Multiple reactor fcc system relying upon a dual cracking catalyst composition

Claim 1

A METHOD FOR CONVERTING HYDROCARBON TO GASOLINE PRODUCT WITH A DUAL COMPONENT CRACKING CATALYST COMPRISING A LARGE PORE CRACKING COMPONENT IN COMBINATION WITH A ZSM-5 TYPE OF CRYSTALLINE ALUMINO-SILICATE WHICH COMPRISES PASSING A SUSPENSION COMPRISING A GAS OIL FEED BOILING ABOVE 450*F. IN ADMIXTURE WITH SAID DUAL COMPONENT CRACKING CATALYST UPWARDLY THROUGH A RISER REACTOR AT A TEMPERATURE IN THE RANGE OF 1,000*F. UP TO 1,400*F. UP TO 1,400*F., INTRODUCING A HIGH COK OIL FEED IN A DOWNSTREAM PORTION OF SAID RISER UNDER CONDITIONS TO SUBSTANTIALLY SUBDUE THE CRACKING ACTIVITY OF THE LARGE PORE CRYSTALLINE ALUMINO-SILICATE, SEPARATING THE SUSPENSION INTO A HYDROCARBON PHASE AND A CATALYST PHASE, RECOVERRING THE SEPARATED HYDROCARBON PHASE, COLLECTING THE SEPARATED CATALYST PHASE AS A DENSE FLUID BED OF CATALYST, BENEATH THE RISER CONERSION OUTLET, COMBINING FRESHLY REGENERATED CATALYST WITH SAID COLLECTED DENSE FLUID BED OF CATALYST TO PROVIDE A BED OF CATALYST WITH A TEMPERATURE TIN THE RANGE OF 800*F. TO 1,200*F., INTRODUCING A HYDROCARBON FEED COMPRISING C3 AND C4 HYDROCARBONS TO A LOWER PORTION OF SAID DENSE FLUID BED FOR CYCLIZATION THEREOF TO AROMATIC COMPONENTS, WITHDRAWING CATALYST FROM SAID DENSE FLUID BED, STRIPPING HE WITHDRAWN CATALYST, REGENERATING THE STRIPPED CATALYST TO REMOVE DEPOSITED CARBONACEOUS MATERIAL AND RETURNING REGENERATED CATALYST TO SAID RISER REACTOR.

Claim 2

A METHOD FOR CONVERTING HYDROCARBON TO GASOLINE PRODUCT WITH A DUAL COMPONENT CRACKING CATALYST COMPRISING A LARGE PORE CRACKING COMPONENT IN COMBINATION WITH A ZSM-5 TYPE OF CRYSTALLINE ALUMINO-SILICATE WHICH COMPRISES PASSING A SUSPENSION COMPRISING A GAS OIL FEED BOILING ABOVE 450*F. IN ADMIXTURE WITH SAID DUAL COMPONENT CRACKING CATALYST UPWARDLY THROUGH A RISER REACTOR AT A TEMPERATURE IN THE RANGE OF 1,000*F. UP TO 1,400*F. UP TO 1,400*F., INTRODUCING A HIGH COK OIL FEED IN A DOWNSTREAM PORTION OF SAID RISER UNDER CONDITIONS TO SUBSTANTIALLY SUBDUE THE CRACKING ACTIVITY OF THE LARGE PORE CRYSTALLINE ALUMINO-SILICATE, SEPARATING THE SUSPENSION INTO A HYDROCARBON PHASE AND A CATALYST PHASE, RECOVERRING THE SEPARATED HYDROCARBON PHASE, COLLECTING THE SEPARATED CATALYST PHASE AS A DENSE FLUID BED OF CATALYST, BENEATH THE RISER CONERSION OUTLET, COMBINING FRESHLY REGENERATED CATALYST WITH SAID COLLECTED DENSE FLUID BED OF CATALYST TO PROVIDE A BED OF CATALYST WITH A TEMPERATURE TIN THE RANGE OF 800*F. TO 1,200*F., INTRODUCING A HYDROCARBON FEED COMPRISING C3 AND C4 HYDROCARBONS TO A LOWER PORTION OF SAID DENSE FLUID BED FOR CYCLIZATION THEREOF TO AROMATIC COMPONENTS, WITHDRAWING CATALYST FROM SAID DENSE FLUID BED, STRIPPING HE WITHDRAWN CATALYST, REGENERATING THE STRIPPED CATALYST TO REMOVE DEPOSITED CARBONACEOUS MATERIAL AND RETURNING REGENERATED CATALYST TO SAID RISER REACTOR.

Claim 3

A method for converting hydrocarbons in the presence of a dual cracking component catalyst comprising a large pore crystalline alumino-silicate and a ZSM-5 type of crystalline alumino-silicate which comprises combining said dual component catalyst with a gas oil feed under conditions to form a suspension at a temperature in the range of 1,000*F up to about 1,400*F., passing the suspension thus formed through a dispersed catalyst phase riser reaction zone for a hydrocarbon residence time in the range of 0.5 seconds to 10 seconds to form cracked products of reaction comprising gasoline and olefinic constituents of cracking, separating the suspension after traversing said riser reaction zone into a hydrocarbon phase and a catalyst phase, recovering the hydrocarbon phase, recovering the catalyst phase as a dense fluid bed of catalyst, contacting the dense fluid bed of catalyst under temperature conditions in the range of 900*F. to 1,100*F. with a high coke producing feed material at a catalyst residence time in the range of 0.5 minutes up to 5 or 10 minutes and sufficient to effect substantial deactivation of the large pore CAS component, passing a portion of the dense fluid bed of catalyst to a stripping zone, stripping the catalyst and passing the stripped catalyst to catalyst regeneration, passing another portion of said dense fluid bed of catalyst to a separate olefin aromatization zone maintained at a temperature in the range of 800*F. to 1,200*F. passing a C3 and C4 olefin rich feed in contact with the catalyst in said aromatization zone, stripping and withdrawing catalyst from said aromatizAtion zone, regenerating catalyst withdrawn from said stripping zone and passing regenerated catalyst to said riser reactor above identified.

Claim 4

A method for converting hydrocarbons in the presence of a dual cracking component catalyst comprising a large pore crystalline alumino-silicate and a ZSM-5 type of crystalline alumino-silicate which comprises combining said dual component catalyst with a gas oil feed under conditions to form a suspension at a temperature in the range of 1,000*F up to about 1,400*F., passing the suspension thus formed through a dispersed catalyst phase riser reaction zone for a hydrocarbon residence time in the range of 0.5 seconds to 10 seconds to form cracked products of reaction comprising gasoline and olefinic constituents of cracking, separating the suspension after traversing said riser reaction zone into a hydrocarbon phase and a catalyst phase, recovering the hydrocarbon phase, recovering the catalyst phase as a dense fluid bed of catalyst, contacting the dense fluid bed of catalyst under temperature conditions in the range of 900*F. to 1,100*F. with a high coke producing feed material at a catalyst residence time in the range of 0.5 minutes up to 5 or 10 minutes and sufficient to effect substantial deactivation of the large pore CAS component, passing a portion of the dense fluid bed of catalyst to a stripping zone, stripping the catalyst and passing the stripped catalyst to catalyst regeneration, passing another portion of said dense fluid bed of catalyst to a separate olefin aromatization zone maintained at a temperature in the range of 800*F. to 1,200*F. passing a C3 and C4 olefin rich feed in contact with the catalyst in said aromatization zone, stripping and withdrawing catalyst from said aromatizAtion zone, regenerating catalyst withdrawn from said stripping zone and passing regenerated catalyst to said riser reactor above identified.

Claim 6

A method of regenerating catalyst which comprises passing a cracking catalyst comprising crystalline aluminosilicate contaminated with carbonaceous material upwardly through separate first and second riser regeneration zones, burning gaseous components discharged from said first and second riser regenerators to convert carbon monoxide to CO2 and produce hot combustion gases, passing catalyst discharged from said first riser regenerator with hot combustion gases in direct heat exchange to a catalyst accumulation zone, separating catalyst from hot combustion gases in said accumulation zone, combining catalyst separated in said accumulation zone with catalyst separated from said second riser regeneration zone and subjecting the combined catalyst to regeneration with oxygen containing gas.

Claim 7

A method of regenerating catalyst which comprises passing a cracking catalyst comprising crystalline aluminosilicate contaminated with carbonaceous material upwardly through separate first and second riser regeneration zones, burning gaseous components discharged from said first and second riser regenerators to convert carbon monoxide to CO2 and produce hot combustion gases, passing catalyst discharged from said first riser regenerator with hot combustion gases in direct heat exchange to a catalyst accumulation zone, separating catalyst from hot combustion gases in said accumulation zone, combining catalyst separated in said accumulation zone with catalyst separated from said second riser regeneration zone and subjecting the combined catalyst to regeneration with oxygen containing gas.

Claim 8

A method for converting a crude oil to gasoline product of acceptable octane rating which comprises, separating a crude oil having a gravity in the range of 15 API to 40 API by atmospheric and vacuum distillation into gas oil fractions, a heating oil fraction and an overhead fraction comprising hydrocarbon gases and straight run gasoline, passing said overhead fraction through a first riser reactor in contact with a dual function cracking catalyst comprising a ZSM-5 type crystalline alumino-silicate component suspended therein at a temperature in the range of 1, 000*F. up to 1,400*F. for a hydrocarbon residence time in the range of 1 to 10 seconds, passing gas oil fractions of atmospheric and vacuum distillation through a second riser reactor in contact with said dual function cracking catalyst as a suspension at a temperature in the range of 900*F. to 1,300*F. for a hydrocarbon residence time in the range of 1 to 10 seconds, separating the suspensions after traverse of said riser reaction zones into a hydrocarbon phase and a catalyst phase, passing the hydrocarbon phase to a fractionation zone, stripping the catalyst phase separated from each riser reaction zone and passing the stripping products to said fractionation zone, passing a portion of the stripped catalyst to catalyst regeneration, passing another portion of the stripped catalyst to a separate aromatization zone, passing gasiform material rich in C3 and C4 hydrocarbons in contact with the catalyst in said aromatization zone maintained at a temperature in the range of 600*F. to 1, 500*F., and a hydrocarbon residence time in the range of 15 seconds to 15 minutes, separating product hydrocarbons from the catalyst in said aromatization zone and passing the thus separated products of aromatization to said fractionation zone, passing catalyst from said aromatizing zone to catalyst regeneration, in said fractionation zone separating the hydrocarbon passed thereto into a gasoline and lOwer boiling hydrocarbon fraction comprising olefins, a heavy naphtha fraction, a light cycle oil fraction, a heavy cycle oil fraction and a bottoms residual fraction, passing the overhead fraction through a deethanizing zone and a debutanizing zone, recovering debutanized gasoline, passing a gaseous fraction rich in C3 and C4 hydrocarbons separated from the gasoline product to said aromatizing zone, passing heavy naphtha product to said first riser reactor with said straight run gasoline feed and passing heavy cycle oil product to said second riser with said gas oil feeds.

Claim 9

A method for converting a crude oil to gasoline product of acceptable octane rating which comprises, separating a crude oil having a gravity in the range of 15 API to 40 API by atmospheric and vacuum distillation into gas oil fractions, a heating oil fraction and an overhead fraction comprising hydrocarbon gases and straight run gasoline, passing said overhead fraction through a first riser reactor in contact with a dual function cracking catalyst comprising a ZSM-5 type crystalline alumino-silicate component suspended therein at a temperature in the range of 1, 000*F. up to 1,400*F. for a hydrocarbon residence time in the range of 1 to 10 seconds, passing gas oil fractions of atmospheric and vacuum distillation through a second riser reactor in contact with said dual function cracking catalyst as a suspension at a temperature in the range of 900*F. to 1,300*F. for a hydrocarbon residence time in the range of 1 to 10 seconds, separating the suspensions after traverse of said riser reaction zones into a hydrocarbon phase and a catalyst phase, passing the hydrocarbon phase to a fractionation zone, stripping the catalyst phase separated from each riser reaction zone and passing the stripping products to said fractionation zone, passing a portion of the stripped catalyst to catalyst regeneration, passing another portion of the stripped catalyst to a separate aromatization zone, passing gasiform material rich in C3 and C4 hydrocarbons in contact with the catalyst in said aromatization zone maintained at a temperature in the range of 600*F. to 1, 500*F., and a hydrocarbon residence time in the range of 15 seconds to 15 minutes, separating product hydrocarbons from the catalyst in said aromatization zone and passing the thus separated products of aromatization to said fractionation zone, passing catalyst from said aromatizing zone to catalyst regeneration, in said fractionation zone separating the hydrocarbon passed thereto into a gasoline and lOwer boiling hydrocarbon fraction comprising olefins, a heavy naphtha fraction, a light cycle oil fraction, a heavy cycle oil fraction and a bottoms residual fraction, passing the overhead fraction through a deethanizing zone and a debutanizing zone, recovering debutanized gasoline, passing a gaseous fraction rich in C3 and C4 hydrocarbons separated from the gasoline product to said aromatizing zone, passing heavy naphtha product to said first riser reactor with said straight run gasoline feed and passing heavy cycle oil product to said second riser with said gas oil feeds.

Claim 10

A method for upgrading a crude oil to useful products comprising a. separating a crude oil by atmospheric and vacuum distillation into a gas oil fraction boiling from about 500*F. up to about 1,100*F., a higher boiling residual fraction, a light oil fraction boiling from about 400*F. up to about 600*F. and a lower boiling fraction comprising straight run gasoline and lower boiling gaseous hydrocarbons, b. cracking said gas oil fraction in a first dispersed catalyst phase reaction zone at a temperature of at least 900*F. in the presence of a dual cracking component catalyst comprising ZSM-5 type crystalline alumino-silicate and a larger pore size cracking component, c. contacting the straight run gasoline and lower boiling gaseous hydrocarbon comprising C3 and higher boiling gaseous hydrocarbons in a second dispersed catalyst phase reaction zone under hydrocarbon conversion conditions in the presence of said dual cracking component catalyst recited above, d. separating hydrocarbons from catalyst after traverse of said first and second reaction zones within a hydrocarbon residence time within the range of 0.5 to 10 seconds and passing separated hydrocarbons to a product fractionation zone, e. collecting and stripping the catalyst recovered from said first and second reaction zones to remove entrained hydrocarbons therefrom, f. passing stripped catalyst to a separate dense fluid bed of catalyst maintained at a temperature within the range of 600*F. up to 1,200*F. to which is passed straight run gasoline and product gasiform hydrocarbons comprising C3 and C4 hydrocarbons under conditions to provide a hydrocarbon residence time within the range of 15 seconds up to about 15 minutes, g. passing reaction products of said separate dense fluid catalyst bed along with stripped products to said product fractionation zone, h. recovering from said product fractionation zone a heavy cycle oil recycled in part to said first reaction zone, a light cycle oil recycled in part to said second reaction zone, a heavy naphtha fraction recycled in part to said second reaction zone, a gasoline and lower boiling C3 and C4 hydrocarbons which are further separated to recover stabilized gasoline therefrom and i. passing C3 and C4 hydrocarbons separated from the gasoline product to said separate dense fluid bed of catalyst.

Claim 11

A method for upgrading a crude oil to useful products comprising a. separating a crude oil by atmospheric and vacuum distillation into a gas oil fraction boiling from about 500*F. up to about 1,100*F., a higher boiling residual fraction, a light oil fraction boiling from about 400*F. up to about 600*F. and a lower boiling fraction comprising straight run gasoline and lower boiling gaseous hydrocarbons, b. cracking said gas oil fraction in a first dispersed catalyst phase reaction zone at a temperature of at least 900*F. in the presence of a dual cracking component catalyst comprising ZSM-5 type crystalline alumino-silicate and a larger pore size cracking component, c. contacting the straight run gasoline and lower boiling gaseous hydrocarbon comprising C3 and higher boiling gaseous hydrocarbons in a second dispersed catalyst phase reaction zone under hydrocarbon conversion conditions in the presence of said dual cracking component catalyst recited above, d. separating hydrocarbons from catalyst after traverse of said first and second reaction zones within a hydrocarbon residence time within the range of 0.5 to 10 seconds and passing separated hydrocarbons to a product fractionation zone, e. collecting and stripping the catalyst recovered from said first and second reaction zones to remove entrained hydrocarbons therefrom, f. passing stripped catalyst to a separate dense fluid bed of catalyst maintained at a temperature within the range of 600*F. up to 1,200*F. to which is passed straight run gasoline and product gasiform hydrocarbons comprising C3 and C4 hydrocarbons under conditions to provide a hydrocarbon residence time within the range of 15 seconds up to about 15 minutes, g. passing reaction products of said separate dense fluid catalyst bed along with stripped products to said product fractionation zone, h. recovering from said product fractionation zone a heavy cycle oil recycled in part to said first reaction zone, a light cycle oil recycled in part to said second reaction zone, a heavy naphtha fraction recycled in part to said second reaction zone, a gasoline and lower boiling C3 and C4 hydrocarbons which are further separated to recover stabilized gasoline therefrom and i. passing C3 and C4 hydrocarbons separated from the gasoline product to said separate dense fluid bed of catalyst.