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

Patent metadata

Field	Value
Publication number	US-11377602-B2
Application number	US-202016838506-A
Country	US
Kind code	B2
Filing date	Apr 2, 2020
Priority date	Apr 3, 2019
Publication date	Jul 5, 2022
Grant date	Jul 5, 2022

Abstract

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.

First claim

What is claimed:

1. A process for the conversion of hydrocarbons, comprising:
separating an effluent from a moving bed reactor, the effluent being at a reactor outlet temperature and comprising a reaction product, a first particulate catalyst, and a second particulate catalyst, wherein the first particulate catalyst has a smaller average particle size and/or is less dense than the second particulate catalyst, to recover a first stream comprising the reaction product and the first particulate catalyst and a second stream comprising the second particulate catalyst;
admixing the second stream comprising the second particulate catalyst with a regenerated catalyst stream, the regenerated catalyst stream comprising first particulate catalyst and second particulate catalyst at an elevated temperature, wherein the admixing produces a mixed catalyst at a temperature intermediate the elevated temperature and the reactor outlet temperature;
contacting, in the moving bed reactor, the mixed catalyst and a light naphtha feedstock to react hydrocarbons therein, the endothermic reaction reducing a temperature of the mixed catalyst to a second intermediate temperature;
contacting, in the moving bed reactor, the mixed catalyst at the second intermediate temperature and a heavy naphtha feedstock to react hydrocarbons therein;
recovering from the moving bed reactor the effluent comprising the reaction product, the first particulate catalyst, and the second particulate catalyst.

2. The process of claim 1 , wherein the moving bed reactor is a vertical reactor, and wherein the light naphtha feedstock is introduced to the reactor at a lower elevation than the heavy naphtha feedstock.

3. The process of claim 1 , wherein:
the elevated temperature is in the range from about 1300° F. to about 1500° F.;
the first intermediate temperature is in the range from about 900° F. to about 1200° F.;
the second intermediate temperature is in the range from about 800° F. to about 1150° F.; and
the reactor effluent temperature is in the range from about 700° F. to about 1150° F.

4. The process of claim 1 , wherein the admixing is performed in the moving bed reactor at an elevation below an elevation at which the light naphtha feedstock is introduced.

5. The process of claim 1 , wherein the admixing is performed external to the moving bed reactor.

6. A system for performing chemical reactions, comprising:
a separator configured to separate a reactor effluent comprising a reaction product, a first particulate catalyst, and a second particulate catalyst, wherein the first particulate catalyst has a smaller average particle size and/or is less dense than the second particulate catalyst, to recover a first stream, comprising the reaction product and the first particulate catalyst, and a second stream, comprising the second particulate catalyst;
a mixing device configured to intimately contact the second stream comprising the second particulate catalyst with a catalyst stream, the catalyst stream comprising first particulate catalyst and second particulate catalyst at an elevated temperature, wherein the intimately contacting produces a mixed catalyst at a uniform temperature intermediate the elevated temperature and the reactor outlet temperature, wherein the mixing devise comprises a standpipe comprising:
a first inlet to receive the second stream from the separator;
a second inlet to receive the catalyst stream from a catalyst regenerator; and
an outlet to supply the mixed catalyst to the moving bed reactor;

a moving bed reactor configured to:
contact the mixed catalyst with a first reactant at the intermediate temperature, reducing a temperature of the mixed catalyst to a second intermediate temperature;
contact the mixed catalyst at the second intermediate temperature with a second reactant;

a flow stream configured to recover the reactor effluent from the moving bed reactor.

7. A system for performing chemical reactions, comprising:
a separator configured to separate a reactor effluent comprising a reaction product, a first particulate catalyst, and a second particulate catalyst, wherein the first particulate catalyst has a smaller average particle size and/or is less dense than the second particulate catalyst, to recover a first stream, comprising the reaction product and the first particulate catalyst, and a second stream, comprising the second particulate catalyst;
a mixing device configured to intimately contact the second stream comprising the second particulate catalyst with a catalyst stream, the catalyst stream comprising first particulate catalyst and second particulate catalyst at an elevated temperature, wherein the intimately contacting produces a mixed catalyst at a uniform temperature intermediate the elevated temperature and the reactor outlet temperature, wherein the mixing device comprises:
a first catalyst distributor disposed in a lower portion of the moving bed reactor, the catalyst distributor configured to receive the second stream from the separator and to disperse the second catalyst contained in the second stream into the moving bed reactor;
a second catalyst distributor disposed proximate the first catalyst distributor configured to receive the catalyst stream from the catalyst regenerator and to disperse the first and second catalysts contained in the catalyst stream into the moving bed reactor and into contact with the second catalyst from the first catalyst distributor;

a moving bed reactor configured to:
contact the mixed catalyst with a first reactant at the intermediate temperature, reducing a temperature of the mixed catalyst to a second intermediate temperature;
contact the mixed catalyst at the second intermediate temperature with a second reactant;

a flow stream configured to recover the reactor effluent from the moving bed reactor.

8. The system of claim 7 , further comprising a gas distributor positioned below the first and second catalyst distributors configured to fluidize and intimately mix the catalysts to attain the uniform intermediate temperature prior to contact with the first reactant.

9. The system of claim 7 , further comprising structure internal to the moving bed reactor and located below a feed elevation of the first reactant to enhance contact of the catalysts to attain the uniform intermediate temperature prior to contact with the first reactant.

10. A process for the conversion of hydrocarbons, comprising:
feeding a catalyst stream comprising a first particulate catalyst and a second particulate catalyst to a reactor, wherein the first particulate catalyst has a smaller average particle size and/or is less dense than the second particulate catalyst and admixing the catalyst stream with a second catalyst stream, comprising second particulate catalyst, to provide a mixed catalyst having a uniform temperature in the range from about 900° F. to about 1250° F.;
feeding a light naphtha feedstock and a heavy naphtha feedstock to the reactor, wherein the light naphtha feedstock is introduced to the reactor at a lower elevation than the heavy naphtha feedstock;
contacting the light and heavy naphtha feedstocks with the mixed catalysts to react hydrocarbons contained therein;
recovering an overhead product from the reactor comprising a converted hydrocarbon effluent, the second particulate catalyst, and the first particulate catalyst;
separating the second particulate catalyst from the overhead product to provide a first stream comprising the first particulate catalyst and the converted hydrocarbon effluent and the second catalyst stream, comprising the separated second particulate catalyst;
returning the separated second particulate catalyst in the second stream to the reactor.

Assignees

• Lummus Technology Inc

Inventors

• Tomsula Bryan
• Chen Liang
• Loezos Peter
• Marri Rama Rao

Classifications

• C10G51/026

  only catalytic cracking steps · CPC title

• C10G11/18 Primary

  according to the "fluidised-bed" technique · CPC title

• B01J8/1827

  the fluidising gas being a reactant · CPC title

• B01J8/0095

  in which two different types of particles react with each other · CPC title

• B01J8/1872

  Details of the fluidised bed reactor (B01J8/1836 takes precedence) · CPC title