Catalytic conversion with catalyst regeneration sequence

Claim 2

An integrated multi-stage system for catalytic conversion of organic compounds comprising a bank of fixed bed catalytic reactors operatively connected to be placed sequentially in selected system stage positions or a regeneration loop; means for feeding a first reactant stream to a primary stage comprising at least one moderate temperature reactor containing active catalyst; means for feeding a second reactant stream to a secondary stage comprising at least one higher temperature reactor containing significantly inactivated catalyst previously used in the primary stage at lower temperature; fluid handling means for sequentially replacing a primary stage reactor containing partially inactivated catalyst with a reactor from the reactor bank containing fresh or regenerated catalyst, while maintaining continuous conversion in the system; means for advancing at least one replaced primary stage reactor containing partially inactivated catalyst to the secondary stage at higher temperature for conversion of the second reactant stream; and means for regenerating inactivated catalyst in a reactor removed from secondary stage service in a separate regeneration loop, while maintaining continuous conversion in the multi-stage system.

Claim 3

A cyclic system for catalytic converting of hydrocarbon feedstock which comprises: a plurality of catalyst reactor zones comprising fixed bed downflow pressurized reactors having a porous bed of conversion catalyst particles; first stage plural serial reactor means for contacting the feedstock in a first catalyst zone at moderate temperature under conditions favorable for conversion of a first reactor stream; means for separating the first stage effluent stream into a first product stream and a second reactant stream containing initially unreacted hydrocarbons; second stage reactor means for contacting the second reactant stream from the separation means in a second catalyst zone containing said conversion catalyst at elevated temperature under conditions favorable for conversion of the second reactant to provide a second reactor effluent stream; cyclic fluid handling means for connecting the first stage serial reactors in operative fluid flow relationship whereby fresh or regenerated catalyst in a terminal reactor stage position receives effluent from at least one preceding first stage reactor operating at moderate temperature, said preceding first stage reactor containing catalyst of less activity than said catalyst in the terminal reactor stage position; means for sequencing system flow to connect said preceding first stage reactor in said second stage to receive the second reactant stream; means for increasing temperature in said previously preceding first stage reactor to second stage temperature conditions; means for removing a second stage reactor containing inactivated catalyst from conversion service and connecting said inactivated catalyst in fluid flow relationship with a catalyst regeneration loop, and means for regenerating said catalyst in situ; means for advancing the terminal reactor of the first stage to a preceding serial position in the first stage; and means for adding a fresh or regenerated catalyst reactor in the first stage terminal position.

Claim 4

A cyclic system for catalytic converting of hydrocarbon feedstock which comprises: a plurality of catalyst reactor zones comprising fixed bed downflow pressurized reactors having a porous bed of conversion catalyst particles; first stage plural serial reactor means for contacting the feedstock in a first catalyst zone at moderate temperature under conditions favorable for conversion of a first reactor stream; means for separating the first stage effluent stream into a first product stream and a second reactant stream containing initially unreacted hydrocarbons; second stage reactor means for contacting the second reactant stream from the separation means in a second catalyst zone containing said conversion catalyst at elevated temperature under conditions favorable for conversion of the second reactant to provide a second reactor effluent stream; cyclic fluid handling means for connecting the first stage serial reactors in operative fluid flow relationship whereby fresh or regenerated catalyst in a terminal reactor stage position receives effluent from at least one preceding first stage reactor operating at moderate temperature, said preceding first stage reactor containing catalyst of less activity than said catalyst in the terminal reactor stage position; means for sequencing system flow to connect said preceding first stage reactor in said second stage to receive the second reactant stream; means for increasing temperature in said previously preceding first stage reactor to second stage temperature conditions; means for removing a second stage reactor containing inactivated catalyst from conversion service and connecting said inactivated catalyst in fluid flow relationship with a catalyst regeneration loop, and means for regenerating said catalyst in situ; means for advancing the terminal reactor of the first stage to a preceding serial position in the first stage; and means for adding a fresh or regenerated catalyst reactor in the first stage terminal position.

Claim 5

The system of claim 2 wherein the first and second stage reactors contain an acid ZSM-5 type catalyst.

Claim 6

The system of claim 3 comprising fixed bed down flow pressurized reactors having a porous bed of ZSM-5 type catalyst particles with an acid activity of about 160 to 200.