Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
  • B01J8/18—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles
  • B01J8/1845—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles with particles moving upwards while fluidised
  • B01J8/1863—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles with particles moving upwards while fluidised followed by a downward movement outside the reactor and subsequently re-entering it
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
  • B01J8/18—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles
  • B01J8/1872—Details of the fluidised bed reactor
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
  • B01J8/18—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles
  • B01J8/24—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles according to "fluidised-bed" technique
  • B01J8/26—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles according to "fluidised-bed" technique with two or more fluidised beds, e.g. reactor and regeneration installations
  • B01J8/28—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles according to "fluidised-bed" technique with two or more fluidised beds, e.g. reactor and regeneration installations the one above the other
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
  • B01J8/18—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles
  • B01J8/24—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles according to "fluidised-bed" technique
  • B01J8/38—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles according to "fluidised-bed" technique with fluidised bed containing a rotatable device or being subject to rotation or to a circulatory movement, i.e. leaving a vessel and subsequently re-entering it
  • B01J8/384—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles according to "fluidised-bed" technique with fluidised bed containing a rotatable device or being subject to rotation or to a circulatory movement, i.e. leaving a vessel and subsequently re-entering it being subject to a circulatory movement only
  • B01J8/388—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles according to "fluidised-bed" technique with fluidised bed containing a rotatable device or being subject to rotation or to a circulatory movement, i.e. leaving a vessel and subsequently re-entering it being subject to a circulatory movement only externally, i.e. the particles leaving the vessel and subsequently re-entering it
• • 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
  • C10G11/16—Catalytic cracking, in the absence of hydrogen, of hydrocarbon oils with preheated moving solid catalysts according to the "moving bed" method
• • 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
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J2208/00—Processes carried out in the presence of solid particles; Reactors therefor
  • B01J2208/00008—Controlling the process
  • B01J2208/00548—Flow
  • B01J2208/00557—Flow controlling the residence time inside the reactor vessel
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J2208/00—Processes carried out in the presence of solid particles; Reactors therefor
  • B01J2208/00796—Details of the reactor or of the particulate material
  • B01J2208/00823—Mixing elements
  • B01J2208/00831—Stationary elements
  • B01J2208/0084—Stationary elements inside the bed, e.g. baffles
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J2208/00—Processes carried out in the presence of solid particles; Reactors therefor
  • B01J2208/00796—Details of the reactor or of the particulate material
  • B01J2208/00938—Flow distribution elements
• • 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
  • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
  • C10G2300/10—Feedstock materials
  • C10G2300/1037—Hydrocarbon fractions
  • C10G2300/104—Light gasoline having a boiling range of about 20 - 100 °C
• • 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
  • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
  • C10G2300/10—Feedstock materials
  • C10G2300/1037—Hydrocarbon fractions
  • C10G2300/1048—Middle distillates
  • C10G2300/1059—Gasoil having a boiling range of about 330 - 427 °C
• • 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
  • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
  • C10G2300/40—Characteristics of the process deviating from typical ways of processing
  • C10G2300/4006—Temperature
• • 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
  • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
  • C10G2300/40—Characteristics of the process deviating from typical ways of processing
  • C10G2300/4012—Pressure
• • 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
  • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
  • C10G2300/40—Characteristics of the process deviating from typical ways of processing
  • C10G2300/4018—Spatial velocity, e.g. LHSV, WHSV
• • 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
  • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
  • C10G2300/40—Characteristics of the process deviating from typical ways of processing
  • C10G2300/4025—Yield
• • 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
  • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
  • C10G2300/70—Catalyst aspects
• • 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
  • C10G2400/00—Products obtained by processes covered by groups C10G9/00 - C10G69/14
  • C10G2400/20—C2-C4 olefins

Definitions

• the invention relates to the field of refining and petrochemicals and of processes and devices for the chemical transformation of petroleum products, in particular petroleum crude oil ("crude oil” according to English terminology) by catalytic cracking in a fluidized bed (“fluid catalytic cracking "or FCC according to English terminology).
• FCC is a process conventionally used in refining to convert a heavy feed, characterized by a boiling point temperature close to 340 ° C, often above 380 ° C, into lighter products which can be used as fuels, in particular in gasoline, first FCC product, characterized by temperatures at the start of boiling close to the ambient and by temperatures at the end of boiling of 160 ° C or even 220 ° C depending on whether we are talking about light gasoline or not .
• the area of operation of the process has expanded in its expenses, with in particular mixtures of heavy products and lighter products (recycled cuts from other processes), but also in its products with in particular the production of propylene (olefin of cut C3) for use in petrochemicals, the other light olefins (ethylene in C2) and butenes (olefins in C4) not generally being used as products for petrochemicals (generally cut C2 is not recovered and cut C4 is oriented towards transformation into petrol via the alkylation processes or MTBE for example).
• the FCC charge (s) were subjected to physical and / or chemical treatments upstream of the process (distillation separations, pretreatment in a catalytic unit to remove nitrogen, metals ).
• US 2014/0357912 A1 describes an FCC unit with a rising gas-solid cocurrent fluidized bed reactor (“riser” according to English terminology) separated into three temperature zones into which various hydrocarbon feedstocks are injected, in order to '' increase the proportion of light olefins.
• said hydrocarbon charges are recycles of cuts produced by the FCC, and all of them are injected into the riser, the contact times are different but remain short.
• US 3,639,228 describes a staged injection of regenerated catalyst at different elevations into the riser, in order to increase the selectivity in gasoline (charge injected at the bottom of the riser).
• US 2018/0079973 A1 describes an FCC unit comprising two reactors and a regenerator using two catalysts, a first catalyst which is finer and less dense than the second catalyst, to improve the production of light olefins.
• a first object of the present invention is to provide FCC units making it possible on the one hand to treat a hydrocarbon fraction with a large range of boiling temperature and on the other hand to maximize the production of light olefins with a logic of increasing the synergy between refining and petrochemicals by reorienting the refining processes and their products towards petrochemicals.
• a catalytic cracking device in a fluidized bed of a hydrocarbon feed comprising: a dense fluidized bed reactor adapted to crack at least partially a first hydrocarbon feedstock in the presence of a catalyst to produce a first effluent, and at least partially supplying catalyst to a transported fluidized bed reactor; and the transported fluidized bed reactor adapted to crack at least partially at least one second hydrocarbon feedstock in the presence of the catalyst to produce a second effluent,
• the second hydrocarbon charge being a heavier charge than the first hydrocarbon charge.
• the abovementioned object as well as other advantages, are obtained by a process for catalytic cracking in a fluidized bed of a hydrocarbon feedstock, comprising: cracking at least partially a first hydrocarbon feedstock in a bed reactor dense fluidized in the presence of a catalyst to produce a first effluent;
• the second hydrocarbon charge being a heavier charge than the first hydrocarbon charge.
• the dense fluidized bed reactor is directly connected to the transported fluidized bed reactor to supply directly the transported fluidized bed reactor with catalyst.
• the dense fluidized bed reactor is a bubbling or turbulent fluidized bed reactor.
• the transported fluidized bed reactor is an ascending or descending gas-solid co-current fluidized bed reactor.
• the fluidized bed reactor transported is an ascending gas-solid co-current fluidized bed reactor.
• the dense fluidized bed reactor is connected to an intermediate charge inlet of the transported fluidized bed reactor.
• the dense fluidized bed reactor comprises at least two compartments for treating the first hydrocarbon charge in the form of at least a first lighter charge and a first less light charge, and in which: either a first compartment is supplied by a first catalyst and a second compartment supplied by a second catalyst; either a first compartment is supplied with the catalyst coming directly from a regenerator and a second compartment is supplied with catalyst by circulation between the first compartment and the second compartment.
• the operating conditions of the dense fluidized bed reactor are as follows:
• - temperature between 500 and 800 ° C and preferably less than 750 ° C;
• the operating conditions of the transported fluidized bed reactor are as follows:
• - temperature between 500 and 700 ° C and preferably less than 650 ° C;
• FIG. 1 describes a diagram of an FCC device according to one or more embodiments of the present invention in which the dense fluidized bed reactor is connected to the bottom of a riser.
• FIG. 2 describes a diagram of an FCC device according to one or more embodiments of the present invention in which the dense fluidized bed reactor is connected to an intermediate charge inlet of a riser.
• FIG. 3A describes a diagram of an FCC device according to FIG. 2 in which the dense fluidized bed reactor is compartmentalized.
• Figure 3B describes a top view of the FCC device according to Figure 3A.
• FIG. 4 describes a diagram of an FCC device according to one or more embodiments of the present invention in which the dense fluidized bed reactor is composed of at least two compartments.
• FIG. 5 describes a diagram of an FCC device according to one or more embodiments of the present invention in which the transported fluidized bed reactor is a gas-solid descending co-current fluidized bed reactor. Description of the embodiments
• the invention relates to the field of FCC methods and devices for at least partially converting petroleum crude oil (e.g. after a first fractionation) into an FCC type unit, with the aim of optimizing the production of light olefins.
• the conversion process and device according to the invention can be defined as a series of steps or reactors / cracking sections intended to convert cuts or all cuts of petroleum crude oil.
• light loads eg naphta
• heavy loads eg VGO
• FCC reactor eg riser
• This implementation which notably comprises successively treating, in the direction followed by the catalyst (solid particles), first the lighter charge in a reactor whose technology offers a long contact time (eg dense fluidized bed), then the heavier charge in a reactor whose technology offers a short contact time (eg entrained bed) is also relevant because it takes advantage of the fact that the cracking of a light fraction is not very coking while the cracking of 'a heavy cut is very coking.
• the catalyst is still active due to its low coke level; it remains operative to crack the heavier fraction, which produces more coke.
• the catalyst no longer plays its catalytic role; the coked catalyst can then be separated from the effluents so that they do not continue to crack under the thermal effect leading to an overproduction of dry gas (also called “dry gas” according to English terminology; light gas fraction at low value ).
• dry gas also called “dry gas” according to English terminology; light gas fraction at low value
• the present invention may be defined as a device for catalytic cracking in a fluidized bed of a hydrocarbon feedstock, comprising a dense fluidized bed reactor suitable for cracking a light feedstock in the presence of a catalyst; and a fluidized bed reactor transported connected to the dense fluidized bed reactor and adapted to crack a heavy load in the presence of the catalyst fed by the dense fluidized bed reactor.
• the transported fluidized bed reactor is directly connected to the dense fluidized bed reactor.
• an outlet from the dense fluidized bed reactor can lead directly to an inlet of the transported fluidized bed reactor.
• the term “dense fluidized bed” means a gas-solid fluidized bed operating in bubbling regime or in turbulent regime.
• the dense fluidized bed reactor is chosen from a bubbling fluidized bed reactor and a turbulent fluidized bed reactor (e.g. contact time greater than 1 second such as several seconds).
• the term “bubbling fluidized bed” means a gas-solid fluidized bed whose gas speed is between the minimum fluidization speed and the speed of transition to the turbulent regime. These speeds depend on the properties of the solid catalyst (density, size, shape of the grains, etc.).
• the volume fraction of solid is between a value close to 0.4 and the maximum volume fraction of solid corresponding to a fixed, non-fluidized bed, generally close to 0.5.
• turbulent fluidized bed means a gas-solid fluidized bed whose gas speed is between the speed of transition to the turbulent regime and the speed of transport.
• the volume fraction of solid is between a value close to 0.25 and a value close to 0.4.
• the term “transported fluidized bed” means a gas-solid fluidized bed whose gas speed is greater than the transport speed.
• the volume fraction of solid is less than a value close to 0.25.
• the term “transport speed” corresponds to the speed with which essentially all the solid is entrained by the gas.
• the transport speed is known to the skilled person.
• the transport speed can be determined as a function of the properties of the gas (eg viscosity and density), the properties of the particles (eg size and density) and the size of the fluidized bed (eg diameter and height).
• the transported fluidized bed reactor is chosen from a gas-solid upward gas-solid co-current fluidized bed reactor and a gas-solid downgoing gas-solid co-current fluidized bed reactor (eg contact time less than 1 second such as around ten ms).
• the transported fluidized bed reactor is a rising gas-solid co-current (riser) fluidized bed reactor.
• FIG. 1 describes a diagram of an FCC device according to one or more embodiments of the present invention comprising:
• a dense fluidized bed reactor 1 suitable for: being fed by and at least partially cracking a first load 2, e.g. light cut (of a crude oil); and produce a first effluent (e.g. gaseous) in the presence of a catalyst 3 (e.g. fresh or regenerated).
• a first load 2 e.g. light cut (of a crude oil)
• a first effluent e.g. gaseous
• a catalyst 3 e.g. fresh or regenerated
• a riser 4 connected to an outlet of the dense fluidized bed reactor 1 and adapted to: be at least partially supplied, and preferably directly supplied, with catalyst (e.g. partially spent catalyst) by the dense fluidized bed reactor 1; be fed by and at least partially crack at least one second charge 10, e.g. heavy cut (from a crude oil) in the presence of catalyst 3 (partially worn); and produce a second effluent (e.g. gaseous);
• catalyst e.g. partially spent catalyst
• a stripper 5 connected (eg directly) to the outlet of the riser 4 and suitable for: being supplied by the second effluent as well as a stripping gas (not shown), the stripping gas being preferably devoid of hydrocarbons and preferably comprising water vapor coming, against the catalyst; desorbing hydrocarbons adsorbed on said portion of the catalyst; send the gaseous products, via a first conduit 6, for example to a fractionation column (not shown); and send, via a
• the regenerator 8 suitable for: burning the coke formed contained in the pore volume of the catalyst; and send, via a third conduit 9, the portion of regenerated catalyst to the dense fluidized bed reactor 1.
• the dense fluidized bed reactor 1 is suitable for: sending the catalyst to the riser 4; and send the first effluent to the fractionation column for example via at least a fourth dedicated conduit 16.
• the device may include a transport member (not shown) suitable for injecting a gas into the riser 4 and ensuring the transport of the catalyst.
• the dense fluidized bed reactor 1 may comprise a gas-solid separation device (not shown) known to those skilled in the art. According to one or more embodiments, the separation of the gaseous effluents and of the catalyst particles in the dense fluidized bed reactor 1 is improved by one or more stages of cyclones.
• the cyclones include return legs recycling the catalyst into the fluidized bed. It is understood that part of the catalyst can be entrained with the first effluent to the fractionation column and that part of the first effluent can be entrained with the catalyst in the riser 4. According to one or more embodiments, at least 95% by weight, preferably at least 98% by weight, very preferably at least 99% by weight, of the catalyst coming from the dense fluidized bed reactor 1 is sent to the riser 4, and / or at least 80% by weight, preferably at least 90% weight, very preferably at least 95% by weight, of the first effluent is sent to the fractionation column.
• the dense fluidized bed reactor 1 is adapted to send the catalyst and at least part of the first effluent to the riser 4.
• the device comprises a loss-of-action member feed (not shown) disposed between the dense fluidized bed reactor 1 and the fractionation column to modify the distribution of the cracked gas towards the riser and / or towards the fractionation column.
• At least 95% by weight, preferably at least 98% by weight, very preferably at least 99% by weight, of the catalyst originating from the dense fluidized bed reactor 1 is sent to the riser 4, and / or to the at least 50% by weight, preferably at least 75% by weight, very preferably at least 90% by weight of the first effluent is sent to the riser 4 with the catalyst from the dense fluidized bed reactor.
• the dense fluidized bed reactor 1 opens into the riser 4 via a diameter restriction arranged (at the interface) between the dense fluidized bed reactor 1 and the riser 4.
• the angle ⁇ formed by the diameter restriction between the dense fluidized bed reactor 1 and the riser 4 is between 90 ° and 165 °, preferably between 90 ° and 150 °.
• the riser can also be off-center with respect to the central axis of the dense fluidized bed reactor 1.
• the riser 4 is adapted to be directly fed by and at least partially crack at least one third load 11, eg cut intermediate (of petroleum crude) and / or one or more fractions of products from the FCC corresponding to liquid fractions, corresponding for example to the cut 20-80 ° C, 20-220 ° C and up to 20-350 ° C (depending on whether you want to maximize the production of olefins or aromatics).
• at least one third load 11 eg cut intermediate (of petroleum crude) and / or one or more fractions of products from the FCC corresponding to liquid fractions, corresponding for example to the cut 20-80 ° C, 20-220 ° C and up to 20-350 ° C (depending on whether you want to maximize the production of olefins or aromatics).
• the terms “light cut”, “couple lighter / lighter than”, “intermediate cut”, “heavy cut” and “lighter cut than” mean a hydrocarbon fraction whose final boiling point is higher / lower than another hydrocarbon fraction.
• the term "light cut” means a cut whose initial boiling point is between 20 and 50 ° C and a final boiling point between 70 to 350 ° C, preferably between 70 and 250 ° C, most preferably between 70 to 220 ° C.
• intermediate cut means a cut whose initial boiling point is between 80 and 220 ° C and a final boiling point between 160 and 350 ° C, preferably between 220 and 350 ° C, such as between 220 and 300 ° C or between 300 and 350 ° C.
• the term "heavy cut” means a cut whose initial boiling point is between 80 ° C and 350 ° C and more generally between 150 ° C and 350 ° C or even between 220 and 350 ° C and a final boiling point greater than 300 ° C, preferably greater than 350 ° C, such as greater than 500 ° C.
• the heavy cut corresponds to a cut whose final boiling point is between 350 and 565 ° C (e.g. conventional FCC charge such as a VGO).
• the order of entry of the charges entering directly into the riser 4 is fixed by so that a lighter load enters upstream of a heavier load.
• the catalyst contains less coke and is therefore more active in treating a charge which is more difficult to crack.
• FIG. 2 describes a diagram of an FCC device according to one or more embodiments of the present invention in which:
• the regenerator 8 is adapted to send, via a fifth conduit 12, a second portion of regenerated catalyst to the riser 4 (e.g. catalyst inlet at the bottom of riser 4); the supply of the third load 11 leads to the lower load input of the riser 4; and
• the outlet of the dense fluidized bed reactor 1 leads to an intermediate charge inlet of the riser 4 located above the lower charge inlet.
• the third charge 11 has the longest contact time in the riser 4 and the second charge 10 has the shortest contact time in the riser 4.
• said first effluent has an intermediate contact time in riser 4.
• the dense fluidized bed reactor 1 is compartmentalized so that said dense fluidized bed reactor 1 can process the first charge 2 in the form of several light loads (2A, 2B and 2C, each of said light loads entering (eg through a dedicated entrance) into a dedicated compartment 14A, 14B, 14C.
• the number of compartments is between 2 and 10, preferably between 2 and 6.
• the solid arrows represent the path of the catalyst (solid) in a dense fluidized bed reactor 1
• the hatched arrows represent the path of the charges and effluents (gas) in said reactor.
• the lightest load 2A (light loads) has the longest contact time in the dense fluidized bed reactor 1 and the least light load 2C (light loads) has the time shortest contact in the dense fluidized bed reactor 1.
• the most slight 2A enters a first compartment 14A; at least one intermediate load 2B enters at least one intermediate compartment (denoted second compartment 14B in FIGS. 3A and 3B); and the least light load 2C enters a last compartment 14C, the first compartment 14A being the largest compartment (eg in volume and / or height) and the last compartment 14C being the smallest compartment.
• the size of the compartments can be chosen to favor a decreasing contact time as the load becomes heavier.
• the fluidized bed reactor 1 is cylindrical and the compartments 14A, 14B, 14C form radial sectors of said reactor.
• the radial sectors are identical and the compartments 14A, 14B, 14C differ in that the first compartment 14A comprises a height of catalyst greater than that of the second compartment 14B and so on until the last compartment 14C comprising the lowest catalyst height.
• the radial sectors are different and the angle b of the radial sector of the first compartment 14A is larger than that of the second compartment 14B and so on until the last compartment 14C whose angle of the sector radial is the smallest.
• the angle b of the first compartment 14A is at least 20 °, preferably at least 30 ° (eg 40 °), larger than that of the second compartment 14B and so on between the second compartment and the third compartment, up to the last compartment 14C.
• the fresh and / or regenerated catalyst 3 enters the first compartment 14A (e.g. by a dedicated inlet 9).
• the catalyst of a compartment 14A and 14B other than the last compartment 14C is sent to a downstream compartment (eg by overflow above a wall 15 disposed between two adjacent compartments) and the catalyst of the last compartment 14C is sent to the riser 4, for example via a lower window 13 (outlet located at the bottom of the last compartment) or any other means allowing the catalyst of the last compartment to pass inside the riser 4.
• the first compartment 14A and the last compartment 14C are separated by a wall 15 adapted to prevent the catalyst 3 from flowing directly from the first compartment 14A to the last compartment 14C.
• the first effluent e.g. all of the effluents from compartments 14A, 14B and 14C
• the fractionation column not shown
• At least one intermediate compartment and / or the last compartment are supplied with fresh or regenerated catalyst.
• the dense fluidized bed reactor 1 can be adapted to send a fresh or regenerated catalyst to the second compartment 14B and / or the last compartment 14C.
• FIG. 4 describes a diagram of an FCC device according to one or more embodiments of the present invention in which the dense fluidized bed reactor 1 is composed of at least two compartments 17A and 17B for treating the first charge 2 under the forms at least two light loads (2A and 2B), a first compartment 17A supplied by a first catalyst 3A, via the sixth conduit 18, and a second compartment 17B supplied by a second catalyst 3B (different from the first catalyst), via the seventh conduit 19.
• the compartments 17A and 17B are of identical or different sizes.
• the lightest charge 2A (light charges) is introduced into the largest compartment 17A and the charge the less light 2B (light loads) is introduced into the smaller compartment 17B - thus, the contact time of the lightest load 2A is greater than the contact time of the least light load 2B.
• the size of the compartments 17A and 17B can be adapted to favor a decreasing contact time as the load becomes heavier.
• the number of compartments is between 2 and 10, preferably between 2 and 6.
• the first catalyst 3A is less dense (i.e., lighter) and / or narrower in particle size (i.e., smaller) than the second catalyst 3B.
• the lightest load 2A (light loads) is introduced into compartment 17A comprising the first catalyst 3A and the least light load 2B (light loads) is introduced into compartment 17B comprising second catalyst 3B.
• the dense fluidized bed reactor 1 can lead, for example via the diameter restriction, into the riser 4.
• the riser 4 is also adapted to be supplied with at least one second charge 10 (heavier than light loads 2A and 2B).
• At least part of the first catalyst 3A and the second catalyst 3B is transported in the riser 4, then in the stripper 5 where the hydrocarbons adsorbed on the catalysts or entrained with the catalyst are stripped (eg the hydrocarbons desorbed or expelled from the interstitial space).
• the desorbed catalysts enter the regenerator 8 where the coke formed on the various catalysts is burned.
• an eighth conduit 20 also called “lift” according to English terminology; ascending gas-solid co-current transport regime, with no reaction other than that of burning coke
• the two regenerated catalysts are transported in a solid separator / solid 21, where the second catalyst 3B, denser and / or wider in particle size, is separated by elutriation from the first catalyst 3A, which is lighter and finer.
• the first catalyst 3A and the second catalyst 3B are sent via the sixth and seventh conduits 18 and 19 to the compartments 17A and 17B of the dense fluidized bed reactor 1, respectively.
• the device further comprises a gas / solid separation system 22 (e.g. cyclone) for separating gases 23 coming from the solid / solid separator 21 from the second catalyst 3B.
• a gas / solid separation system 22 e.g. cyclone
• the fluidized bed reactor is transported a fluidized bed reactor in co-current gas-solid descending (downer) having the advantage of avoiding the cracked gases a 1 st time to be a cracked 2 nd time, and allowing to be more selective towards products of interest and to form less dry gas.
• the integration of a descending gas-solid cocurrent fluidized bed reactor can be achieved by modifying the dense fluidized bed reactor 1 as shown in FIGS. 3A and 3B so that it is suitable for connect (directly) a downer instead of the riser 4.
• the device comprises:
• the dense fluidized bed reactor 1 adapted to crack the first charge 2 in the presence of the catalyst 3 and produce the first effluent 25, which is distributed via an upper opening 26 of the dense fluidized bed reactor 1 (eg opening surmounted by a breeze jet), for example to the fractionation column (not shown); and
• a downer 24 adapted to crack the second charge 10 in the presence of the catalyst 3 (e.g. partially worn) and produce the second effluent.
• the catalyst 3 is sent into the downer 24 by overflow, for example via the upper opening 26 of the dense fluidized bed reactor 1.
• the dense fluidized bed reactor 1 is fluidized by a fluidization gas distributor common to all of the compartments (not shown), for example a single crown which serves each compartment, either by a member fluidization individual to each compartment (not shown), it can commonly be a crown or a "sparger" according to English terminology. Any system for distributing the fluidizing gas in the form of branches is called a sparger.
• the fluidizing gas is a mixture comprising the vaporized charge.
• the operating conditions of the dense fluidized bed reactor 1 are as follows:
• the dense fluidized bed reactor 1 is adapted to send into the stripper 5 a solid flow of between 10 and 200 kg / m 2 / s. According to one or more embodiments, the dense fluidized bed reactor 1 is adapted to send into the stripper 5 a solid flow of between 30 and 150 kg / m 2 / s.
• the operating conditions of the riser 4 are as follows:
• a mass ratio of the catalyst to the C / O charge between 3 and 50.
• the operating conditions of the descending gas-solid cocurrent fluidized bed reactor are as follows:
• a mass ratio of the catalyst to the C / O charge between 5 and 50.
• the "light cut” is a mixture of the light cut from petroleum crude (eg after a first fractionation) and a part (or all) of the gasoline cut from the fractionation column .
• the “intermediate cut” is a mixture of the intermediate cut obtained from petroleum crude oil (eg after a first fractionation) and part (or all) of the gasoline cut resulting from the fractionation column. .
• the “heavy cut” is a mixture of the heavy cut resulting from petroleum crude (eg after a first fractionation) and a part (or all) of the light diesel cut (“Light Cycle Oil ”Or LCO according to English terminology) from the fractionation column.
• the catalyst is a solid catalyst (eg density, size and shape of the grains chosen for use in a fluidized bed).
• the densities, sizes and shapes of catalysts for fluidized beds are known to those skilled in the art, and will not be described further.
• the catalyst is an FCC type catalyst, containing for example what is commonly called a matrix made of clay, silica or silica alumina, binder and zeolite, for example from 15 to 50% by weight of zeolite relative to the weight of the catalyst, preferably a Y zeolite and / or a ZSM-5 zeolite.
• the catalyst comprises a ZSM-5 zeolite.
• the grain density of the catalyst is between 1000 and 2000 kg / m 3 .
• the grain density of the catalyst is between 1250 and 1750 kg / m 3 .
• the term “understand” is synonymous with (means the same as) “include” and “contain”, and is inclusive or open and does not exclude other elements not recited. It is understood that the term “understand” includes the exclusive and closed term “consist”. Furthermore, in the present description, the terms “approximately”, “substantially””substantially”,”essentially”,”only” and “approximately close ”are synonymous with (mean the same as) lower and / or higher margin of 10%, preferably 5%, very preferably 1%, of the given value. For example, an effluent comprising essentially or only compounds A corresponds to an effluent comprising at least 90%, preferably at least 95%, very preferably at least 99%, of compounds A.
• Example 1 conversion of a light charge as a function of the contact time
• the catalyst comprises a commercial additive containing 40% ZSM-5.
• the reaction temperature is adapted to have a conversion identical to that which one would have in a riser at 540 ° C.
• Table 3 shows the conversion (in% load weight) as a function of the contact time, obtained in riser (for the shortest contact time) and in dense fluidized bed (LF).
• table 4 shows the yield structure in light olefins as a function of contact time, obtained in riser (for the shortest contact time) and in dense fluidized bed ( LF).
• the contact time can be adapted.
• a contact time close to 2075 ms makes it possible to obtain mainly propylene, but it may be interesting to continue to increase it, for example to 4080 ms, in a logic of maximum olefins.
• Example 3 optimal contact time depending on the loads Table 5 below shows that for two different loads, the contact time set to obtain similar light olefin yields is higher for the lightest load (1454 ms for the load of density 0.6905; 2652 ms for the density load 0.67305).
• EXAMPLE 4 Considering a partitioned reactor with the dimensioning indicated in the following table 6, a solid flow of 80 kg / m 2 / s in the stripper, a density of catalyst grain of 1500 kg / m 3 and a gas speed in each 0.8 m / s compartment, the contact times obtained are as follows:

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