Lummus Technology Inc.

Rama Rao Marri

Liang Chen

Peter Loezos

Bryan Tomsula

Justin Breckenridge

Jon A Hood

Hardik Singh

Michael Dorsey

Dalip Singh Soni

Pramod Kumar

Zan Liu

Leonce Francis Castagnos, Jr

Manoj Som

Alan Claude

Vish Hariharan

Apparatus and processes herein provide for converting hydrocarbon feeds to light olefins and other hydrocarbons. The processes and apparatus include, in some embodiments, feeding a hydrocarbon, a first catalyst and a second catalyst to a reactor, wherein the first catalyst has a smaller average particle size and is less dense than the second catalyst. A first portion of the second catalyst may be recovered as a bottoms product from the reactor, and a cracked hydrocarbon effluent, a second portion of the second catalyst, and the first catalyst may be recovered as an overhead product from the reactor. The second portion of the second catalyst may be separated from the overhead product, providing a first stream comprising the first catalyst and the hydrocarbon effluent and a second stream comprising the separated second catalyst, allowing return of the separated second catalyst in the second stream to the reactor.

Fluid catalytic cracking process and apparatus for maximizing light olefin yield and other applications

A reactor system configured for efficiently removing contaminants (CCR, nickel, vanadium, nitrogen, sodium, iron, calcium, chlorine etc.) from a heavy portion of the crude oil. The products are routed to a common main fractionation section. The heavy feed with lower contaminants may then be processed in a fluid catalytic cracking (FCC) unit, the overall concept employing a fluid catalytic reaction platform with carbon rejection approach. Also disclosed is a reactor system for efficiently processing crude oil in a fluid catalytic cracking unit with a dual-reactor and dual catalyst system to maximize petrochemical building blocks such as ethylene, propylene, butylenes, BTX (benzene, toluene and xylene) rich naphtha from a variety of crude oils.

Production of light olefins from crude oil via fluid catalytic cracking process and apparatus

Processes and systems for the conversion of hydrocarbons herein may include separating an effluent from a moving bed reactor, the effluent including reaction product, first particulate catalyst, and second particulate catalyst. The separating may recover a first stream including the reaction product and first particulate catalyst and a second stream including second particulate catalyst. The second stream may be admixed with a regenerated catalyst stream including both first and second particulate catalyst at an elevated temperature. The admixing may produce a mixed catalyst at a relatively uniform temperature less than the elevated regenerated catalyst temperature, where the temperature is more advantageous for contacting light naphtha and heavy naphtha within the moving bed reactor to produce the effluent including the reaction product, the first particulate catalyst, and the second particulate catalyst.

Staged fluid catalytic cracking processes incorporating a solids separation device for upgrading naphtha range material

Apparatus and processes herein provide for converting hydrocarbon feeds to light olefins and other hydrocarbons. The processes and apparatus include a conventional riser reactor in combination with a mixed flow (e.g., including both counter-current and co-current catalyst flows) fluidized bed reactor designed for maximizing light olefins production. The effluents from the riser reactor and mixed flow reactor are processed in a catalyst disengagement vessel, and the catalysts used in each reactor may be regenerated in a common catalyst regeneration vessel. Further, integration of the two-reactor scheme with a catalyst cooler provides a refinery the flexibility of switching the operation between the two-reactor flow scheme, a catalyst cooler only flow scheme, or using both simultaneously.

Fluid catalytic cracking processes and apparatus

A feed injector may have a body having an outer wall and an inner wall with a first conduit formed between the outer wall and the inner wall. The first conduit is configured to receive a atomizing gas. Additionally, a second conduit may be formed by the inner wall, and the second conduit is configured to receive a liquid. The first conduit and the second conduit are separated by the inner wall. Further, a mixing chamber may be provided at an outlet of the first conduit and an outlet of the second conduit. The atomizing gas from the first conduit and the liquid from the second conduit hit and/or mix together in the mixing chamber to form liquid droplets and a mixture of the atomizing gas and the liquid. Furthermore, a flow cone may have a first end in the second conduit and a second end in the mixing chamber.

Fluid catalytic cracking feed injector

Systems for separating a contaminant trapping additive from a cracking catalyst may include a contaminant removal vessel having one or more fluid connections for receiving contaminated cracking catalyst, contaminated contaminant trapping additive, fresh contaminant trapping additive, and a fluidizing gas. In the contaminant removal vessel, the spent catalyst may be contacted with contaminant trapping additive, which may have an average particle size and/or density greater than the cracking catalyst. A separator may be provided for separating an overhead stream from the contaminant removal vessel into a first stream comprising cracking catalyst and lifting gas and a second stream comprising contaminant trapping additive. A recycle line may be used for transferring contaminant trapping additive recovered in the second separator to the contaminant removal vessel, allowing contaminant trapping additive to accumulate in the contaminant removal vessel. A bottoms product line may provide for recovering contaminant trapping additive from the contaminant removal vessel.

Process and apparatus for enhanced removal of contaminants in fluid catalytic cracking processes

A fluid catalytic cracking apparatus and process is disclosed, providing for efficient conversion of heavy hydrocarbon feeds to light olefins, aromatics, and gasoline. A countercurrent flow reactor operating in bubbling or turbulent fluidization regimes is integrated with a fluid catalytic cracking riser reactor. A heavy hydrocarbon feed is catalytically cracked to naphtha and light olefins in the riser reactor, a co-current flow reactor. To enhance the yields and selectivity to light olefins, cracked hydrocarbon products from the riser reactor, such as Cand naphtha range hydrocarbons, may be recycled and processed in the countercurrent flow reactor. The integration of the countercurrent flow reactor with a conventional FCC riser reactor and catalyst regeneration system may overcome heat balance issues commonly associated with two-stage cracking processes, may substantially increase the overall conversion and light olefins yield, and/or may increases the capability to process heavier feedstocks.

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Bloomfield, NJ, United States of America

Rama Rao Marri