Ultra-short contact time fluidized catalytic cracking process
First Claim
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1. A fluidized process for the conversion of a hydrocarbon oil charge stock to lower molecular weight liquid product comprising:
- (a) atomizing a primary charge-stock to provide a stream of liquid particles of a preselected size;
(b) introducing said atomized primary charge-stock substantially horizontally into a primary reaction zone;
(c) introducing a stream of hot fluidized cracking catalyst particles mixed with gaseous dispersion media downwardly into said reaction zone at a velocity greater than 10 feet per second to intimately contact said atomized primary charge-stock therein, the temperature, pressure and contact time with said atomized primary charge-stock being sufficient to vaporize hydrocarbons in said charge-stock and to crack the hydrocarbons to lower molecular weight product;
(d) vaporizing a substantial portion of said hydrocarbons to form a mixture of said catalyst particles in the resulting vaporized hydrocarbons and cracking said vaporized hydrocarbons in said reaction zone to form cracked product vapors and spent catalyst;
(e) rapidly passing a mixture of the resulting cracked product vapors, said media and a majority of said spent catalyst particles substantially horizontally through said reaction zone and into a reactor separation zone to provided a hydrocarbon/catalyst contact time prior to passage into said separation zone of not greater than 0.5 second and separating spent catalyst particles from said cracked product, said spent catalyst particles containing deposit of carbonaceous material thereon which reduce the cracking activity of said catalyst;
(f) passing said spent catalyst particles to a combustion zone;
(g) contacting said spent catalyst with an oxygen-containing gas in said combustion zone to burn said carbonaceous deposits and to provide a regenerated catalyst and a flue gas;
(h) recycling the resulting hot, regenerated catalyst to said reaction zone to contact fresh atomized charge-stock; and
(i) recovering a hydrocarbon product having a molecular weight lower than said charge stock.
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Abstract
A fluid catalytic cracking process wherein a hydrocarbon charge-stock is atomized and injected, in a contactor/reactor, into a vertical curtain of hot regenerated catalyst to vaporize and crack hydrocarbons in the charge-stock, wherein the catalyst preferably contains at least 40% by weight of a zeolitic cracking component and the contact time of the hydrocarbon vapors and the catalyst in the contactor/reactor is ultra-short, preferably not greater than 0.5 second.
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18 Claims
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1. A fluidized process for the conversion of a hydrocarbon oil charge stock to lower molecular weight liquid product comprising:
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(a) atomizing a primary charge-stock to provide a stream of liquid particles of a preselected size; (b) introducing said atomized primary charge-stock substantially horizontally into a primary reaction zone; (c) introducing a stream of hot fluidized cracking catalyst particles mixed with gaseous dispersion media downwardly into said reaction zone at a velocity greater than 10 feet per second to intimately contact said atomized primary charge-stock therein, the temperature, pressure and contact time with said atomized primary charge-stock being sufficient to vaporize hydrocarbons in said charge-stock and to crack the hydrocarbons to lower molecular weight product; (d) vaporizing a substantial portion of said hydrocarbons to form a mixture of said catalyst particles in the resulting vaporized hydrocarbons and cracking said vaporized hydrocarbons in said reaction zone to form cracked product vapors and spent catalyst; (e) rapidly passing a mixture of the resulting cracked product vapors, said media and a majority of said spent catalyst particles substantially horizontally through said reaction zone and into a reactor separation zone to provided a hydrocarbon/catalyst contact time prior to passage into said separation zone of not greater than 0.5 second and separating spent catalyst particles from said cracked product, said spent catalyst particles containing deposit of carbonaceous material thereon which reduce the cracking activity of said catalyst; (f) passing said spent catalyst particles to a combustion zone; (g) contacting said spent catalyst with an oxygen-containing gas in said combustion zone to burn said carbonaceous deposits and to provide a regenerated catalyst and a flue gas; (h) recycling the resulting hot, regenerated catalyst to said reaction zone to contact fresh atomized charge-stock; and (i) recovering a hydrocarbon product having a molecular weight lower than said charge stock. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14)
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15. A fluidized process for the conversion of a hydrocarbon oil charge-stock to lower molecular weight liquid product comprising:
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(a) introducing a hydrocarbon oil charge-stock into a reaction zone; (b) introducing a mixture of hot fluidized particles of a cracking catalyst containing at least 40% by weight of a zeolitic component having a substantial cracking activity mixed with a gaseous dispersion media into said reaction zone in a first downward direction and at a velocity greater than 10 feet per second to intimately contact said charge-stock therein, the temperature, pressure and contact time with said primary charge-stock in said reaction zone being sufficient to vaporize hydrocarbons in said charge-stock and to crack the hydrocarbons to lower molecular weight cracked product; (c) vaporizing a substantial portion of said hydrocarbons to form a mixture of said catalyst particles in the resulting vaporized hydrocarbons and cracking said vaporized hydrocarbons in said reaction zone to form cracked product vapors and spent catalyst; (d) rapidly passing a mixture of the resulting cracked product vapors, said media and a majority of said spent catalyst particles through said reaction zone in a second direction substantially transverse to said first direction and into a reactor separation zone and separating spent catalyst particles from said cracked product, the hydrocarbon/catalyst contact time in said reaction zone prior to passage into said separation zone being not greater than 0.5 second, while a portion of said spent catalyst particles settles into a catalyst stripping zone positioned below said reaction zone; and (e) recovering a hydrocarbon product having a molecular weight lower than said charge stock. - View Dependent Claims (16, 17, 18)
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Specification