WO2005080531A1 - Apparatus and process for downflow fluid catalytic cracking - Google Patents
Apparatus and process for downflow fluid catalytic cracking Download PDFInfo
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- WO2005080531A1 WO2005080531A1 PCT/GB2004/000527 GB2004000527W WO2005080531A1 WO 2005080531 A1 WO2005080531 A1 WO 2005080531A1 GB 2004000527 W GB2004000527 W GB 2004000527W WO 2005080531 A1 WO2005080531 A1 WO 2005080531A1
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- Prior art keywords
- catalyst
- feed
- distributor
- regenerated catalyst
- regenerated
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Classifications
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G11/00—Catalytic cracking, in the absence of hydrogen, of hydrocarbon oils
- C10G11/14—Catalytic cracking, in the absence of hydrogen, of hydrocarbon oils with preheated moving solid catalysts
- C10G11/18—Catalytic cracking, in the absence of hydrogen, of hydrocarbon oils with preheated moving solid catalysts according to the "fluidised-bed" technique
Definitions
- the present invention relates to an apparatus and to a process for downflow fluid catalytic cracking, the apparatus comprising a regenerated catalyst riser, a distributor for said regenerated catalyst, a downflow reactor, and a quick separation device inside a collector vessel. JVIdre specifically, the invention relates to an apparatus and to a process for downflow catalytic cracking of heavy feeds with maximization of catalytic cracking and valuable products which makes use of a regenerated catalyst distributor the design of which allows a more evenly distribution of the catalyst to be contacted with the feed in the downflow reactor reaction zone.
- the apparatus as a whole incorporates other favorable features, which add to the performance of the whole system and ultimately to the downflow FCC process.
- BACKGROUND INFORMATION FCC processes are well known. In the more usual FCC processes employing riser reactors the. catalyst and the hydrocarbon feed flow upward, while in FCC processes employing downflow . reactors the catalyst and the hydrocarbon feed flow downward. In riser reactors, solids flow upward due to the lift caused by the ascending vaporized feed. However, the velocity of the hydrocarbon vapor is lower near the wail than it is near the center of the reactor.
- the catalyst will move more slowly near the reactor wall than near the center, resulting in a slower moving area with a high catalyst density near the wail and a low-resistance path of ascending hydrocarbon vapor near the center.
- the hydrocarbon vapor mainly flows through the center, whereas the catalyst is mainly located near the walls.
- the resulting flow pattern is called care-an ⁇ ulus.
- the upward flow of solid catalyst and hydrocarbon vapor in riser reactors oppose gravity, resulting in a catalyst flow that is significantly slower than the much lighter hydrocarbon flow.
- the ratio of feed velocity to catalyst velocity, i.e., the slip factor generally is about 2-3.
- downflow reactors do not display large differences in velocity and catalyst density between the center and the wall of the reactor. Furthermore, as the catalyst particles do not oppose gravity, the difference in velocity between the catalyst flow and the hydrocarbon flow in these reactors is smaller than in riser reactors.
- the slip-factor of downflow reactors generally is about 1. • Consequently, backmixing is largely avoided, the catalyst is more evenly distributed across the entire reactor, and the effective contact time of the catalyst and the feed in a downflow reactor is less than in a riser reactor.
- US patent 5,498,326 teaches a process for catalytic cracking and the associated apparatus in which the cracking reaction takes place in two substantially vertical and successive reaction zones, the feed being introduced into the first zone where it circulates from the top downwards, then at least a portion of the product obtained is introduced in a second reaction zone in which it circulates in an ascending fashion. It is alleged that in downward reactors the separation is made more difficult in virtue of the substantial concentration of catalyst in the reaction medium, which requires specifically designed equipment if suitable efficiency is to be enjoyed. That is why the separation is effected after the reaction in the ascending mode.
- US patent 5,468,369 ('369 patent) teaches a process for short contact time fluidized catalytic cracking of heavy oil feed using a reactor with an upflow catalyst-to-oil vaporizer and a downflow reactor.
- Catalyst slip permits efficient mixing and limited conversion in the upflow section, while cracking is completed in the downflow reactor with minimal segregation of catalyst.
- the catalyst has a 25wt % Y zeolite content and total vapor residence time is less than 5 seconds.
- the patent contains a thorough explanation on the kinds of short contact time reactors, that is, risers and downflow reactors.
- a downflow reactor by contrast, has no mechanism for moving oil from catalyst-lean to catalyst-rich regions and vice versa. Oil, which enters in a region of low solid density will remain there through the entire reactor, ultimately subject to thermal cracking due to premature deactivation of the catalyst. Oil in a high-density region tends to be overcracked. Hence the products of low catalyst-to-o ⁇ and high catalyst-to-oil ratios do not in any way "average" to the products of the correct catalyst-to-oii ratio.
- the present invention overcomes this and other drawbacks of downflow reactors by using a novel regenerated catalyst distributor, which improves the efficiency of the catalyst-to-oil mixing, a proprietary feed injectors and a lean catalyst phase. Further, it should be pointed out that the '369 patent fails to. achieve the alleged goals since the upflow internal mixing section.
- the present invention makes use of a proprietary device, object of Brazilian Patent Application PI BR 0101433-1 herein completely incorporated as reference, said device being a portion of the regenerated catalyst distributor of the invention, said device basically comprising, according to Figure 1 of said Brazilian application, a conduit (1 ) the diameter of which is smaller than the diameter of the downflow reactor, a plate (3) provided with evenly distributed perforations and which makes up- the bottom of a collector/distributor catalyst vessel (2) predominantly cylindrical, axially and longitudinally mounted inside conduit (1).
- the device taught in PI BR 0101433-1 does not allow processing a mixture of catalyst and gas. Catalyst only may be adequately distributed through the perforated plate, for instance, received from a slide valve mounted on top of the perforated plate. This restricts the use of such a device to a situation where there is catalyst flow only, preferably below a regenerated catalyst slide valve.
- the present application can be used to an admixture of catalyst and carrying fluid from a riser, then properly separating carrying fluid from catalyst and adequately distributing catalyst in a distributor to contact the feed so as to vaporize and crack same.
- the present invention makes use in the present downflow reactor apparatus, of another proprietary device, fully incorporated herein as reference " , hich is a feed injector, published as WO 01/44406A1 , such injector comprising two concentric conduits, where an atomization fluid flows through an inner conduit, while the liquid feed flows through the annular space formed by the outer surface of the inner conduit and the inner surface of the outer conduit; an atomization unit having nozzles arranged in rows, with one row having central nozzles connected to the inner conduit for atomization fluid, and two or more rows of side nozzles, connected to the outer feed conduit, the central nozzles and side nozzles of the atomization unit being geometrically placed so that energy of the atomization fluid is fuily transferred by contact to the flow of feed, this resulting in the complete atomization of the feed; and a mixing chamber formed by the edges of the central nozzles, the dimensions of which are able to prevent the
- the proposed equipment involves a ballistic separation zone having a cross- sectional area within the range of 20 to 30 times the cross-sectional area of the reaction zone and open at its lower end to a stripping zone therefore permitting unobstructed free fall of catalyst under the influence of gravity.
- the problem is that discharging catalyst into separation section 15 of vessel 16 having such a high ratio of cross sectional area implies in augmented possibilities of undesirable thermal cracking and coke build-up.
- the concept of US patent 4,514,285 does not allow to processing a mixture of catalyst and gas. Catalyst only may be adequately distributed through the perforated plate, for instance, catalyst received from a slide valve mounted on the top of the perforated plate.
- US patent 5,582,712 is also directed to quick separation methods involving two-step separation of spent catalyst and hydrocarbon products resulting from a downflow FCC reactor. It should be pointed out that the use of enclosing cyclone separators taught by said US patent may be a problem whenever there is any unsteady operation of the reactor,, which leads to a lower separatbr efficiency and therefore to undesirable overcracking reactions due to entrainme ⁇ t of the gas phase which reacted with the catalyst suspension, as well as heavy catalyst losses to the product fractioning system and auxiliary equipment thereof. Also, US patent 5,582,712 does not recognize the necessity of providing an external path for stripper . gases. On the contrary, the stripper gas is withdrawn through a conduit together with the vapor products.
- US patent 5,569,435 of the Applicant and fully inco ⁇ orated herein as reference teaches a system for separating catalyst particles from reacted hydrocarbons which includes an u ⁇ confined cycio ⁇ e device made up of a diplegless cyclone opening directly into a large volume separator vessel downwardly through a mouth and upwardly through an annular space between concentric pipes.
- the proposed system is applied to upward .
- FCC reactors In the present application said system may be applied to effect the quick separation of spent catalyst from reacted hydrocarbons in a downward reactor.
- the process of the invention comprises directing a stream of regenerated catalyst from a regeneration zone admixed to a carrying fluid through a riser and into the catalyst distributor, where carrying fluid and catalyst are centrifuged and catalyst is evenly distributed and is directed downwards to meet the feed which has been atomized by the feed injectors, the feed being vaporized as heat is provided by said stream of regenerated catalyst, reacting then catalyst and feed in said downflow reactor then spent catalyst and reacted hydrocarbons are separated in a quick separation device inside a collector vessel.
- the present invention provides an apparatus for FCC downflow reactions which combines a regenerated catalyst riser which lifts a diluted phase catalyst phase up to a catalyst distributor the design of which, combined to the features of the feed injectors, connected through a properly designed catalyst acceleration zone, allows an optimum catalyst-to-oil mixing.
- the present invention provides still an apparatus for FCC downflow reactions which permits quick and easy separation of spent catalyst and reacted hydrocarbons, further improving overall process performance.
- the present invention provides further a low-cost installation of the present apparatus in an existing FCC unit.
- the invention provides still a process for the fluid catalytic cracking of high boiling point hydrocarbon oils under short contact time reaction conditions with high yields in valuable light hydrocarbons and gasoline fraction, while keeping coke within acceptable levels.
- FIGURE 1 attached is a schematic view of the apparatus of the invention.
- FIGURE 2 attached is a schematic view of the regenerated catalys distributor of the invention.
- FIGURE 3 is a view of the feed injectors of WO 01/44406 used to vaporize the feed.
- FIGURE 4 illustrates the mixing zone with the feed injectors.
- FIGURE 4A is a schematic view of the mixing zone with the feed injectors.
- F1GURE 4B is a top view including planes of perforated plate and tip of feed injectors.
- FIGURE 5 attached is the quick separation device inside the collector " vessel of the invention, as adapted from US patent 5,569,435.
- the present invention is thus directed to an apparatus and to a process for the fluidized catalytic cracking of a hydrocarbon feed oil containing liquid hydrocarbons boiling between 340°C to 720°C.
- One aspect of the invention is an apparatus for catalytic cracking using a downflow reactor.
- a second aspect of the invention is the FCC process carried out using the inventive apparatus.
- a collector vessel 60 provided with a quick separation device to swiftly separating spent catalyst from reacted hydrocarbon gases.
- the quick separation device is provided with dipiegless cyclones 61 to effect the swift separation of cracked hydrocarbons from particulate phases, outlet pipe 66 to exit the stream of cracked hydrocarbons substantially free from catalyst particles and to the fractioning system, and a spent catalyst conduit 65.
- regenerated catalyst riser 10 as used in tiie present application is a current riser in that it is a conduit for carrying a fluid. It should be pointed out that riser 10 of the present apparatus is not used for effecting any cracking reaction. Instead, it is employed for carrying a diluted phase of regenerated catalyst, which has been regenerated in a regeneration section (not represented in the Figure). According to the concept of the invention, the expression "diluted phase of regenerated catalysf in regenerated catalyst riser 10 means a catalyst mass flux in said riser of from 50 to 500 kg/(m 2 .s), with an average range of from 150 to 300 kg/(m 2 .s).
- the regeneration section useful for the pu ⁇ oses of the invention is any usual section belonging to any well-known catalyst regeneration technique.
- Regenerated catalyst riser 10 allows that the present apparatus be installed on existing units at a cost below that entailed by modifications of the direction of flow.
- Regenerated catalyst is directed from the regenerated catalyst standpipe
- a useful carrying fluid is steam.
- Another option is to use water to replace steam.
- the water option may be the preferred one whenever it is intended to promote a major impact in the FCC thermal balance so that the regenerator operates under a lower temperature and cataiyst circulation is increased. In this case water, receiving heat from the regenerated catalyst, is vaporized at the injection point.
- a further possibility for a carrying fluid is a naphtha stream. Like the water option, the naphtha stream is vaporized while admitted to the riser, working therefore as a cooling medium. Still, the process encompasses the use of fuel gas as catalyst carrying fluid, according to availability in the Gas Compressor (not represented).
- a further alternative is the use of a natural gas. stream depending on the availability of same in the refinery. The combined use of those streams is possible as well, in any amount of each stream. Even distribution of the carrying fluid is secured by using a fluidizatio ⁇ ring situated at the bottom of regenerated catalyst riser 10 and radial nozzles (not represented) situated upwards (not represented). A crossover section 20 connects the upper end of regenerated catalyst riser
- Crossover section 20 is a section of a cylindrical or preferably rectangular shape sloped towards catalyst distributor 30 at an angle with the horizontal sufficient to avoid the undesirable phenomenon of saltation - separation of catalyst at the bottom of pipe - assuring transfer at a low pressure differential. Also, such crossover 20 is connected to distributor 30 in such a position that the catalyst flow enters the sai ⁇ distributor in a tangential position. So, through riser 10, regenerated catalyst as a diluted phase is directed via crossover section 20 to regenerated catalyst distributor 30. A detailed picture of regenerated catalyst distributor 30 is represented in
- Regenerated catalyst distributor 30 comprises:
- distributor 30 dispenses with closed plug 38.
- the number of pipes 33 may vary of from two to several pipes, according to the unit size. So, two, four or more pipes 33 may be used.
- the admixture of carrying fluid and catalyst from regenerated catalyst riser 10 is directed to regenerated catalyst distributor 30 where said admixture is centrifuged to separate carrying fluid and catalyst with the catalyst being then directed to mixing zone 40.
- Catalyst distributor 30 is therefore designed to perform a double task: centrifuging .
- regenerated catalyst entry into regenerated catalyst distributor 30 is to be effected in the tangential mode.
- the velocity at which regenerated catalyst enters regenerated catalyst distributor 30 is an important process parameter. The minimum velocity is to be kept at 9.14 m/s (30 fi/s). The maximum velocity should not exceed 20 m/s (65
- Catalyst distributor 30 receives, through crossover section 20 the admixture of regenerated catalyst and carrying fluid from regenerated catalyst riser 10, separating regenerated catalyst from carrying fluid by centrifuging.
- Regenerated catalyst flows through conical surface 34 arid feeds a distributing basket 35, the bottom of which is provided with a perforated plate 32, while carrying fluid flows through pipes 33 and is admixed at low velocity to regenerated catalyst under basket 35 in the tapered section of catalyst acceleration zone 37, without causing any disturbance to the homogeneous catalyst distribution provided for by the said basket 35.
- Said low velocity is of from 3 to 8 m/s (10 to 25 ft/s).
- the shape of said pipes 33 is preferably that of a rectangular section linked to two semi circular sections constituted of half-pipes leading to an oblong shape, instead of a simple cylindrical section.
- the cross section of pipes 33 may be so that gas velocity inside these pipes is no more than 20 m/s (65 ft s) and that the free area for catalyst flowing at conical surface 34 is sufficient to assure a catalyst mass velocity preferably of no more than 500 kg/(m 2 .s).
- steam injection through nozzles 36 aids in making uniform the catalyst level on distributing basket 35 and in fluidizing the catalyst bed.
- a portion of injected steam (or other carrying fluid) flows through pipes 33 while another portion, admixed to catalyst, crosses distributing basket 35 and flows through catalyst acceleration zone 37.
- the catalyst carrying fluid admixture, with the catalyst distributed in catalyst acceleration zone 37 of catalyst distributor 30, takes the shape of thin threads formed by perforations of perforated plate 32 of basket 35, and descends by gravity, through catalyst acceleration zone 37, towards mixing zone 40 (pick up section).
- the diameter of perforations of perforated plate 32, the periphery of each perforation being hardened with a proper material, is such that an easiness of penetration of feed jet Into catalyst threads is achieved in mixing zone 40 located below, assuring perfect contact among catalyst particles and feed.
- a suitable range for the diameter of perforations of perforated plate 32 is of from 20-100 mm, more preferably between 40-80 mm.
- the total perforated area may be so that catalyst mass velocity (or mass flux) is in the range of from 250 to 750 kg/(m 2 .s), preferably of from 400 to 600 kg/(m 2 .s).
- the circumference of perforated plate 32 must be so that its projection fits . with the circumference formed by the tips of feed injectors 41, located below at mixing zone 40, as illustrated in Figure 4B. Those criteria enable that full advantage of the downflow pattern is acquired, assuring prevailing of catalytic cracking over thermal cracking and full reaction completion. in the improbable situation of plugging of perforated plate 32 of distributing basket 35, catalyst outflows through pipes 33, flowing together with carrying fluid by the area which is annular to said basket.
- This area and that of the gas pipes is sufficiently dimensioned so as to accommodate the overall catalyst circulation. In this case it might be necessary to inject fluidization steam through nozzles 36 connected to distributing basket 35, provisioned to attend this situation.
- Regenerated catalyst having been distributed through regenerated catalyst distributor 30, the catalyst is directed to mixing zone 40, said mixing zone 40 being the site of feed injection of downflow reactor 50 of Figure 1 , the reactor being provided with feed injectors 41, said feed injectors being a device for atomizing the feed into a mist of hydrocarbon droplets in such a way as to minimize feed vaporization time and optimize cataiyst-to-oiJ contact.
- Catalyst begins to accelerate under the action of gravity in catalyst acceleration zone 37, designed so that the length of same is sufficient for the catalyst to attain a final velocity adequate to introduce the catalyst into the jet of feed admixed by feed injectors 41, located at mixing zone 40.
- Said velocity may be of from 1.5 to 11 m/s (5-35 f/s) more preferably of from 5 to 8 m/s (15-25 ft s).
- the diameter of the cylindrical portion of acceleration zone 37 is adjusted to satisfy two conditions: the velocity of the carrying fluid that descends with the catalyst is similar to the catalyst velocity and the cross section of said cylindrical portion is adjusted to be the same as that of distributing catalyst basket 35.
- Feed injectors 41 are illustrated in Figure 3.
- Feed injectors 41 are basically made up of an atomization chamber provided with central nozzles 110 for atomization fluid and side nozzles 120 for liquid feed.
- a concentric conduit system conveys atomization fluid and the liquid feed to the atomization unit where the flows of atomization fluid and liquid feed will encounter each other. The relative arrangement of the said central and side nozzles will cause the complete atomization of the feed while promoting the optimized interaction with the descending catalyst.
- a variable number of feed injectors are installed.
- the number of said injectors is a function of the cross sectional area of the reaction zone, the number of injectors being chosen so as to cover the highest possible cross sectional area.
- Feed injectors can be accommodated in one single stage or in more than one stage, according to different level elevations in the downflow reactor. Thus, 2, 4, 6 or more of said injectors may be used.
- feed injectors may be installed at angles between -30° and +30° relative to the horizontal.
- injectors are mounted at an inclination of 0° to +30°, or with a slight negative angle, with the atomized feed being injected in a direction opposite to the catalyst flow.
- the admixture of the liquid feed and the atomization fluid occurs in an atomization chamber, the geometry of which plays a major role in the complete atomization of the feed.
- Rgure 4A illustrates the bottom part of distributor 30 with distributing basket 35, perforations 32 and catalyst acceleration zone 37 connected to mixing zone 40 containing feed injectors 41 , followed by reactor 50.
- Figure 4B is a top view including planes of perforated plate and tip of feed injectors where the dotted line is a projection of the inner surface representing the area covered by the catalyst threads through perforated plate 32 of distributing basket 35.
- opening angle ⁇ defines the area to be covered by the feed jet.
- Hatched surface 42 represents the only area not covered by the feed jet. In this area catalyst only may be found.
- the surface area of perforated plate 32 as well as the cross sectional areas of mixing zone 40 are defined so as to minimize hatched surface 42.
- the depth at which feed injectors 41 are inserted in mixing zone 40 is an important parameter. Thus, if tip of feed injectors 41 are too close to the wall of mixing zone 40, an area wiil be created where there is feed only and no catalyst On the other hand, if tips of feed injectors 41 are too far from the wail of mixing zone 40, hatched area 42 wiil increase beyond desirable boundaries.
- Regenerated catalyst from catalyst distributor 30 contacts feed in the mixing zone 40 of downflow reactor 50, providing the required heat to vaporize the feed, bringing the feed to the reaction temperature and providing for the e ⁇ dothermai heat of the desirable cracking reactions.
- the diameter of said mixing zone 40 is such as to assure a gas velocity in the rang of from 2 to 15 m/s, preferably of from 5 to 10 m/s.
- Downflow reactor 50 is a pipe where the cracking reaction is earned out.
- Reactor 50 has a substantially vertical axis provided with feed injectors 41 in the upper part of same for introducing feed.
- the bottom of downflow reactor 50 is connected to diplegless cyclones 61 inside collector vessel 60 by means of pipe 67 for discharge of the obtained cracked hydrocarbons and spent catalyst
- the exit temperature of downflow reactor 50 is -controlled by altering the catalyst circulation by acting on the opening of the regenerated catalyst slide valve. In order to attain the desired conversion levels established in the Engineering project, such temperature should be kept between 450°C and
- a preferred temperature is of from 520°C to 570°C.
- Downflow reactor 50 preferably operates at a pressure of from 1.0 to 2.0 bar.
- the carrying fluid used in regenerated catalyst riser 10 will aid in reducing the partial hydrocarbon pressure in reactor 50 as well as the catalyst temperature, this in turn contributing to reducing thermal cracking undesirable side reactions.
- the admixture of catalyst, cracked hydrocarbons, steam and inert gases entrained from regenerator (not represented) crosses the. overall downflow reactor 50.
- the catalyst-to-oii contact time preferably is 0.5 to 5 seconds, more preferably 1 to 4 seconds, and even more preferably 1.5 to 3 seconds.
- the catalyst mass velocity (or mass flux) in downflow reactor 50 is of from 50 to 500 kg/(s.m 2 ), more preferably of from 100 to 350 kg/(s.m 2 ), and even more preferably of from 150 to 250 kg/(s.m 2 ).
- cracked hydrocarbons and spent catalyst are produced, which should be separated in diplegless cyclones 61of the quick separation device inside collector vessel 60, that is, a system according to US patent 5,569,435 adapted for downflow reactors.
- collector vessel 60 which contains diplegless cyclones 61 is indicated by numeral 60.
- Collector vessel 60 and its internals are represented in Figure 5.
- diplegless cyclones 61 allows the quick separation of catalyst from cracked hydrocarbons so as to avoid product overcracking after the reaction zone, while minimizing the amount of hydrocarbons entrained to the stripping zone.
- the rich suspension of spent catalyst particles and lighter cracked hydrocarbons adsorbed onto the catalyst is discharged from the bottom of said downflow reactor 50 and is directed to rectangular cross section pipe 67 connected to downflow reactor 50 bringing about the swift separation of the gas phase from particulate phases inside diplegless cyclones 61.
- the stream of cracked hydrocarbons, substantially free from catalyst particles, leaves diplegless cyclones 61 to outlet pipe 66, which receives said.
- diplegless cyclones 61 more than 99% of the catalyst is separated from hydrocarbon gases, the separated catalyst leaving cyclones 61 through mouth 62 and being deposited in the bottom of vessel 60.
- the gases leave quick separation vessel 60 through outlet pipes 66, which are fed by the separated
- the apparatus 100 of the invention may be used with other, state-of-the-art quick separation systems, the invention therefore not being limited to the quick separation system inside collector vessel 60 shown in Figure 5.
- the quick separation performed in collector vessel 60 avoids hydrocarbon overcracking. Once the hydrocarbon gas phase and catalyst phase are separated, the gas phase is directed to the product fractioning system (not represented) and the spent catalyst is directed to a stripping vessel (not represented).
- Coke-recovered spent catalyst deposited in the bottom of quick separation vessel 60 is directed to a stripper (not represented) that contacts the catalyst particles with a stripping gas for displacement of remaining hydrocarbon gases in the void volume of the catalyst.
- Catalyst activity is restored by coke combustion in a regenerator.
- Catalyst regeneration occurs at a low steam partial pressure, due to the low hydrogen content in coke resulting from the quick separation device.
- the regenerator bed operates at temperatures of from 600 to 750° C, preferably of from 670° C to 720"C and at a pressure of from 1.0 to 2.5 bar.
- Catalyst fines recovered by regenerator first stage cyclones and regenerator second stage cyclones return .
- the FCC process to be earned out in the said apparatus is mainly directed to heavy feeds.
- the density d 2m of an exemplary heavy vacuum gasoil is 0.9386, with a Ramsbottom Carbon Residue RCR of 0.38 wt %.
- Final boiling point is . higher than 500" C.
- the process wiil then operate at catalyst-to-oil ratios of from 3 to 15, more preferably of from 6 to 10 and still more preferably, of from 7.0 to 9.0.
- the operation temperature of the feed varies of from 200°C to 400°C.
- a preferred operation range is of from 310 to 350°C.
- feed at 320 ⁇ C is introduced in downflow reactor 50 through a set of feed injectors 41 according to WO 01/44406.
- the so-dispersed feed is atomized by dispersion steam into droplets the size of which is lower than 200 ⁇ m, in a mixing chamber 101 situated at the lower end of dispersion nozzles 120, from which feed is injected in downflow reactor 50 as a fine spray.
- the temperature to introduce regenerated catalyst into the regenerated catalyst standpipe is of from 600°C to 750°C, more preferably of from 670°C to 720°C.
- catalyst is introduced in the regenerated catalyst standpipe, the flow of same being controlled through a slide valve (not represented). Slide valve is actuated under the reaction temperature control, said temperature being determined at a chosen site at the lower end of the downflow reactor 50.
- present FCC technology makes use mainly of riser reactors.
- the present invention leads to high yields in valuable products such as propylene, LPG and gasoline vyhile keeping coke yields within reasonable values.
- the FCC process as carried out in the inventive apparatus yields neatly superior results.
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Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
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BRPI0405641-8A BRPI0405641B1 (en) | 2004-02-10 | 2004-02-10 | apparatus and process for downward reactor fluid catalytic cracking. |
CNB2004800425171A CN100564486C (en) | 2004-02-10 | 2004-02-10 | Down-flow fluidization catalytic cracking device and method |
PCT/GB2004/000527 WO2005080531A1 (en) | 2004-02-10 | 2004-02-10 | Apparatus and process for downflow fluid catalytic cracking |
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PCT/GB2004/000527 WO2005080531A1 (en) | 2004-02-10 | 2004-02-10 | Apparatus and process for downflow fluid catalytic cracking |
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WO2005080531A1 true WO2005080531A1 (en) | 2005-09-01 |
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US7758820B2 (en) | 2006-12-21 | 2010-07-20 | Uop Llc | Apparatus and process for regenerator mixing |
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US8691081B2 (en) | 2009-09-09 | 2014-04-08 | Uop Llc | Process for contacting hydrocarbon feed and catalyst |
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CN1191324C (en) * | 2002-04-26 | 2005-03-02 | 中国石油化工股份有限公司 | Desending catalytic cracking reactor and its application |
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2004
- 2004-02-10 WO PCT/GB2004/000527 patent/WO2005080531A1/en active Application Filing
- 2004-02-10 CN CNB2004800425171A patent/CN100564486C/en not_active Expired - Lifetime
- 2004-02-10 BR BRPI0405641-8A patent/BRPI0405641B1/en active IP Right Grant
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Cited By (12)
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EP2046919A2 (en) * | 2006-07-13 | 2009-04-15 | Saudi Arabian Oil Company | Ancillary cracking of heavy oils in conjuction with fcc unit operations |
EP2046919A4 (en) * | 2006-07-13 | 2012-09-05 | Saudi Arabian Oil Co | Ancillary cracking of heavy oils in conjuction with fcc unit operations |
US7585470B2 (en) | 2006-12-21 | 2009-09-08 | Uop Llc | Apparatus for mixing in fluidized beds |
US7758820B2 (en) | 2006-12-21 | 2010-07-20 | Uop Llc | Apparatus and process for regenerator mixing |
US8709235B2 (en) | 2006-12-21 | 2014-04-29 | Uop Llc | Process for mixing in fluidized beds |
US8691081B2 (en) | 2009-09-09 | 2014-04-08 | Uop Llc | Process for contacting hydrocarbon feed and catalyst |
US20120266525A1 (en) * | 2011-04-21 | 2012-10-25 | Shell Oil Company | Process for converting a solid biomass material |
US20130109892A1 (en) * | 2011-04-21 | 2013-05-02 | Shell Oil Company | Process for converting a solid biomass material |
US9217111B2 (en) * | 2011-04-21 | 2015-12-22 | Shell Oil Company | Process for converting a solid biomass material |
US9238779B2 (en) * | 2011-04-21 | 2016-01-19 | Shell Oil Company | Process for converting a solid biomass material |
WO2019108930A1 (en) * | 2017-11-30 | 2019-06-06 | Uop Llc | Process and apparatus for cracking hydrocarbons to lighter hydrocarbons |
US10781377B2 (en) | 2017-11-30 | 2020-09-22 | Uop Llc | Process and apparatus for cracking hydrocarbons to lighter hydrocarbons |
Also Published As
Publication number | Publication date |
---|---|
CN100564486C (en) | 2009-12-02 |
BRPI0405641A (en) | 2005-10-25 |
CN1926219A (en) | 2007-03-07 |
BRPI0405641B1 (en) | 2013-04-09 |
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