Heat balance in FCC process and apparatus with downflow reactor riser

Claim 2

A fluid catalytic cracking process comprising admixing a hydrocarbonaceous feed with a regenerated catalyst in the top section of a downflow reactor riser, passing the hydrocarbonaceous feed and the catalyst admixed therewith through the downstream section of the riser, thereby effecting cracking of the hydrocarbonaceous feed at the process temperature under endothermic process conditions and deactivating the catalyst by deposition of carbonaceous deposits thereon, separating the deactivated catalyst from the cracked hydrocarbonaceous feed, passing the deactivated catalyst to a regenerator vessel wherein the carbonaceous deposits are removed from the deactivated catalyst under exothermic process conditions by means of a regenerating medium introduced into the regenerator vessel by a regenerating medium distribution means, thereby regenerating and heating the catalyst, passing the regenerated hot catalyst to the top section of the downflow reactor riser, and transferring at least a portion of the thermal energy by heat exchanging means from the downflow riser to the regenerator vessel.

Claim 3

A process according to claim 1, wherein the heat exchanging means comprises an air heat exchanger.

Claim 4

A process according to claim 1, wherein the heat exchanging means comprises a steam heat exchanger.

Claim 5

A process according to claim 2, wherein the catalyst contains carbon monoxide burning promoter.

Claim 6

A process according to claim 3, wherein the catalyst contains carbon monoxide burning promoter.

Claim 7

A process according to claim 2, wherein the portion of the thermal energy transferred to the regenerator vessel is introduced into the regenerator vessel above the regenerating medium distribution means.

Claim 8

A process according to claim 3, wherein the portion of the thermal energy transferred to the regenerator vessel is introduced into the regenerator vessel above the regenerating medium distribution means.

Claim 9

A process according to claim 6, wherein the air heat exchanger is controlled by a temperature sensing means placed in the regenerator vessel below the point of introduction of the portion of the thermal energy into the regenerator vessel.

Claim 10

A process according to claim 7, wherein the steam heat exchanger is controlled by a temperature sensing means placed in the regenerator vessel below the point of introduction of the portion of the thermal energy into the regenerator vessel.

Claim 11

A process according to claim 8, wherein the air heat exchanger has the surface area of at least 1200 square feet.

Claim 12

A process according to claim 9, wherein the steam heat exchanger has the surface area of at least 200 square feet.

Claim 13

A process according to claim 10, wherein the carbonaceous deposits are removed from the deactivated catalyst by air having a temperature of 300° to 500° F.

Claim 14

A process according to claim 11, wherein the carbonaceous deposits are removed from the deactivated catalyst by air having a temperature of 300° to 500° F.

Claim 15

A process according to claim 12, wherein the air heat exchanger is placed about the downflow riser at a distance beginning at 15% to 70% of the total downflow riser length and terminating at a distance of 20% to 90% of the total downflow riser length.

Claim 16

A process according to claim 13, wherein the steam heat exchanger is placed about the downflow riser at a distance beginning at 15% to 70% of the total downflow riser length and terminating at a distance of 20% to 90% of the total riser length.

Claim 17

A process according to claim 15, wherein the steam, after passing through the steam heat exchanger, is conducted to a regenerating medium preheating means to preheat the regenerating medium before the introduction thereof into the regenerator vessel.

Claim 18

A process according to claim 1 further comprising a method for controlling said process, which comprises comparing the temperature of the catalyst in the regenerator vessel with a predetermined temperature to obtain a catalyst temperature deviation; and controlling the rate of flow of a heat exchanging medium into the heat exchanging means in a direction to reduce the temperature deviation.

Claim 19

A fluid catalytic cracking process comprising admixing a hydrocarbonaceous feed with a regenerated catalyst in the top section of a downflow reactor riser, passing the hydrocarbonaceous feed and the catalyst admixed therewith through the downstream section of the riser, thereby effecting cracking of the hydrocarbonaceous feed at the process temperature under endothermic process conditions and deactivating the catalyst by deposition of carbonaceous deposits thereon, separating the deactivated catalyst from the cracked hydrocarbonaceous feed, passing the deactivated catalyst to a regenerator vessel wherein the carbonaceous deposits are removed from the deactivated catalyst under exothermic process conditions by means of a regenerating medium introduced into the regenerator vessel by a regenerating medium distribution means, thereby regenerating and heating the catalyst, passing the regenerated hot catalyst to the top section of the downflow reactor riser, and transferring at least a portion of the thermal energy by heat exchanging means from the downflow riser to the regenerator vessel, thereby recovering an improved yield of gasoline product having higher octane over that obtainable at the same reactor vessel outlet temperature without the heat exchanging means.

Claim 20

A fluid catalytic cracking process comprising admixing a hydrocarbonaceous feed with a regenerated catalyst in the top section of a downflow reactor riser, passing the hydrocarbonaceous feed and the catalyst admixed therewith through the downstream section of the riser, thereby effecting cracking of the hydrocarbonaceous feed at the process temperature under endothermic process conditions and deactivating the catalyst by deposition of carbonaceous deposits thereon, separating the deactivated catalyst from the cracked hydrocarbonaceous feed, passing the deactivated catalyst to a regenerator vessel wherein the carbonaceous deposits are removed from the deactivated catalyst under exothermic process conditions by means of a regenerating medium introduced into the regenerator vessel by a regenerating medium distribution means, thereby regenerating and heating the catalyst, passing the regenerated hot catalyst to the top section of the downflow reactor riser, and transferring at least a portion of the thermal energy by heat exchanging means from the downflow riser to the regenerator vessel, thereby recovering an improved yield of gasoline product having higher octane over that obtainable at the same reactor vessel outlet temperature without the heat exchanging means.

Claim 21

A process according to claim 14, wherein the air heat exchanger is placed about the downflow riser at a distance beginning at 20% to 50% of the total downflow riser length and terminating at a distance of 25% to 90% of the total downflow riser length.

Claim 22

A process according to claim 15, wherein the steam heat exchanger is placed about the downflow riser at a distance beginning at 20% to 50% of the total downflow riser length and terminating at a distance of 25% to 90% of the total downflow riser length.

Claim 23

A process according to claims 1, 15, 16, 17, 18, 19 or 20, wherein the temperature in the upstream section of the downflow riser is increased by at least 2° F. over that obtainable without the heat exchanging means.

Claim 24

A process according to claim 21, wherein the temperature in the upstream section of the downflow riser is increased by 5° F. to 50° F.

Claim 25

A process according to claim 22, wherein the temperature in the upstream section of the down flow riser is increased by 10° F. to 30° F.

Claim 26

A fluid catalytic cracking apparatus comprising a reactor vessel and a regenerator vessel, said reactor vessel comprising a downflow riser divided into an upstream and a downstream section, said downflow riser being equipped with a heat exchanging means for transferring at least a portion of thermal energy from said downflow riser to said regenerator vessel, said regenerator vessel comprising a regenerating medium inlet conduit cooperating with a regenerating medium distribution means in the lower section thereof and a solid-gas separation means in the upper section thereof, a means for conveying a deactivated catalyst from said reactor vessel to said regenerator vessel, a means for conveying a regenerated catalyst froom said regenerator vessel to said reactor vessel, a first means for sensing temperature at the outlet of said reactor vessel, said first means for sensing temperature controlling said means for conveying the regenerated catalyst from said regenerator vessel to said reactor vessel.

Claim 27

A fluid catalytic cracking apparatus comprising a reactor vessel and a regenerator vessel, said reactor vessel comprising a downflow riser divided into an upstream and a downstream section, said downflow riser being equipped with a heat exchanging means for transferring at least a portion of thermal energy from said downflow riser to said regenerator vessel, said regenerator vessel comprising a regenerating medium inlet conduit cooperating with a regenerating medium distribution means in the lower section thereof and a solid-gas separation means in the upper section thereof, a means for conveying a deactivated catalyst from said reactor vessel to said regenerator vessel, a means for conveying a regenerated catalyst froom said regenerator vessel to said reactor vessel, a first means for sensing temperature at the outlet of said reactor vessel, said first means for sensing temperature controlling said means for conveying the regenerated catalyst from said regenerator vessel to said reactor vessel.

Claim 28

An apparatus according to claim 24, wherein said heat exchanging means is an air heat exchanger.

Claim 29

An apparatus according to claim 24, wherein said heat exchanging means is a steam heat exchanger.

Claim 30

An apparatus according to claim 25, wherein said air heat exchanger introduces said portion of thermal energy into said regenerator vessel above said regenerating medium distribution means.

Claim 31

An apparatus according to claim 26, wherein said steam heat exchanger introduces said portion of thermal energy into said regenerator vessel above the regenerating medium distribution means.

Claim 32

An apparatus according to claim 27 further comprising a second temperature sensing means, placed in said regenerator vessel below the point of introduction of said portion of thermal energy by said air heat exchanger into said regenerator vessel, to control said air heat exchanger.

Claim 33

An apparatus according to claim 28 further comprising a second temperature sensing means, placed in said regenerator vessel below the point of introduction of said portion of thermal energy by said steam heat exchanger into said regenerator vessel, to control said steam heat exchanger.

Claim 34

An apparatus according to claim 29, wherein said air heat exchanger has the surface area of at least 1200 square feet.

Claim 35

An apparatus according to claim 30, wherein said steam heat exchanger has the surface area of at least 200 square feet.

Claim 36

An apparatus according to claim 31, wherein said air heat exchanger is placed about the downflow riser at a distance beginning at 15% to 70% of the total downflow riser length and terminating at a distance of 20% to 90% of the total downflow riser length.

Claim 37

An apparatus according to claim 32, wherein said steam heat exchanger is placed about the downflow riser at a distance beginning at 15% to 70% of the total downflow riser length and terminating at a distance of 20% to 90% of the total downflow riser length.

Claim 38

An apparatus according to claim 33, wherein said air heat exchanger is placed about the downflow riser at a distance beginning at 20% to 50% of the total downflow riser length and terminating at a distance of 25% to 90% of the total downflow riser length.

Claim 39

An apparatus according to claim 34, wherein said steam heat exchanger is placed about the downflow riser at a distance beginning at 20% to 50% of the total downflow riser length and terminating at a distance of 25% to 90% of the total downflow riser length.

Claim 40

A fluid catalytic cracking apparatus comprising a reactor vessel and a regenerator vessel, said reactor vessel comprising a downflow riser divided into an upstream section and a downstream section, said regenerator vessel comprising a regenerating medium inlet conduit cooperating with a regenerating medium distribution means in the lower section thereof and a solid-gas separation means in the upper section thereof, a means for conveying a deactivated catalyst from said reactor vessel to said regenerator vessel, a means for conveying a regenerated catalyst from said regenerator vessel to said reactor vessel, a first means for sensing temperature at the outlet of said reactor vessel, said first means for sensing temperature controlling said means for conveying the regenerated catalyst from said regenerator vessel to said reactor vessel; said downflow riser being equipped with an air heat exchanger for transferring at least a portion of thermal energy from said downflow riser to said regenerator vessel, said portion of thermal energy being introduced into said regenerator vessel above the regenerating medium distribution means; a second temperature sensing means, placed in said regenerator vessel below the point of introduction of said portion of thermal energy by said air heat exchanger into said regenerator vessel to control said air heat exchanger; said air heat exchanger being placed about the downflow riser at a distance beginning at 15% to 70% of the total downflow riser length and terminating at a distance of 20% to 90% of the total downflow riser length; said air heat exchanger having a surface area of at least 1200 square feet.

Claim 41

A fluid catalytic cracking apparatus comprising a reactor vessel and a regenerator vessel, said reactor vessel comprising a downflow riser divided into an upstream section and a downstream section, said regenerator vessel comprising a regenerating medium inlet conduit cooperating with a regenerating medium distribution means in the lower section thereof and a solid-gas separation means in the upper section thereof, a means for conveying a deactivated catalyst from said reactor vessel to said regenerator vessel, a means for conveying a regenerated catalyst from said regenerator vessel to said reactor vessel, a first means for sensing temperature at the outlet of said reactor vessel, said first means for sensing temperature controlling said means for conveying the regenerated catalyst from said regenerator vessel to said reactor vessel; said downflow riser being equipped with an air heat exchanger for transferring at least a portion of thermal energy from said downflow riser to said regenerator vessel, said portion of thermal energy being introduced into said regenerator vessel above the regenerating medium distribution means; a second temperature sensing means, placed in said regenerator vessel below the point of introduction of said portion of thermal energy by said air heat exchanger into said regenerator vessel to control said air heat exchanger; said air heat exchanger being placed about the downflow riser at a distance beginning at 15% to 70% of the total downflow riser length and terminating at a distance of 20% to 90% of the total downflow riser length; said air heat exchanger having a surface area of at least 1200 square feet.

Claim 42

A fluid catalytic cracking apparatus comprising a reactor vessel and a regenerator vessel, said reactor vessel comprising a downflow riser divided into an upstream section and a downstream section, said regenerator vessel comprising a regenerating medium inlet conduit cooperating with a regenerating medium distribution means in the lower section thereof and a solid-gas separation means in the upper section thereof, a means for conveying a deactivated catalyst from said reactor vessel to said regenerator vessel, a means for conveying a regenerated catalyst from said regenerator vessel to said reactor vessel, a first means for sensing temperature at the outlet of said reactor vessel, said first means for sensing temperature controlling said means for conveying the regenerated catalyst from said regenerator vessel to said reactor vessel; said downflow riser being equipped with a steam heat exchanger for transferring at least a portion of thermal energy from said downflow riser to said regenerator vessel, said portion of thermal energy being introduced into said regenerator vessel above the regenerating medium distribution means; a second temperature sensing means, placed in said regenerator vessel below the point of introduction of said portion of thermal energy by said steam heat exchanger into said regenerator vessel to control said steam heat exchanger; said steam heat exchanger being placed about the downflow riser at a distance beginning at 15% to 70% of the total downflow riser length and terminating at a distance of 20% to 90% of the total downflow riser length; said steam heat exchanger having a surface area of at least 200 square feet.

Claim 43

A fluid catalytic cracking apparatus comprising a reactor vessel and a regenerator vessel, said reactor vessel comprising a downflow riser divided into an upstream section and a downstream section, said regenerator vessel comprising a regenerating medium inlet conduit cooperating with a regenerating medium distribution means in the lower section thereof and a solid-gas separation means in the upper section thereof, a means for conveying a deactivated catalyst from said reactor vessel to said regenerator vessel, a means for conveying a regenerated catalyst from said regenerator vessel to said reactor vessel, a first means for sensing temperature at the outlet of said reactor vessel, said first means for sensing temperature controlling said means for conveying the regenerated catalyst from said regenerator vessel to said reactor vessel; said downflow riser being equipped with a steam heat exchanger for transferring at least a portion of thermal energy from said downflow riser to said regenerator vessel, said portion of thermal energy being introduced into said regenerator vessel above the regenerating medium distribution means; a second temperature sensing means, placed in said regenerator vessel below the point of introduction of said portion of thermal energy by said steam heat exchanger into said regenerator vessel to control said steam heat exchanger; said steam heat exchanger being placed about the downflow riser at a distance beginning at 15% to 70% of the total downflow riser length and terminating at a distance of 20% to 90% of the total downflow riser length; said steam heat exchanger having a surface area of at least 200 square feet.