EP0593827A1 - Dispositif de dépouillement d'effluent contenant des plaques de dissipation pour procédés FCC - Google Patents

Dispositif de dépouillement d'effluent contenant des plaques de dissipation pour procédés FCC Download PDF

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Publication number
EP0593827A1
EP0593827A1 EP92309716A EP92309716A EP0593827A1 EP 0593827 A1 EP0593827 A1 EP 0593827A1 EP 92309716 A EP92309716 A EP 92309716A EP 92309716 A EP92309716 A EP 92309716A EP 0593827 A1 EP0593827 A1 EP 0593827A1
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EP
European Patent Office
Prior art keywords
vessel
catalyst
stripping
disengaging
outlet
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
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EP92309716A
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German (de)
English (en)
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EP0593827B1 (fr
Inventor
Ismail Birkan Cetinkaya
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Honeywell UOP LLC
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UOP LLC
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Publication date
Priority claimed from US07/613,037 external-priority patent/US5158669A/en
Priority to US07/613,037 priority Critical patent/US5158669A/en
Priority to CA002080974A priority patent/CA2080974C/fr
Priority to AU27278/92A priority patent/AU649889B1/en
Priority to DE69213458T priority patent/DE69213458T2/de
Application filed by UOP LLC filed Critical UOP LLC
Priority to AT92309716T priority patent/ATE142247T1/de
Priority to ES92309716T priority patent/ES2093798T3/es
Priority to EP92309716A priority patent/EP0593827B1/fr
Priority to CN92112441A priority patent/CN1035773C/zh
Priority to US07/966,776 priority patent/US5314611A/en
Priority to US07/966,777 priority patent/US5316662A/en
Priority claimed from US07/966,777 external-priority patent/US5316662A/en
Priority claimed from US07/966,776 external-priority patent/US5314611A/en
Publication of EP0593827A1 publication Critical patent/EP0593827A1/fr
Publication of EP0593827B1 publication Critical patent/EP0593827B1/fr
Application granted granted Critical
Priority to GR960403018T priority patent/GR3021647T3/el
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    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G11/00—Catalytic cracking, in the absence of hydrogen, of hydrocarbon oils
    • C10G11/14—Catalytic cracking, in the absence of hydrogen, of hydrocarbon oils with preheated moving solid catalysts
    • C10G11/18—Catalytic cracking, in the absence of hydrogen, of hydrocarbon oils with preheated moving solid catalysts according to the "fluidised-bed" technique

Definitions

  • This invention relates generally to methods and apparatus for fluidized catalytic cracking (FCC) units. More specifically this invention relates to methods for separating catalyst from product vapors in an FCC reaction zone.
  • FCC fluidized catalytic cracking
  • the fluidized catalytic cracking of hydrocarbons is the main stay process for the production of gasoline and light hydrocarbon products from heavy hydrocarbons such as vacuum gas oils.
  • Heavy hydrocarbons such as vacuum gas oils.
  • Large hydrocarbon molecules associated with the heavy hydrocarbon feed are cracked to break large hydrocarbon chains thereby producing lighter hydrocarbons.
  • lighter hydrocarbons are recovered as product and can be used directly or further processed to raise the octane barrel yield relative to the heavy hydrocarbon feed.
  • the basic equipment or apparatus for the fluidized catalytic cracking of hydrocarbons has been in existence since the early 1940's.
  • the basic component of the FCC process include a reactor, a regenerator and a catalyst stripper.
  • the reactor includes a contact zone where the hydrocarbon feed is contacted with a particulate catalyst and a separation zone where product vapors from the cracking reaction are separated from the catalyst. Further product separation takes place in a catalyst stripper that receives catalyst from the separation zone and removes entrained hydrocarbons from the catalyst by countercurrent contact with steam or another stripping medium.
  • the FCC process is carried out by contacting the starting material, whether it be vacuum gas oil, reduced crude or another source of relatively high boiling hydrocarbons with a catalyst made up of a finely divided or particulate solid material.
  • the catalyst is transported like a fluid by passing gas or vapor through it at sufficient velocity to produce a desired regime of fluid transport.
  • the contact of the oil with fluidized material catalyses the cracking reaction. During the cracking reaction
  • Coke is comprised of hydrogen and carbon and can include other materials in trace quantities such as sulfur and metals that enter the process with the starting material. Coke interferes with the catalytic activity of the catalyst by blocking active sites on the catalyst surface where the cracking reactions take place. Catalyst is transferred from the stripper to a regenerator for purposes of removing the coke by oxidation with an oxygen-containing gas. An inventory of catalyst having a reduced coke content, relative to the catalyst in the stripper, hereinafter referred to as regenerated catalyst, is collected for return to the reaction zone. Oxidizing the coke from the catalyst surface releases a large amount of heat, a portion of which escapes the regenerator with gaseous products of coke oxidation generally referred to as flue gas.
  • the fluidized catalyst is continuously circulated from the reaction zone to the regeneration zone and then again to the reaction zone.
  • the fluidized catalyst acts as a vehicle for the transfer of heat from zone to zone. Catalyst exiting the reaction zone is spoken of as being spent, i.e., partially deactivated by the deposition of coke upon the catalyst. Specific details of the various contact zones, regeneration zones, and stripping zones along with arrangements for conveying the catalyst between the various zones are well known to those skilled in the art.
  • the rate of conversion of the feedstock within the reaction zone is controlled by regulation of the temperature of the catalyst, activity of the catalyst, quantity of the catalyst (i.e., catalyst to oil ratio) and contact time between the catalyst and feedstock.
  • the most common method of regulating the reaction temperature is by regulating the rate of circulation of catalyst from the regeneration zone to the reaction zone which simultaneously produces a variation in the catalyst to oil ratio as the reaction temperatures change. That is, if it is desired to increase the conversion rate an increase in the rate of flow of circulating fluid catalyst from the regenerator to the reactor is effected. Since the catalyst temperature in the regeneration zone is usually held at a relatively constant temperature, significantly higher than the reaction zone temperature, any increase in catalyst flux from the relatively hot regeneration zone to the reaction zone affects an increase in the reaction zone temperature.
  • the hydrocarbon product of the FCC reaction is recovered in vapor form and transferred to product recovery facilities.
  • product recovery facilities normally comprise a main column for cooling the hydrocarbon vapor from the reactor and recovering a series of heavy cracked products which usually include bottom materials, cycle oil, and heavy gasoline. Lighter materials from the main column enter a concentration section for further separation into additional product streams.
  • the catalyst particles employed in an FCC process have a large surface area, which is due to a great multitude of pores located in the particles. As a result, the catalytic materials retain hydrocarbons within their pores and upon the external surface of the catalyst. Although the quantity of hydrocarbon retained on each individual catalyst particle is very small, the large amount of catalyst and the high catalyst circulation rate which is typically used in a modern FCC process results in a significant quantity of hydrocarbons being withdrawn from the reaction zone with the catalyst.
  • hydrocarbons that entered the regenerator increase its carbon-burning load and can result in excessive regenerator temperatures. Stripping hydrocarbons from the catalyst also allows recovery of the hydrocarbons as products. Avoiding the unnecessary burning of hydrocarbons is especially important during the processing of heavy (relatively high molecular weight) feedstocks, since processing these feedstocks increases the deposition of coke on the catalyst during the reaction (in comparison to the coking rate with light feedstocks) and raises the combustion load in the regeneration zone. Higher combustion loads lead to higher temperatures which at some point may damage the catalyst or exceed the metallurgical design limits of the regeneration apparatus.
  • the most common method of stripping the catalyst passes a stripping gas, usually steam, through a flowing stream of catalyst, countercurrent to its direction of flow.
  • a stripping gas usually steam
  • Such steam stripping operations with varying degrees of efficiency, remove the hydrocarbon vapors which are entrained with the catalyst and hydrocarbons which are adsorbed on the catalyst.
  • the efficiency of catalyst stripping is increased by using vertically spaced baffles to cascade the catalyst from side to side as it moves down a stripping apparatus and countercurrently contacts a stripping medium. Moving the catalyst horizontally increases contact between the catalyst and the stripping medium so that more hydrocarbons are removed from the catalyst. In these arrangements, the catalyst is given a labyrinthine path through a series of baffles located at different levels. Catalyst and gas contact is increased by this arrangement that leaves no open vertical path of significant cross-section through the stripping apparatus.
  • the typical stripper arrangement comprises a stripper vessel, a series of baffles in the form of frusto-conical sections that direct the catalyst inwardly onto a baffle in a series of centrally located conical or frusto conical baffles that divert the catalyst outwardly onto the outer baffles.
  • the stripping medium enters from below the lower baffle in the series and continues rising upward from the bottom of one baffle to the bottom of the next succeeding baffle.
  • riser cracking One improvement to FCC units, that has reduced the product loss by thermal cracking, is the use of riser cracking.
  • riser cracking In riser cracking, regenerated catalyst and starting materials enter a pipe reactor and are transported upward by the expansion of the gases that result from the vaporization of the hydrocarbons, and other fluidizing mediums if present upon contact with the hot catalyst.
  • Riser cracking provides good initial catalyst and oil contact and also allows the time of contact between the catalyst and oil to be more closely controlled by eliminating turbulence and backmixing that can vary the catalyst residence time.
  • An average riser cracking zone today will have a catalyst to oil contact time of 1 to 5 seconds.
  • a number of riser reaction zones use a lift gas as a further means of providing a uniform catalyst flow. Lift gas is used to accelerate catalyst in a first section of the riser before introduction of the feed and thereby reduces the turbulence which can vary the contact time between the catalyst and hydrocarbons.
  • catalysts and conversion products still enter a large chamber for the purpose of initially disengaging catalyst and hydrocarbons.
  • the large open volume of the disengaging vessel exposes the hydrocarbon vapors to turbulence and backmixing that continues catalyst contact for varied amounts of time and keeps the hydrocarbon vapors at elevated temperatures for a variable and extended amount of time.
  • thermal cracking can be a problem in the disengaging vessel.
  • a final separation of the hydrocarbon vapors from the catalyst is performed by cyclone separators that use centripedal acceleration to disengage the heavier catalyst particles from the lighter vapors which are removed from the reaction zone.
  • a third object of this invention is to provide a cyclone type separation vessel that can receive the entire effluent from an FCC reactor riser and provide a high separation efficiency without a susceptibility to overload from pressure surges.
  • a fourth object of this invention is to provide an FCC process that provides a quick separation of catalyst from product vapors and thus minimizes overcracking and is not susceptible to overload from pressure surges or changes in operation of the reactor system.
  • the objects of this invention are realized by a separation system that is directly connected to the outlet of the riser in an FCC unit and provides a high degree of separation by using a basic cyclone operation within a disengaging vessel and partition or dissipator plates below the disengaging vessel to improve catalyst separation and prevent catalyst reentrainment.
  • These partitions or dissipators are located immediately below the outer vortex that is formed in most cyclone operations. Ordinarily, a tangential velocity is introduced by the vortex, and if not dissipated will create turbulence that will reentrain free catalyst. Contact with the plates dissipates these tangential velocities and reduces turbulence immediately below the vortex.
  • the dissipator plates can also be arranged to trap catalyst particles as they fall from the vortex to reduce the particle velocity and prevent reentrainment.
  • this invention is a fluid catalytic cracking apparatus that includes a reactor vessel, a tubular riser having an inlet end for receiving feed and catalyst and an outlet end.
  • An elongated disengaging vessel is located in the reactor vessel and has an upper and a lower end.
  • the upper end of the disengaging vessel has a tangential inlet in direct communication with the outlet end of the riser and a central gas outlet at the top.
  • the lower end has an open bottom wherein the outermost portion of the open bottom is unoccluded to permit unobstructed fluid and particulate flow.
  • a stripping vessel is located directly below the disengaging vessel.
  • the stripping vessel has an inlet that communicates directly with the open bottom of the disengaging vessel and an outlet for withdrawing catalyst from the stripping vessel. Means are provided for adding stripping gas to the stripping vessel.
  • a segregation zone is located in the stripping vessel and includes at least two vertical partition or dissipation plates spaced below the open bottom of the disengaging vessel.
  • this invention comprises a fluid catalytic cracking apparatus that includes a reactor vessel and a tubular riser having an inlet end for receiving feed and catalyst and an outlet end.
  • An elongated disengaging vessel is located in the reactor vessel and has upper and lower ends.
  • the upper end of the disengaging vessel has a tangential inlet in direct communication with the outlet end of the riser and a central gas outlet at the top.
  • the lower end has a vertically extending sidewall, an open bottom and a plurality of circumferentially spaced ports at the bottom of the vertically extending sidewall.
  • a stripper vessel having an upper end located in the reactor vessel and into which the lower end of the disengaging vessel extends is located immediately below the disengaging vessel.
  • At least two dissipator plates are located inside the stripper vessel.
  • the dissipator plates extend inwardly from the walls of the stripper vessel with each dissipator plate lying in a common plane with the centerline of the stripper vessel.
  • the dissipator plates have a central portion, the top of which is spaced below the lower end of the disengaging vessel.
  • the stripper vessel also has a catalyst outlet at its lower end and at least one inner and at least one outer stripping baffle located between the top of the central portion of the dissipator plates and the catalyst outlet and means for introducing a stripping fluid into the stripping vessel.
  • a vortex stabilizer extends into the lower end of the disengaging vessel. Means are provided for withdrawing gas from the open volume of the reactor vessel.
  • this invention is a fluid catalytic cracking apparatus that includes a reactor vessel and a tubular riser having an inlet end for receiving feed and an outlet end.
  • An elongated disengaging vessel is located in the reactor vessel and has an upper end and a lower end.
  • the upper end has a tangential inlet in direct communication with the outlet end of the riser and a central gas outlet at the top of the disengaging vessel.
  • the lower end has a vertically extending sidewall, an open bottom and a plurality of circumferentially spaced slots bordering the bottom of the vertically extending sidewall.
  • a stripper vessel having upper and lower sections is at least partially located in the reactor vessel.
  • the upper section of the stripper vessel is fixed to the lower end of the disengaging vessel and the lower section of the stripper is fixed to the lower end of the reactor vessel.
  • a slip joint between the upper and lower sections of the stripper vessel joins the two stripper sections.
  • the stripper vessel also includes means for communicating the interior of the stripping vessel with the interior of the reactor vessel.
  • the upper section of the stripping vessel also has a larger diameter than the lower end of the disengaging vessel and at least two dissipator plates extending inwardly from the walls of the stripper vessel with each dissipator plate lying in a common plane with the centerline of the stripper vessel.
  • the dissipator plates have a central portion spaced below the lower end of the disengaging vessel and an outer portion that extends vertically from the top of the central portion above the open bottom of the disengaging vessel.
  • At least one stripping baffle is located at the bottom of the dissipator plates.
  • the lower section of the stripping vessel has an upper end located in the reactor vessel and a lower end located outside of the reactor vessel.
  • the lower end of the stripping vessel lower section has a catalyst outlet and a distributor for adding stripping gas to the stripping vessel.
  • the upper end of the lower section has at least one stripping baffle located therein.
  • a vortex stabilizer extends into the lower end of the disengaging vessel. Means are provided for adding a fluidizing gas to the bottom of the reactor vessel.
  • a cyclone separator receives product vapors and catalyst from the gas outlet of the disengaging vessel.
  • the cyclone has a dip leg that returns catalyst to the reactor vessel.
  • a first conduit communicates product vapors directly from the gas outlet to the cyclone separator.
  • a second conduit communicates product vapors from the cyclone to product recovery facilities.
  • the apparatus includes means for venting fluidizing gas out of the reactor vessel.
  • this invention is a process for the fluidized catalytic cracking of an FCC feedstream which utilizes the FCC apparatus described in any of the previous embodiments.
  • the process includes the steps of passing an FCC catalyst and the FCC feedstream to a riser reaction zone and contacting the feedstream with the FCC catalyst in the riser reaction zone to convert the feedstream to product vapors, discharging a mixture of the product vapors and the spent FCC catalyst from the riser directly to the inlet of a disengaging vessel, and directing the mixture from the inlet tangentially into the disengaging vessel to form an inner and outer vortex of product gases in the disengaging vessel, stabilizing the inner vortex with a vortex stabilizer in the disengaging vessel, emptying catalyst particles from the bottom of the disengaging vessel directly into the top of a subadjacent stripping vessel.
  • the process includes injecting a stripping gas into the stripping vessel and contacting the catalyst particles with the stripping gas to desorb hydrocarbons from the catalyst particles, discharging a gaseous stream of desorbed hydrocarbons and stripping gas upwardly through the stripping vessel past a plurality of vertical disengaging plates into the disengaging vessel through an open volume of the stripping vessel located above a central portion of the disengaging plates and below the bottom of the disengaging vessel and out of the top of the stripping vessel and into the bottom of the disengaging vessel; maintaining a relatively dense bed of catalyst in the stripping vessel below the central portion of the dissipator plates; withdrawing the product vapors and the gaseous stream from the top of the disengaging vessel through a central outlet; passing the product vapor and the gaseous stream from the central outlet to a separator to recover additional catalyst particles; recovering a product stream from the separator; transferring catalyst particles from the separator to a lower portion of the stripping vessel; removing spent catalyst from the lower end of the stripping
  • Figure 1 is a sectional elevation of a reactor riser, reactor vessel and regenerator arrangement that incorporates the separation system of this invention.
  • FIG. 2 is an enlarged detail of the separation section located in the reactor vessel of Figure 1.
  • Figure 3 is a section of the enlarged separation section taken across lines 3/3 of Figure 2.
  • Figure 4 is a detailed cross-section of a secondary stripper section shown in Figure 1.
  • Figure 5 is an enlarged view of the upper section of the reactor shown in Figure 1.
  • the typical feed to an FCC unit is a gas oil such as a light or vacuum gas oil.
  • Other petroleum-derived feed streams to an FCC unit may comprise a diesel boiling range mixture of hydrocarbons or heavier hydrocarbons such as reduced crude oils. It is preferred that the feed stream consist of a mixture of hydrocarbons having boiling points, as determined by the appropriate ASTM test method, above about 230 o C and more preferably above about 290 o C.
  • FCC type units which are processing heavier feedstocks, such as atmospheric reduced crudes, as residual crude cracking units, or residual cracking units.
  • the process and apparatus of this invention can be used for either FCC or residual cracking operations. For convenience, the remainder of this specification will only make reference to the FCC process.
  • the chemical composition and structure of the feed to an FCC unit will affect the amount of coke deposited upon the catalyst in the reaction zone. Normally, the higher the molecular weight, Conradson carbon, heptane insolubles, and carbon/hydrogen ratio of the feedstock, the higher will be the coke level on the spent catalyst. Also, high levels of combined nitrogen, such as found in shale-derived oils, will increase the coke level on spent catalyst. Processing of heavier feedstocks, such as deasphalted oils or atmospheric bottoms from a crude oil fractionation unit (commonly referred to as reduced crude) results in an increase in some or all of these factors and therefore causes an increase in the coke level on spent catalyst.
  • the term "spent catalyst" is intended to indicate catalyst employed in the reaction zone which is being transferred to the regeneration zone for the removal of coke deposits. The term is not intended to be indicative of a total lack of catalytic activity by the catalyst particles.
  • the reaction zone which is normally referred to as a "riser", due to the widespread use of a vertical tubular conduit, is maintained at high temperature conditions which generally include a temperature above 427 o C.
  • the reaction zone is maintained at cracking conditions which include a temperature of from 480 o C to 590 o C and a pressure of from 65 to 601 kPa but preferably less than 376 kPa.
  • the catalyst/oil ratio based on the weight of catalyst and feed hydrocarbons entering the bottom of the riser, may range up to 20:1 but is preferably between 4:1 and 10:1. Hydrogen is not normally added to the riser, although hydrogen addition is known in the art. On occasion, steam may be passed into the riser.
  • the average residence time of catalyst in the riser is preferably less than 5 seconds.
  • the type of catalyst employed in the process may be chosen from a variety of commercially available catalysts. A catalyst comprising a zeolitic base material is preferred, but the older style amorphous catalyst can be used if desired. Further information on the operation of FCC reaction zones may be obtained from U.S.-A-4,541,922 and U.S.-A-4,541,923.
  • An FCC process unit comprises a reaction zone and a catalyst regeneration zone.
  • This invention may be applied to any configuration of reactor and regeneration zone that uses a riser for the conversion of feed by contact with a finely divided fluidized catalyst maintained at an elevated temperature and at a moderate positive pressure.
  • contacting of catalyst with feed and conversion of feed takes place in the riser.
  • the riser comprises a principally vertical conduit and the effluent of the conduit empties into a disengaging vessel.
  • One or more additional solids-vapor separation devices almost invariably a cyclone separator, is normally located within and at the top of the large separation vessel. The disengager vessel and cyclone separate the reaction products from a portion of catalyst which is still carried by the vapor stream.
  • One or more conduits vent the vapor from the cyclone and separation zone. Alter initial separation the spent catalyst passes through a stripping zone that is located directly beneath the disengaging vessel. It is essential to this invention that the stripping vessel is located below the disengaging zone and that the upper portion of the stripping vessel contain means for dissipating turbulence at the outlet of the disengaging vessel. After the catalyst has passed through the stripping zone it can be transferred to the reactor vessel or pass through one or more additional stages of stripping.
  • catalyst flows to a regeneration zone.
  • catalyst is continuously circulated from the reaction zone to the regeneration zone and then again to the reaction zone.
  • the catalyst therefore acts as a vehicle for the transfer of heat from zone to zone as well as providing the necessary catalytic activity.
  • Catalyst which is being withdrawn from the regeneration zone is referred to as "regenerated" catalyst.
  • the catalyst charged to the regeneration zone is brought into contact with an oxygen-containing gas such as air or oxygen-enriched air under conditions which result in combustion of the coke. This results in an increase in the temperature of the catalyst and the generation of a large amount of hot gas which is removed from the regeneration zone and referred to as a flue gas stream.
  • the regeneration zone is normally operated at a temperature of from 600 o C to 800 o C. Additional information on the operation of FCC reaction and regeneration zones may be obtained from U.S.-A-4,431,749; U.S.-A-4,419,221 and U.S.-A-4,220,623.
  • the catalyst regeneration zone is preferably operated at a pressure of from 136 to 601 kPa.
  • the spent catalyst being charged to the regeneration zone may contain from 0.2 to 5 wt.% coke. This coke is predominantly comprised of carbon and can contain from 3 to 15 wt.% hydrogen, as well as sulfur and other elements.
  • the oxidation of coke will produce the common combustion products: carbon dioxide, carbon monoxide, and water.
  • the regeneration zone may take several configurations, with regeneration being performed in one or more stages. Further variety in the operation of the regeneration zone is possible by regenerating fluidized catalyst in a dilute phase or a dense phase.
  • the term "dilute phase" is intended to indicate a catalyst/gas mixture having a density of less than 320 kg/m3.
  • the term "dense phase” is intended to mean that the catalyst/gas mixture has a density equal to or more than 320 kg/m3.
  • Representative dilute phase operating conditions often include a catalyst/gas mixture having a density of 15 to 150 kg/m3.
  • FIG. 1 shows a traditional stacked FCC reactor/regenerator arrangement that has been modified to incorporate the separation system of this invention.
  • feed enters the lower end of a riser 10 through a nozzle 12 where it is contacted with fresh regenerated catalyst from a regenerated catalyst conduit 14.
  • a valve 16 controls the rate of catalyst addition to riser 10.
  • Steam may also be added with the feed through nozzle 12 in order to achieve the desired feed velocity and help the dispersion of feed into the stream of catalyst particles.
  • Feed hydrocarbons are cracked by contact with the catalyst in the riser and spent catalyst and product vapors exit the upper end of riser 10 through a horizontal pipe section 18. Pipe section 18 discharges the catalyst and product vapor mixture directly into a disengaging vessel 20.
  • a reactor vessel 19 contains stripping gas, spent catalyst and product vapors.
  • Catalyst disengaged from the stripping gas and product vapors in disengager 20 pass downwardly into a stripping vessel 22.
  • Steam entering stripping vessel 22 through a nozzle 24 countercurrently contacts catalyst particles to strip additional hydrocarbons from the catalyst.
  • Catalyst exits stripping vessel 22 through nozzle 26 and enters a second catalyst stripper 28.
  • Steam entering stripping vessel 28 through nozzle 30 again countercurrently contacts the catalyst particles to remove additional hydrocarbons from the catalyst.
  • Stripping gas and separated hydrocarbons rise upwardly through stripping vessels 28 and 22 and are withdrawn in a manner hereinafter more fully described through disengaging vessel 20 and a central gas outlet 32.
  • a manifold 34 conducts stripping fluid and product vapors into cyclones 36 that effect a further separation of catalyst particles from the stripping fluid and product vapors.
  • a manifold 38 collects stripping fluid and product vapors from the cyclone 36 which are removed from the reactor vessel by conduits 40. Product vapor and stripping fluid are taken from manifold 38 to product separation facilities of the type normally used for the recovery of FCC products.
  • Spent catalyst collected by cyclones 36 drops downwardly through dip legs 42 and collects as a dense bed 44 in a space between the wall of reactor vessel 19 and the outside of stripping vessel 22.
  • a plurality of ports 46 hereinafter more fully described, transfer catalyst from bed 44 to the interior of stripping vessel 22.
  • Spent catalyst stripped of hydrocarbons is withdrawn from the bottom of vessel 28 through spent catalyst conduit 48 at a rate regulated by control valve 50.
  • a regenerator 52 the catalyst is regenerated by oxidizing coke from the surface of the catalyst particles and generating flue gas that contains H2O, CO and CO2 as the products of combustion.
  • the catalyst enters regenerator 52 through a nozzle 54 and is contacted with air entering the regeneration vessel through a nozzle 56.
  • This invention does not require a specific type of regeneration system.
  • the regeneration vessel pictured in Figure 1 ordinarily operates with a dense bed 58 in its lower section. Some form of distribution device across the bottom of the regeneration vessel distributes air over the entire cross-section of the vessel. A variety of such distribution devices are well known to those skilled in the art. Alternatively, this invention can be practiced with a regeneration zone that provides multiple stages of coke combustion.
  • the regeneration zone can achieve complete CO combustion or partial CO combustion.
  • flue gas and entrained catalyst particles rise up from bed 58.
  • a first stage cyclone 60 collects flue gas and performs an initial separation of the catalyst particles which are returned to bed 58 by dip leg 62 and the flue gas which is transferred by a conduit 64 to a second cyclone 66.
  • a further separation of catalyst from the flue gas takes place in cyclones 66 with the catalyst particles returning to bed 58 via a dip leg 68 and the flue gas leaving the upper end of cyclone 66 and the regeneration vessel via a collection chamber 70 and a flue gas conduit 72.
  • FIG. 2 shows disengaging vessel 20 located completely within reactor vessel 19.
  • Disengaging vessel 20 operates with the mixture of spent catalyst and product vapors entering the upper end of disengaging vessel 20 tangentially through horizontal conduit 18. Tangential entry of the gases and solids into disengaging vessel 20 forms the well-known double helix flow pattern through the disengaging vessel that is typically found in the operation of traditional cyclones.
  • Catalyst and gas swirls downwardly in the first helix near the outer wall of vessel 20 and starts back upwardly as an inner helix that spirals through the center of disengaging vessel 20 and exits the top of the disengaging vessel through central gas outlet 32.
  • the spinning action of the gas and catalyst mixture concentrates the solid particles near the wall of vessel 20. Gravity pulls the particles downward along the wall of vessel 20 and out through a lower outlet 74.
  • the efficiency of the disengager is improved by controlling the positioning of the double helix with a vortex stabilizer 76 that is located in the center of disengaging vessel 20. More than 95% of the solids passing through conduit 18 are removed by disengaging vessel 20 so that the gas stream that exits through conduit 32 contains only a light loading of catalyst particles.
  • the vortex shape is also enhanced by giving disengaging vessel 20 a slight frusto-conical shape such that the upper section has a larger diameter than the lower section.
  • disengaging vessel 20 be designed such that the bottom of the outer helix ends at or about the bottom of opening 74. This design differs from traditional cyclones which are designed such that they will have a much longer length than the outer helix length.
  • the required space for disengaging vessel 20 has been reduced by designing it such that the bottom of the outer helix extends to or only slightly below the outlet 74.
  • the length of the disengager required for a specific helix configuration will depend on its size and the gas velocity. For disengagers of average size, those ranging from 5 to 10 feet (1.5 to 3 m) in diameter, the length of the disengager from the bottom of the gas and catalyst inlet to the outlet 74 will be 2 to 3 times the largest diameter of the disengaging vessel.
  • outlet 74 As the solids leave disengaging vessel 20 through outlet 74, it tends to be reentrained by gas that is circulating near opening 74 or entering disengaging vessel 20 through opening 74. Locating the outlet 74 near the bottom of the outer helix of the disengaging vessel can create turbulence that will reentrain additional catalyst. Stripping gas and stripped hydrocarbons flowing upwardly from the stripping vessel into the disengaging vessel can also reentrain catalyst particles. In one embodiment of this invention, a portion of catalyst particles exit outlet 74 radially through a series of slots or ports 78 that extend circumferentially around the lower portion of outlet 74. Typically, the outlet will have 8 to 24 of such slots spaced around the outside.
  • slots will usually vary from 12 to 24 in (305 to 610 mm) in height and approximately 3 to 6 in (76 to 152 mm) in width.
  • the slots improve the separation efficiency by containing the vortex that is near the outlet 74 while allowing catalyst particles to spray outwardly under the influence of the vortex into the outer portion of stripping vessel 22, thereby clearing the central portion of outlet 74 for the influx of gas.
  • Disengaging vessel 20 opens directly into the top of stripping vessel 22. Swirling gas flow associated with the cyclonic vortex and the countercurrent flow of gas upwardly from the stripping vessel 22 normally would create a long zone of turbulence below outlet 74. The effect of any turbulence is reduced by a set of plates 80 that function to dissipate any turbulence associated with the swirling action of the helical gas flows. These plates are spaced below the bottom of opening 74 such that an open area 84 provided between the top 82 of the central portion of the dissipator or partition plates 80, and the bottom of outlet 74. The length of this space is indicated by Dimension A and will preferably be equal to approximately half the diameter of the outlet 74. This space is provided and the top 82 of plates 80 is not brought all the way up to the bottom of opening 74 in order to reduce the velocity of the descending vortex before it contacts the dissipator plates.
  • the dissipator plates 80 are attached to the inner walls of stripper 22 and extend inwardly to the center line of vessel 22. Plates 80 are preferably arranged vertically. In most cases at least four dissipator plates will extend inwardly from the walls of vessel 22 and divide the cross-section of the stripper vessel in the region of the dissipator plates into four quadrants. Plates 80 dissipate any horizontal components of gas flow that extend below the open area 84.
  • the plates 80 also provide a convenient means of locating and supporting vortex stabilizer 76 and stripper baffle 88. The vertical orientation of plates 80 obstruct any tangential or horizontal components of gas velocity such that the effects of any vortex does not extend past upper plate section 82.
  • the horizontal momentum of any catalyst particles that extend below plate boundary 82 is stopped by plate 80 so that the particles have a more direct downward trajectory and the total distance traveled by the particles through the stripping vessel is reduced. Reducing the travel path of the particles through stripping vessel 22 lessens the tendency of catalyst reentrainment.
  • at least one dissipator plate bisects the cross-section of the stripping vessel 22.
  • the Diameter B of the dissipator plates about the central portion 82 should be at least equal to the diameter of outlet 74. The effectiveness of the dissipator plates is increased by having the Diameter B at least slightly larger than the diameter of outlet 74.
  • the stripping vessel can be arranged such that its outer wall has a diameter equal to Dimension B.
  • the effectiveness of the dissipator plates can be further increased by increasing the diameter of stripping vessel 22 relative to Dimension B and providing the dissipator plates with an outer section 86 that extends outwardly to the region beyond Dimension B and above the central portion 82 of the plates. Outer section 86 preferably extends above outlet 74 and more preferably above the top of slots 78.
  • the additional plate area provided by sections 86 of the dissipator plates 80 serves to further reduce tangential gas velocity components and moreover to provide a relatively stagnant area for collecting catalyst particles that accumulate on the outside wall of stripper vessel 22. Plate sections 86 function to further direct catalyst particles, that would otherwise become entrained in the upflowing stripping gas and swirling gas associated with the cyclonic separation, to flow downwardly into the stripping vessel.
  • conical baffles are provided to increase the contact between the solid particles and the stripping gas in the middle or lower sections of the stripping vessel.
  • These stripping baffles have the usual cone arrangement that is ordinarily found in FCC strippers.
  • an uppermost inner cone type baffle 88 is attached to partition plates 80 and a lower outer cone 90 is attached to the wall of stripping vessel 22.
  • These baffles can be of any ordinary design well known to those skilled in the art and commonly used in FCC strippers.
  • the stripper baffles will be provided with skirts that depend downwardly from the lower conical portion of the baffle. It is also known that such skirts can be perforated to increase the contacting efficiency between the stripping fluid and the catalyst particles.
  • Figure 2 depicts an arrangement of the stripping vessel wherein an upper portion 22' is located in the reactor vessel 19 and a lower portion 22'' extends below the interior of reactor vessel 19. This arrangement facilitates the location of nozzle 26 for the withdrawal of spent catalyst from the stripping vessel.
  • the stripping vessel and the disengaging vessel may be supported from the reactor vessel 19 in any manner that will allow for thermal expansion between disengaging vessel 20 and reactor vessel 19.
  • One support arrangement uses a solid stripping vessel fixed to the bottom shell of reactor vessel 19 and a disengaging vessel fixed rigidly thereto. In such an arrangement, thermal expansion of the disengaging vessel and the upper portion 22' of the stripping vessel is provided by expansion joints in the conduit 18 and the central outlet 32 or the manifolds located thereabove.
  • Figure 2 shows an arrangement wherein the upper portion 22' is fixed to the bottom of disengaging vessel 20 and a slip joint is provided between the upper portion 22' and the lower portion 22'' of the stripping vessel.
  • Catalyst bed 44 surrounds the location of stripper section 22'.
  • the lower portion of reactor vessel 19 must have a catalyst inlet to transfer catalyst from bed 44 to stripper vessel 22.
  • catalyst drains into the stripper vessel through the slots 46 in the manner previously described.
  • Fluidizing gas which is generally steam, distributed to the bottom of bed 44 by distributor 98 facilitates the transport of catalyst into the stripping vessel through slots 46 and strips the catalyst discharged from the dip legs of the reactor cyclones.
  • slip joint arrangement of Figure 2 shows additional slots in the upper portion of lower stripper section 22'. These slots provide clearance for the dissipator plates as the disengaging vessel and upper stripper section 22 grow downward with respect to the lower stripper section 22'.
  • FIG. 3 depicts the dissipator plates, upper stripper baffle, slip joint and slots in plan view. Looking at Figure 3, four dissipator plates are shown spaced 90 o apart and extending from the outer wall of the upper stripper section 22' to the outside of vortex stabilizer 76. Vortex stabilizer 76 is centrally supported from the dissipator plates.
  • the slots 92 spaced about the upper end of section 22'' lie directly beneath the dissipator plates 80 to prevent interference between the bottom of the dissipator plates and the top of section 22''.
  • Slots 46 are spaced regularly about the lower periphery of section 22'. Four to sixteen of such slots 46 are usually provided. The slots are sized to maintain a catalyst level in bed 44 and prevent the leakage of gas outwardly from the stripping vessel into the open area of reactor vessel 19. For a typical arrange-ment, the slots 46 will be 500 to 1000 mm in height and from 300 to 400 mm wide. Slots 92 are sized as necessary to provide adequate clearance for the dissipator plates; for an ordinary arrangement, slots approximately 250 mm x 250 mm will provide adequate clearance.
  • Stripping vessel 28 shown in more detail by Figure 4, operates in a conventional manner. Catalyst passes downwardly through the stripper and is cascaded side/side through a series of inner baffles 100 and outer baffles 102. Catalyst is withdrawn through ports 104 in a lower portion of a support conduit 106 to which inner stripper baffles 100 are attached. Ports 104 direct the catalyst into conduit 48 for transfer into regenerator vessel 52 in the manner previously described. Stripping baffles 100 and 102 may again be provided with dependent skirts and orifices to increase the contact between catalyst and steam that enters the stripping vessel through nozzle 30. Steam or other stripping fluid that contacts the spent catalyst rises countercurrently to the catalyst and flows out of stripping vessel 28 through nozzle 26.
  • FIG. 5 shows the upper portion of reactor vessel 19.
  • the top of disengaging vessel 20 extends into the upper section of reactor vessel 19.
  • the disengaging vessel is supported by support lugs (not shown) which are attached to the wall of vessel 19.
  • Central gas nozzle 32 extends upwardly and branches into a manifold that provides transfer conduits 32 having arms 110.
  • Each of arms 110 is connected to a cyclone inlet 112 for cyclones 36.
  • the upper section of the manifold arms and cyclones are supported by gas outlet tubes 40.
  • An expansion joint 114 is provided in the branch arms to accommodate differential thermal expanison between the gas tube and branch arms and the shell of reactor vessel 19.
  • Pressure equalizer ports 116 are provided in the sides of central gas tubes 32 and communicate the open area of the reactor vessel with the interior of the gas tube to vent fluidizing gas from the open area of the reactor vessel.
  • the ports 116 are sized to maintain a suitable pressure drop usually less than 0.7 kPa between the open area of the reactor vessel and the central gas conduit 32.
  • venting of gases from the open area of the reactor can be provided by a vent located in the branch arms 110, the cyclone inlets 112, or even a separate cyclone vessel located within or outside of the reactor vessel 19.
  • this invention can be used with any number of secondary cyclones 36.

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  • Chemical & Material Sciences (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)
  • Devices And Processes Conducted In The Presence Of Fluids And Solid Particles (AREA)
  • Separation Of Suspended Particles By Flocculating Agents (AREA)
  • Removal Of Specific Substances (AREA)
  • Physical Water Treatments (AREA)
  • Working-Up Tar And Pitch (AREA)
  • Fats And Perfumes (AREA)
  • Beans For Foods Or Fodder (AREA)
EP92309716A 1990-11-15 1992-10-23 Dispositif de dépouillement d'effluent contenant des plaques de dissipation pour procédés FCC Expired - Lifetime EP0593827B1 (fr)

Priority Applications (11)

Application Number Priority Date Filing Date Title
US07/613,037 US5158669A (en) 1990-11-15 1990-11-15 Disengager stripper
CA002080974A CA2080974C (fr) 1990-11-15 1992-10-20 Separateur rectificateur a plaques de dissipation pour procede de craquage catalytique fluide
AU27278/92A AU649889B1 (en) 1990-11-15 1992-10-21 Disengager stripper containing dissipation plates for use in an FCC process
DE69213458T DE69213458T2 (de) 1990-11-15 1992-10-23 Dissipationsplatten enthaltenden Abflussabstreibeinrichtung für FCC-Verfahren
AT92309716T ATE142247T1 (de) 1990-11-15 1992-10-23 Dissipationsplatten enthaltenden abflussabstreibeinrichtung für fcc-verfahren
ES92309716T ES2093798T3 (es) 1990-11-15 1992-10-23 Separador por arrastre de desprendimiento que contiene placas de disipacion para uso en un procedimiento de craqueo catalitico fluidizado (fcc).
EP92309716A EP0593827B1 (fr) 1990-11-15 1992-10-23 Dispositif de dépouillement d'effluent contenant des plaques de dissipation pour procédés FCC
CN92112441A CN1035773C (zh) 1990-11-15 1992-10-26 流化催化裂化原料的流化催化裂化方法及其装置
US07/966,777 US5316662A (en) 1990-11-15 1992-10-27 Integrated disengager stripper and its use in fluidized catalytic cracking process
US07/966,776 US5314611A (en) 1990-11-15 1992-10-27 External integrated disengager stripper and its use in fluidized catalytic cracking process
GR960403018T GR3021647T3 (en) 1990-11-15 1996-11-14 Disengager stripper containing dissipation plates for use in an FCC process

Applications Claiming Priority (7)

Application Number Priority Date Filing Date Title
US07/613,037 US5158669A (en) 1990-11-15 1990-11-15 Disengager stripper
CA002080974A CA2080974C (fr) 1990-11-15 1992-10-20 Separateur rectificateur a plaques de dissipation pour procede de craquage catalytique fluide
AU27278/92A AU649889B1 (en) 1990-11-15 1992-10-21 Disengager stripper containing dissipation plates for use in an FCC process
EP92309716A EP0593827B1 (fr) 1990-11-15 1992-10-23 Dispositif de dépouillement d'effluent contenant des plaques de dissipation pour procédés FCC
CN92112441A CN1035773C (zh) 1990-11-15 1992-10-26 流化催化裂化原料的流化催化裂化方法及其装置
US07/966,777 US5316662A (en) 1990-11-15 1992-10-27 Integrated disengager stripper and its use in fluidized catalytic cracking process
US07/966,776 US5314611A (en) 1990-11-15 1992-10-27 External integrated disengager stripper and its use in fluidized catalytic cracking process

Publications (2)

Publication Number Publication Date
EP0593827A1 true EP0593827A1 (fr) 1994-04-27
EP0593827B1 EP0593827B1 (fr) 1996-09-04

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EP92309716A Expired - Lifetime EP0593827B1 (fr) 1990-11-15 1992-10-23 Dispositif de dépouillement d'effluent contenant des plaques de dissipation pour procédés FCC

Country Status (8)

Country Link
EP (1) EP0593827B1 (fr)
CN (1) CN1035773C (fr)
AT (1) ATE142247T1 (fr)
AU (1) AU649889B1 (fr)
CA (1) CA2080974C (fr)
DE (1) DE69213458T2 (fr)
ES (1) ES2093798T3 (fr)
GR (1) GR3021647T3 (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1800728A1 (fr) * 2005-12-21 2007-06-27 Institut Français du Pétrole Nouveau système de séparation gaz solide et de stripage pour les unités de craquage catalytique en lit fluidisé
WO2020210181A1 (fr) * 2019-04-12 2020-10-15 Uop Llc Appareil et processus pour séparer des gaz d'un catalyseur

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN1055492C (zh) * 1996-03-22 2000-08-16 中国石油化工集团公司 提升管催化裂化反应系统气固快速分离和气体快速引出方法及装置
US5869008A (en) * 1996-05-08 1999-02-09 Shell Oil Company Apparatus and method for the separation and stripping of fluid catalyst cracking particles from gaseous hydrocarbons

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US4414100A (en) * 1981-12-29 1983-11-08 Chevron Research Company Fluidized catalytic cracking
US4500423A (en) * 1981-02-26 1985-02-19 Chevron Research Company Separation of reacted hydrocarbons and catalyst in fluidized catalytic cracking
EP0169008A1 (fr) * 1984-07-18 1986-01-22 Mobil Oil Corporation Méthode pour le "stripping" d'un catalyseur de craquage catalytique fluidisé
US4572780A (en) * 1984-10-22 1986-02-25 Mobil Oil Corporation Multistage stripper for FCC unit with catalyst separation by spinning
US4988430A (en) * 1989-12-27 1991-01-29 Uop Supplying FCC lift gas directly from product vapors
US5043145A (en) * 1986-08-21 1991-08-27 Exxon Research & Engineering Company Minimal holdup reactor grid
US5158669A (en) * 1990-11-15 1992-10-27 Uop Disengager stripper

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US4749471A (en) * 1983-09-06 1988-06-07 Mobil Oil Corporation Closed FCC cyclone process
US4927527A (en) * 1984-07-18 1990-05-22 Mobil Oil Corporation Method for reducing overcracking during FCC catalyst separation
CN1009659B (zh) * 1985-06-24 1990-09-19 法国石油公司 流化床催化裂化工艺和装置
GB8904409D0 (en) * 1989-02-27 1989-04-12 Shell Int Research Process for the conversion of a hydrocarbonaceous feedstock
US5062945A (en) * 1988-09-23 1991-11-05 Mobil Oil Corporation Method of FCC spent catalyst stripping for improved efficiency and reduced hydrocarbon flow to regenerator
US5059302A (en) * 1989-05-16 1991-10-22 Engelhard Corporation Method and apparatus for the fluid catalytic cracking of hydrocarbon feed employing a separable mixture of catalyst and sorbent particles

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Publication number Priority date Publication date Assignee Title
US4500423A (en) * 1981-02-26 1985-02-19 Chevron Research Company Separation of reacted hydrocarbons and catalyst in fluidized catalytic cracking
US4414100A (en) * 1981-12-29 1983-11-08 Chevron Research Company Fluidized catalytic cracking
EP0169008A1 (fr) * 1984-07-18 1986-01-22 Mobil Oil Corporation Méthode pour le "stripping" d'un catalyseur de craquage catalytique fluidisé
US4572780A (en) * 1984-10-22 1986-02-25 Mobil Oil Corporation Multistage stripper for FCC unit with catalyst separation by spinning
US5043145A (en) * 1986-08-21 1991-08-27 Exxon Research & Engineering Company Minimal holdup reactor grid
US4988430A (en) * 1989-12-27 1991-01-29 Uop Supplying FCC lift gas directly from product vapors
US5158669A (en) * 1990-11-15 1992-10-27 Uop Disengager stripper

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1800728A1 (fr) * 2005-12-21 2007-06-27 Institut Français du Pétrole Nouveau système de séparation gaz solide et de stripage pour les unités de craquage catalytique en lit fluidisé
WO2020210181A1 (fr) * 2019-04-12 2020-10-15 Uop Llc Appareil et processus pour séparer des gaz d'un catalyseur

Also Published As

Publication number Publication date
EP0593827B1 (fr) 1996-09-04
CA2080974C (fr) 2004-02-17
CN1035773C (zh) 1997-09-03
DE69213458T2 (de) 1997-01-02
AU649889B1 (en) 1994-06-02
GR3021647T3 (en) 1997-02-28
ATE142247T1 (de) 1996-09-15
CN1086247A (zh) 1994-05-04
DE69213458D1 (de) 1996-10-10
ES2093798T3 (es) 1997-01-01
CA2080974A1 (fr) 1994-04-21

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