Quenching downstream of an external vapor catalyst separator

Claim 2

A catalytic cracking process, comprising the steps of: catalytically cracking feed oil in a catalytic cracking unit comprising a regenerator and at least one catalytic cracking reactor selected from the group consisting of a riser reactor and a fluidized bed reactor, in the presence of a cracking catalyst to produce a catalyst-laden stream comprising upgraded oil and coked catalyst; separating substantially all of said cracking catalyst from said catalyst laden stream in an external gross-cut separator downstream of said reactor into a catalyst rich stream comprising said coked catalyst and a product stream comprising said upgraded oil, and substantially immediately thereafter; quenching said product stream of upgraded oil discharged from said external gross-cut separator to substantially decrease thermal cracking of said upgraded oil to less valuable hydrocarbon products and light hydrocarbon gases and concurrently enhance the yield of naphtha to substantially increase the production of gasoline; regenerating said coked catalyst in a regenerator; and recycling said regenerated catalyst to said catalytic cracking reactor.

Claim 3

A catalytic cracking process in accordance with claim 1 wherein: said feed oil comprises gas oil; and said coked catalyst is regenerated in the presence of a combustion-supporting gas comprising excess molecular oxygen in an amount greater than the stoichiometric amount required to completely combust the coke on said coked catalyst to carbon dioxide.

Claim 4

A catalytic cracking process, comprising the steps of: catalytically cracking feed oil in the presence of a cracking catalyst; grossly separating said catalytically cracked oil from said cracking catalyst in an external gross-cut separator; cooling said catalytically cracked feed oil after said gross separation to substantially minimize thermal cracking of said catalytically cracked oil to fuel gas and concurrently enhance the yield of naphtha to substantially increase the production of gasoline by contacting said catalytically cracked oil with a hydrocarbon liquid quench having a boiling point greater than water, a molecular weight over 90, and a volumetric expansion less than about 20 percent of the volume of the said cracked oil substantially immediately after said cracking catalyst has been separated from said catalytically cracked oil in said external gross-cut separator.

Claim 5

A catalytic cracking process, comprising the steps of: catalytically cracking feed oil in the presence of a cracking catalyst; grossly separating said catalytically cracked oil from said cracking catalyst in an external gross-cut separator; cooling said catalytically cracked feed oil after said gross separation to substantially minimize thermal cracking of said catalytically cracked oil to fuel gas and concurrently enhance the yield of naphtha to substantially increase the production of gasoline by contacting said catalytically cracked oil with a hydrocarbon liquid quench having a boiling point greater than water, a molecular weight over 90, and a volumetric expansion less than about 20 percent of the volume of the said cracked oil substantially immediately after said cracking catalyst has been separated from said catalytically cracked oil in said external gross-cut separator.

Claim 6

A catalytic cracking process in accordance with claim 3 wherein said quench comprises previously cracked hydrocarbons.

Claim 7

A catalytic cracking process in accordance with claim 3 wherein said quench comprises virgin feedstock.

Claim 8

A catalytic cracking process in accordance with claim 3 wherein said quench comprises hydrotreated hydrocarbons.

Claim 9

A catalytic cracking process in accordance with claim 3 wherein catalytically cracked oil is cooled by said quench by an amount ranging from about 30° F. (17° C.) to about 200° F. (93° C.).

Claim 10

A catalytic cracking process in accordance with claim 3 wherein said volumetric expansion of said quench is less than about 5% of the volume of said cracked oil.

Claim 11

A catalytic cracking process in accordance with claim 3 wherein said quench enhances the stability of the naphtha product.

Claim 12

A catalytic cracking process in accordance with claim 3 wherein a substantial portion of said quench has a boiling point of at least about 430° F. (221° C.).

Claim 13

A catalytic cracking process in accordance with claim 10 wherein a substantial portion of said quench has a boiling point below about 900° F. (482° C.) and substantially completely vaporizes in the dilute phase.

Claim 14

A catalytic cracking process in accordance with claim 11 wherein said quench is selected from the group consisting of light catalytic cycle oil, heavy catalytic cycle oil, heavy catalytic naphtha, coker gas oil, and coker distillates.

Claim 15

A catalytic cracking process, comprising the steps of: catalytically cracking feed oil in a reactor of a catalytic cracking unit in the presence of a cracking catalyst to produce a catalytically cracked effluent stream of upgraded oil containing catalyst; substantially separating said catalyst from said upgraded oil in an external gross cut separator and in a disengaging vessel; quenching said upgraded oil downstream of said external gross cut separator and upstream of said disengaging vessel with a quench comprising at least one member selected from the group consisting of light catalytic cycle oil, heavy catalytic cycle oil, heavy catalytic naphtha, kerosene, coker distillates, light coker gas oil, hydrotreated distillate, virgin gas oil, and virgin naphtha.

Claim 16

A catalytic cracking process, comprising the steps of: catalytically cracking feed oil in a reactor of a catalytic cracking unit in the presence of a cracking catalyst to produce a catalytically cracked effluent stream of upgraded oil containing catalyst; substantially separating said catalyst from said upgraded oil in an external gross cut separator and in a disengaging vessel; quenching said upgraded oil downstream of said external gross cut separator and upstream of said disengaging vessel with a quench comprising at least one member selected from the group consisting of light catalytic cycle oil, heavy catalytic cycle oil, heavy catalytic naphtha, kerosene, coker distillates, light coker gas oil, hydrotreated distillate, virgin gas oil, and virgin naphtha.

Claim 17

A catalytic cracking process in accordance with claim 13 wherein: said feed oil comprises gas oil; said quenching further includes decreasing the temperature of said stream; minimizing thermal cracking of said stream; and said quench is injected into said stream in an amount ranging from about 2% to about 20% by volume per barrel of feed oil.

Claim 18

A catalytic cracking process in accordance with claim 13 wherein said quench contacts said product stream in an amount ranging from about 5% to about 15% by volume per barrel of feed oil.

Claim 19

A catalytic cracking process, comprising the steps of: substantially desalting petroleum comprising crude oil; heating said desalted crude oil in a furnace; pumping said heated crude oil to a primary distillation tower; separating said heated crude oil in said primary distillation tower into streams of naphtha, primary gas oil, and primary reduced crude; pumping said primary reduced crude oil to a pipestill vacuum tower; separating said primary reduced crude oil in said pipestill vacuum tower into streams of wet gas, heavy gas oil, and vacuum reduced crude oil providing resid oil; conveying a feed oil comprising said primary gas oil from said primary distillation tower to an upright elongated riser reactor of a catalytic cracking unit; feeding fresh and regenerated crystalline cracking catalyst to said riser reactor; catalytically cracking said feed oil in said riser reactor in the presence of said cracking catalyst under catalytic cracking conditions to produce an upgraded effluent product stream of catalytically cracked oil containing spent coked catalyst; separating a substantial amount of said spent coked catalyst from said product stream in an external rough cut separator downstream of said riser reactor to make a gross separation of said coked catalyst from said product stream; injecting and quenching said product stream soon after said product stream exits said external separator with a cycle oil quench for substantially minimizing thermal cracking of said product stream to less valuable hydrocarbons and concurrently enhancing the yield of naphtha to substantially increase the production of gasoline, said quench comprising a cycle oil selected from the group consisting of light catalytic cycle oil and heavy catalytic cycle oil, said quench being injected into said product stream in an amount ranging from about 5% to about 15% by volume per barrel of feed oil; conveying said quenched product stream into an upper dilute phase portion of a disengaging vessel; disengaging and separating a substantial amount of the remaining spent coked catalyst from said quenched product stream in at least one internal cyclone in said dilute phase portion of said disengaging vessel; stripping volatile hydrocarbons from said coked catalyst in a stripping section of said disengaging vessel; passing said stripped coked catalyst to a regenerator of said catalytic cracking unit; injecting air into said regenerator; regenerating said spent catalyst by substantially combusting coke on said spent catalyst in the presence of air in said regenerator; recycling said regenerated catalyst to said riser reactor; separating said cracking oil in a fractionator into streams of light hydrocarbon gases, catalytic naphtha, catalytic cycle oil including light catalytic cycle oil, and decanted oil; and recycling said light catalytic cycle oil from said fractionator to a quench injection line located between said external cyclone and said fluidized bed reactor for use as said quench.

Claim 20

A catalytic cracking process, comprising the steps of: substantially desalting petroleum comprising crude oil; heating said desalted crude oil in a furnace; pumping said heated crude oil to a primary distillation tower; separating said heated crude oil in said primary distillation tower into streams of naphtha, primary gas oil, and primary reduced crude; pumping said primary reduced crude oil to a pipestill vacuum tower; separating said primary reduced crude oil in said pipestill vacuum tower into streams of wet gas, heavy gas oil, and vacuum reduced crude oil providing resid oil; conveying a feed oil comprising said primary gas oil from said primary distillation tower to an upright elongated riser reactor of a catalytic cracking unit; feeding fresh and regenerated crystalline cracking catalyst to said riser reactor; catalytically cracking said feed oil in said riser reactor in the presence of said cracking catalyst under catalytic cracking conditions to produce an upgraded effluent product stream of catalytically cracked oil containing spent coked catalyst; separating a substantial amount of said spent coked catalyst from said product stream in an external rough cut separator downstream of said riser reactor to make a gross separation of said coked catalyst from said product stream; injecting and quenching said product stream soon after said product stream exits said external separator with a cycle oil quench for substantially minimizing thermal cracking of said product stream to less valuable hydrocarbons and concurrently enhancing the yield of naphtha to substantially increase the production of gasoline, said quench comprising a cycle oil selected from the group consisting of light catalytic cycle oil and heavy catalytic cycle oil, said quench being injected into said product stream in an amount ranging from about 5% to about 15% by volume per barrel of feed oil; conveying said quenched product stream into an upper dilute phase portion of a disengaging vessel; disengaging and separating a substantial amount of the remaining spent coked catalyst from said quenched product stream in at least one internal cyclone in said dilute phase portion of said disengaging vessel; stripping volatile hydrocarbons from said coked catalyst in a stripping section of said disengaging vessel; passing said stripped coked catalyst to a regenerator of said catalytic cracking unit; injecting air into said regenerator; regenerating said spent catalyst by substantially combusting coke on said spent catalyst in the presence of air in said regenerator; recycling said regenerated catalyst to said riser reactor; separating said cracking oil in a fractionator into streams of light hydrocarbon gases, catalytic naphtha, catalytic cycle oil including light catalytic cycle oil, and decanted oil; and recycling said light catalytic cycle oil from said fractionator to a quench injection line located between said external cyclone and said fluidized bed reactor for use as said quench.

Claim 21

A catalytic cracking process in accordance with claim 16 wherein light catalytic cycle oil is injected into said feed oil as at least part of said quench.

Claim 22

A catalytic cracking process in accordance with claim 16 including feeding some of said resid oil to said riser reactor for use as part of said feed oil and said quench comprises heavy catalytic cycle oil.

Claim 23

A catalytic cracking process in accordance with claim 16 including: coking at least some of said vacuum reduced crude oil in a coker; conveying said coker resid oil to a combined tower; separating said coker reside oil in said combined tower into streams of coker gases, coker naphtha, and coker gas oil; conveying said heavy gas oil from said vacuum tower to a catalytic feed hydrotreating unit having catalytic feed hydrotreating catalyst therein or to said riser reactor; conveying said coker gas oil to said catalytic feed hydrotreating unit or to said riser reactor; injecting hydrogen-rich gases to said catalytic feed hydrotreating unit; hydrotreating said heavy gas oil in said catalytic feed hydrotreating unit in the presence of said catalytic feed hydrotreating catalyst to produce hydrotreated oil; feeding said hydrotreated oil to said riser reactor as part of said feed oil; and said separator comprises an external rough cut cyclone.

Claim 24

A catalytic cracking process, comprising the steps of: substantially desalting petroleum comprising crude oil; heating said desalted crude oil in a furnace; pumping said heated crude oil to a pipestill; separating said heated crude oil in said pipestill into streams of wet gas, naphtha, primary gas oil, heavy gas oil, and vacuum reduced crude oil providing resid oil; conveying a feed oil comprising at least one member selected from the group consisting of said primary gas oil and said heavy gas oil, from said pipestill to an upright elongated riser reactor of a catalytic cracking unit; feeding fresh and regenerated crystalline cracking catalyst to said riser reactor; catalytically cracking said feed oil in said riser reactor in the presence of said cracking catalyst under catalytic cracking conditions to produce an upgraded effluent product stream of catalytically cracked oil containing spent coked catalyst; separating a substantial amount of said spent coked catalyst from said product stream in an external rough cut separator downstream of said riser reactor to make a gross separation of said coked catalyst from said product stream; injecting and quenching said product stream soon after said product stream exits said external separator with a cycle oil quench for substantially minimizing thermal cracking of said product stream to less valuable hydrocarbons and concurrently enhancing the yield of naphtha to substantially increase the production of gasoline, said quench comprising a cycle oil selected from the group consisting of light catalytic cycle oil and heavy catalytic cycle oil, said quench being injected into said product stream in an amount ranging from about 5% to about 15% by volume per barrel of feed oil; conveying said quenched product stream into an upper dilute phase portion of a disengaging vessel; disengaging and separating a substantial amount of the remaining spent coked catalyst from said quenched product stream in at least one internal cyclone in said dilute phase portion of said disengaging vessel; stripping volatile hydrocarbons from said coked catalyst in a stripping section of said disengaging vessel; passing said stripped coked catalyst to a regenerator of said catalytic cracking unit; injecting air into said regenerator; regenerating said spent catalyst by substantially combusting coke on said spent catalyst in the presence of air in said regenerator; recycling said regenerated catalyst to said riser reactor; separating said cracking oil in a fractionator into streams of light hydrocarbon gases, catalytic naphtha, catalytic cycle oil including light catalytic cycle oil, and decanted oil; and recycling said light catalytic cycle oil from said fractionator to a quench injection line located between said external cyclone and said fluidized bed reactor for use as said quench.

Claim 25

A catalytic cracking process, comprising the steps of: substantially desalting petroleum comprising crude oil; heating said desalted crude oil in a furnace; pumping said heated crude oil to a pipestill; separating said heated crude oil in said pipestill into streams of wet gas, naphtha, primary gas oil, heavy gas oil, and vacuum reduced crude oil providing resid oil; conveying a feed oil comprising at least one member selected from the group consisting of said primary gas oil and said heavy gas oil, from said pipestill to an upright elongated riser reactor of a catalytic cracking unit; feeding fresh and regenerated crystalline cracking catalyst to said riser reactor; catalytically cracking said feed oil in said riser reactor in the presence of said cracking catalyst under catalytic cracking conditions to produce an upgraded effluent product stream of catalytically cracked oil containing spent coked catalyst; separating a substantial amount of said spent coked catalyst from said product stream in an external rough cut separator downstream of said riser reactor to make a gross separation of said coked catalyst from said product stream; injecting and quenching said product stream soon after said product stream exits said external separator with a cycle oil quench for substantially minimizing thermal cracking of said product stream to less valuable hydrocarbons and concurrently enhancing the yield of naphtha to substantially increase the production of gasoline, said quench comprising a cycle oil selected from the group consisting of light catalytic cycle oil and heavy catalytic cycle oil, said quench being injected into said product stream in an amount ranging from about 5% to about 15% by volume per barrel of feed oil; conveying said quenched product stream into an upper dilute phase portion of a disengaging vessel; disengaging and separating a substantial amount of the remaining spent coked catalyst from said quenched product stream in at least one internal cyclone in said dilute phase portion of said disengaging vessel; stripping volatile hydrocarbons from said coked catalyst in a stripping section of said disengaging vessel; passing said stripped coked catalyst to a regenerator of said catalytic cracking unit; injecting air into said regenerator; regenerating said spent catalyst by substantially combusting coke on said spent catalyst in the presence of air in said regenerator; recycling said regenerated catalyst to said riser reactor; separating said cracking oil in a fractionator into streams of light hydrocarbon gases, catalytic naphtha, catalytic cycle oil including light catalytic cycle oil, and decanted oil; and recycling said light catalytic cycle oil from said fractionator to a quench injection line located between said external cyclone and said fluidized bed reactor for use as said quench.