derived from the contaminants in the charge. The mixture of hydrocarbon vapors and solid particles are rapidly separated, carbon is burned from the separated particles, and the resulting hot solid particles are recycled to the contacting zone. The hydrocarbon vapors are condensed and there is recovered a liquid product having a substantially reduced content of contaminants.

Liquid-solid separation process and apparatus

An improved hydrocarbon conversion process is disclosed of the type employing circulating solids between a reactor (contactor) and regenerator (combustor). The entire process is in the dilute phase and is characterized by all the catalyst passing through the cyclones and never returning to a dense bed in either the reactor or regenerator.

Hydrocarbon conversion-regeneration process using dilute and dense beds

A method for updating a concentrate of tar sands bitumen containing fine mineral matter and optionally coarse mineral matter in which solvent-diluted bitumen is contacted for a short time in a riser with hot attrition-resistant substantially catalytically inert acid-resistant fluidizable particles, causing a selective vaporization of the lighter high hydrogen content components of the bitumen. The preferred particles are composed of silica-alumina, most preferably a mixture of mullite and crystalline silica or mullite, crystalline silica and an acid-resistant form of alumina. A portion of the heavier asphaltenes and most of the components which contain metals, sulfur and nitrogen remain on the attrition-resistant fluidizable particles. Fine mineral matter in the bitumen feed also deposits on the fluidized particles instead of being carried over with the vaporized hydrocarbon product. The contact material, with deposit, is contacted with a solution of acid to remove the deposit of mineral matter and deposited metals without decomposing the particles of contact material. The heated particles of contact material are reintroduced into the riser for further contact with incoming diluted bitumen charge.

Growing community of inventors

Watchung, NJ, United States of America

David B Bartholic