RU2793541C2 - Method, reactor and system for catalytic cracking of liquid oil products - Google Patents

Abstract

FIELD: oil production.

SUBSTANCE: process for the catalytic cracking of liquid petroleum products, comprising the stage of injecting of the initial liquid petroleum products, in particular heavy initial petroleum products, in contact with a catalytic cracking catalyst for reaction in a reactor containing one or more fast fluidized reaction zones. At least one of the fast fluidized reaction zones of the reactor is a fully dense-phase reaction zone, and the axial solid fractions ε of the catalyst, measured in the upper, middle and lower parts of the reaction zone, divided into equal parts in the axial direction, in each case are not less than about 0.1 and not more than about 0.2 such that the axial solids fraction ε of the catalyst is adjusted within the range from about 0.1 to about 0.2 throughout the entire dense-phase reaction zone from bottom to top. The method also includes the following stages: injection of an initial heavy oil product, as a low grade heavy oil product, with a catalytic cracking catalyst in a fully dense-phase reaction zone of the reactor to react under efficient conditions to produce light olefins, wherein the axial solids fraction ε of the catalyst is controlled within a range from about 0.1 to about 0.2 in the entire fully dense-phase reaction zone of the reactor from bottom to top; separating the effluent from the reactor to obtain a reaction product enriched in light olefins and a spent catalyst; regenerating the spent catalyst and recycling at least a part of the resulting regenerated catalyst to stage (i) as a catalytic cracking catalyst; and optionally separating the reaction product to produce dry gas, liquefied petroleum gas, naphtha, diesel fuel, and a catalyst slurry. A reactor and system for the catalytic cracking of liquid petroleum products.

EFFECT: low output of dry gas and coke, proper distribution of products and high output of ethylene and propylene.

21 cl, 8 ex, 4 tbl, 5 dwg

Description

Cross-reference to related applications

The present application claims the priority of PRC Patent Application No. 201810778081.6 entitled "Method and System for Fast Fluidized Catalytic Cracking" filed on July 16, 2018, which is hereby incorporated by reference in its entirety.

TECHNICAL FIELD OF THE INVENTION

The present application relates to the field of catalytic cracking technology, in particular, to a method, reactor and system for catalytic cracking of liquid petroleum products.

State of the art of the present invention

Light olefins such as ethylene and propylene are the main raw materials for the chemical industry. In China and abroad, natural gas or light oil fraction is mainly used as a feedstock for the production of light olefins using the steam cracking process in an integrated ethylene production plant. Benzene, toluene and xylene (BTX) are important major chemical feedstocks, of which para-xylene (XX) accounts for approximately 45% of total BTX consumption. With the development of industries such as the polyester industry in the PRC, the demand for VTX is expected to continue to grow at a high rate. Approximately 90% ethylene, approximately 70% propylene, 90% butadiene and 30% aromatics provide steam cracking by-products. Although steam cracking technology has been developed for several decades and this technology is continuously improved, steam cracking technology still has the technical limitations of high energy consumption, high production cost, large CO ₂ emissions, difficult to control distribution of products, etc. When the conventional route for producing ethylene and propylene using steam cracking in the petrochemical industry is adopted, numerous limiting factors may occur, including shortage of light feed oil, insufficient production capacity, high cost, and so on. In addition, as steam cracking feedstocks become lighter, reduced yields of propylene and light aromatics increase the tension between supply and demand. Catalytic cracking technology can be used as a beneficial addition to the industrial process for producing light olefins and light aromatics and can provide clear social and economic benefits when used to produce chemical feedstocks in refineries and chemical process integrated plants.

PRC Patent Application Publication No. CN1234426A discloses a process for the simultaneous production of light olefins and high aromatics gasoline from a heavy oil product, which involves introducing a heavy petroleum hydrocarbon and steam into a catalytic cracking reaction in a composite reactor, which is composed of a vertical reactor and a dense phase fluidized bed, as a result, the yield of light olefins, in particular propylene, increases, and the content of aromatic compounds in gasoline increases to approximately 80 wt. %.

PRC Patent Application Publication No. CN1393510A discloses a method for improving the production of ethylene and propylene by catalytically converting a heavy petroleum hydrocarbon, which involves contacting and reacting crude liquid petroleum products with a catalyst containing a high silica content pentasil-type zeolite in a vertical reactor or a reactor with fluidized bed. This method can not only increase the yield of ethylene and propylene, but also to some extent reduce the hydrothermal deactivation of the catalyst.

PRC Patent Application Publication No. CN1721510A discloses a process for producing light olefins and aromatics using catalytic cracking in two reaction zones, where different hourly volumes of oil per unit mass of catalyst are provided in the two reaction zones for the purpose of producing light olefins such as propylene and ethylene. , from heavy initial oil products to the maximum extent, and the output of propylene exceeds 20 wt. %, and the simultaneous production of aromatic compounds such as toluene and xylene.

US Patent Application Publication Nos. US2002003103A and US2002189973A disclose a fluid catalytic cracker (FCC) containing twin vertical reactors for improving propylene production, where gasoline (60-300°F/15-150°C) obtained from the reaction cracking, enters the second vertical reactor for subsequent reaction, and the catalyst is a mixture of a USY type molecular sieve catalyst and a ZSM-5 type molecular sieve catalyst.

US Patent Application Publication No. US2002195373A and International Patent Application Publication No. WO2017223310A disclose processes using a downflow reactor operating at high temperature (1020-1200°F/550-650°C), short contact time (less than 0 .5 seconds) and a high catalyst to oil ratio (15-25). The primary catalyst (Faujasite Type Y) exhibits low hydrogen transfer activity and is designed to maximize light olefin yields in combination with operating conditions. A high efficiency separator is used to separate the product from the catalyst within 0.1 second, thus minimizing secondary reactions and coke formation. In addition, light cycle oil (LCO) is used to quench the separated product gas to a temperature of approximately 930°F/500°C and to prevent further cracking.

US Patent No. US6538169A and US Patent Application Publication No. US2003121825A also disclose methods using a reaction-regeneration system consisting of two reaction zones and a common regenerator. In the first reaction zone, the heavy feedstock is cracked to produce light olefins or intermediates that can be converted to light olefins at high temperature and high catalyst to oil ratio. The second reaction zone is a second vertical reactor where the process conditions are more stringent and the yield of light components from the gasoline feedstock is increased. A configuration selective molecular sieve such as ZSM-5 is used to facilitate the conversion of gasoline to light olefins and suitable feedstocks include vacuum gas oil (VGO), heavy vacuum gas oil (HVGO) and hydrogenated gas oil.

PRC Patent Application Publication No. CN1403540A discloses a catalytic conversion process for the production of ethylene and propylene, which uses a reactor composed of a vertical reactor and a dense phase fluidized bed connected in series, a light feed material is introduced into the vertical reactor to carry out the reaction under highly stringent conditions, and the product reaction and covered with precipitated coke catalyst is sent to a fluidized bed for subsequent reaction under relatively mild conditions. This method can provide a relative increase in the total yield of ethylene, propylene and butene.

PRC Patent Application Publication No. CN102051213A discloses a catalytic cracking process which includes the steps of contacting a heavy feedstock with a catalyst in a first vertical reactor containing at least two cracking reaction zones, and contacting a light feedstock and a cracked heavy oil product with a catalyst in the second vertical reactor and the fluidized bed reactor for carrying out the cracking reaction. When used for catalytic cracking of heavy oils, this process can provide a high degree of conversion of heavy oils and a high yield of propylene, as well as a low yield of dry gas and coke.

The structural contradiction of the petrochemical industry is becoming more and more serious. On the one hand, significant problems are the overproduction of traditional petrochemicals and the contradiction between the supply and demand of final petroleum products. On the other hand, there is also a significant shortage of high-grade petrochemical feedstocks. Thus, the transformation of oil refining into the chemical industry represents an irresistible trend. Catalytic crackers, which serve as bridges between the oil refining and chemical industries, must withstand unprecedented pressure and testing. At present, the proportion of atmospheric distillation residue in blended petroleum products that feed catalytic cracking units is constantly increasing, and there is even a proposal to introduce vacuum distillation residue into the blended petroleum products. Current catalytic cracking technology typically uses vacuum gas oil or atmospheric distillation residue based on paraffinic hydrocarbons as the feedstock, while the most advanced catalytic cracking technology uses a reactor that consists of twin vertical reactors or a vertical reactor connected in series with a dense phase bed in high rigidity conditions, for the purpose of increasing the production of light olefins and/or light aromatics. The problem of high dry gas and coke yields inevitably arises when such a reactor is used to process residue-containing heavy oil mixtures. A reduction in coke yield can be achieved by using a downflow reactor, but the conversion rate in the reaction is relatively low and a specialized catalyst is required. As the feed becomes heavier, the demand for mixed feeds containing residual oil products for catalytic cracking units increases. In order to efficiently use the resources of low grade heavy oil products and meet the growing demand for chemical feedstocks such as light olefins and heavy aromatics, it becomes necessary to develop a catalytic cracking process for converting a feedstock containing low grade heavy oil products into high value-added products.

Brief summary of the present invention

The object of the present application is to provide, for the catalytic cracking of liquid petroleum products, a novel process, reactor and system which are particularly suitable for use in the production of light olefins such as ethylene and propylene from liquid petroleum feedstocks, in particular heavy petroleum feedstocks, by means of catalytic cracking. The catalytic cracking process, reactor and system has the advantages of low dry gas and coke yields, good product distribution, and high ethylene and propylene yields.

In order to solve the problem presented above, according to one aspect of the present application, a process for the catalytic cracking of liquid petroleum products is provided, including the step of contacting the initial liquid petroleum products, in particular, heavy initial petroleum products, in contact with a catalytic cracking catalyst for reaction in a reactor containing one or more fast fluidized reaction zones , wherein at least one of the fast fluidized reaction zones of the reactor is a fully dense phase reaction zone, and the axial solid fraction ε of the catalyst is controlled within the range of from about 0.1 to about 0.2 throughout the fully dense phase reaction zone.

According to another aspect of the present application, a reactor suitable for use in the catalytic cracking of liquid petroleum products, in particular heavy petroleum products, is provided, which consists of an optional preliminary riser section, a fully dense phase reaction zone, a transition section and an outlet zone located from the bottom up, and a fully dense phase reaction the zone is present in the form of a hollow column having an approximately circular cross-section with a constant diameter or a variable diameter, an open lower end and an open upper end, an optional preliminary riser section is in communication with the lower end of the fully dense phase reaction zone, the upper end of the fully dense phase reaction zone is in communicating with the outlet zone via a transition section, the optional pre-lift section and/or bottom section of the full dense phase reaction zone comprises at least one catalytic cracking catalyst inlet, and the optional pre-lift section and/or bottom section of the full dense phase reaction zone comprises at least one feed inlet,

wherein the cross-sectional diameter of the lower end of the fully dense phase reaction zone is greater than or is the same as the diameter of the optional pre-lift section and the cross-sectional diameter of the upper end of the fully dense phase reaction zone is greater than the diameter of the outlet zone, and the side wall of the fully dense phase reaction zone comprises one or more inlets for additional catalyst, each inlet independently located at a height within the range from more than 0% to about 90% of the total height of the fully dense phase reaction zone.

According to a further aspect of the present application, a system suitable for use in the catalytic cracking of liquid petroleum products, in particular heavy petroleum products, is provided, comprising a catalytic cracking reactor, a catalyst separating device, an optional reaction product separator and a regenerator,

wherein the catalytic cracking reactor comprises a catalyst inlet at the bottom, a feedstock inlet at the bottom, and an outlet at the top, the catalyst separating device comprises an inlet, a catalyst outlet, and an outlet of reaction products, an optional reaction product separator comprises an inlet of reaction products, an outlet of dry gas, an outlet liquefied petroleum gas, a naphtha outlet, a diesel fuel outlet and a catalyst slurry outlet, and the regenerator comprises a catalyst inlet and a catalyst outlet,

wherein the catalyst inlet of the catalytic cracking reactor is in fluid transfer communication with the regenerator catalyst outlet, the catalytic cracking reactor outlet is in fluid transfer communication with the inlet of the catalyst separating device, the outlet of the reaction products of the catalyst separating device is in transfer communication a fluid medium with an inlet of the reaction products of an optional separator of the reaction products, the catalyst outlet of the catalyst separating device is in communication with the possibility of transferring a fluid medium with the inlet of the catalyst of the regenerator,

moreover, the catalytic cracking reactor contains a reactor according to the present application.

Compared with the conventional liquid petroleum catalytic cracking process, the density of the catalyst in the reactor can be effectively increased by the presence of a completely dense-phase reaction zone, so that the ratio of the catalyst and liquid petroleum feedstock in the reactor during the reaction is greatly increased, and a relatively long residence time is obtained. hydrocarbon and catalyst, whereby sufficient contact and reaction can be achieved between the catalyst and the original liquid oil, in particular, low-grade heavy oil using the method, reactor and system according to the present application. As a result, the conversion reaction rate can be increased, the yield of light olefins and light aromatics can be increased, the required reaction temperature can be lowered, and at the same time, the production of dry gas and coke can be effectively reduced, so that product distribution and product quality are improved.

By applying the method, reactor and system of the present application, high value-added chemical raw materials can be obtained from cheap low-grade heavy oils in petrochemical plants to the maximum extent, an improved way of integrating oil refining and chemical technology in refineries can be provided, the problem can be solved shortage of petrochemical feedstocks, and the social and economic benefits of the petrochemical industry can be improved.

Other characteristics and advantages of the present application will be described in detail herein in the section "Detailed Disclosure of the Present Invention" below.

Brief description of the figures

The figures that form part of the present description are presented to aid understanding of the present application and should not be construed as limiting. The present application may be construed with reference to the figures in conjunction with the "Detailed Disclosure of the Present Invention" section below. Among the figures:

in fig. 1 is a schematic diagram of a preferred embodiment of the present application;

in fig. 2 is a schematic diagram of another preferred embodiment of the present application; And

in fig. 3-5 are schematic diagrams of several preferred embodiments of the reactor according to the present application.

Description of symbols

Detailed disclosure of the present invention

Hereinafter, the present application will be described in detail herein with reference to the respective specific embodiments and accompanying figures. It should be noted that specific embodiments of the present application are presented solely for the purpose of illustration, but are not intended to be limiting in any way.

Any specific numerical values, including the end points of the numerical range, which are described in the context of this application, are not limited to the corresponding exact values, but should be construed as further covering all values around the specified exact value, for example, all possible values within ± 5% from the exact value. In addition, with respect to any numerical range described herein, arbitrary combinations may be made between the end points of the range, between each end point and any particular value within the range, or between any two particular values within the range to produce one or more new numerical ranges, and these new numerical ranges should also be considered as specifically described in this application.

According to the present application, the term "fast fluidized reaction zone" means a reaction zone in which the catalyst particles are present in a fast fluidized state. The fast fluidized state is a bubble-free fluidized contact state of gaseous and solid phases, an important characteristic of which is that solid particles tend to move in clusters. When the catalyst is present in a fast fluidized state, the axial solids fraction ε of the catalyst in the reaction zone typically ranges from about 0.05 to about 0.4. However, in conventional fast fluidized beds, the catalyst is typically distributed in a rarefied to dense state from top to bottom, for example, the axial solids fraction ε of the catalyst at the top may range from about 0.05 to about 0.1, and the axial the solid fraction ε of the catalyst at the bottom can range from about 0.3 to about 0.4.

According to the present application, in a fast fluidized reaction zone, when the axial solids fraction ε of the catalyst is adjusted within the range from about 0.1 to about 0.2 from the bottom up (i.e., the axial solids fraction ε of the catalyst, measured in the upper, middle and lower parts of the reaction zone divided into equal parts in the axial direction, in each case are not less than about 0.1 and not more than about 0.2), the catalyst is distributed in a quasi-uniform fully dense phase manner throughout the rapid fluidized reaction zone. Under such circumstances, the fast fluidized reaction zone may be referred to by the term "totally dense phase reaction zone".

According to the present application, the term "mass ratio of water and oil" means the ratio of the total mass of steam introduced into the reactor, and the mass of the source material.

According to the present application, the terms "upstream" and "downstream" are used in relation to the direction of movement of the reaction stream. For example, when the reaction stream moves from bottom to top, the term "upstream" means a lower position, and the term "downstream" means a higher position.

Unless otherwise indicated, terms used herein have the meanings commonly understood by those skilled in the art; and if terms are defined herein and their definitions differ from the common understanding in the art, then the definitions provided herein shall prevail.

In the context of this application, other than items that are specified in a certain way, any item or items that are not mentioned, should be considered the same as items known in the art, without any change. In addition, any of the embodiments that are described herein may be freely combined with one or more other embodiments that are described herein, and the technical solutions or ideas resulting from this should be considered as part of the original disclosure. or the original description of the present application, but should not be considered as a new subject that was not described or predicted in this document, unless it is clear to specialists in the art that such a combination is obviously unreasonable.

All patent and non-patent documents cited herein, including, but not limited to, tutorials and scientific articles, are incorporated herein by reference in their entirety.

According to a first aspect of the present application, there is provided a process for the catalytic cracking of liquid petroleum products, comprising the step of contacting the feed liquid petroleum products, in particular heavy feedstocks, with a catalytic cracking catalyst for reaction in a reactor containing one or more fast fluidized reaction zones, wherein at least one of the fast fluidized reaction zones of the reactor is a full dense phase reaction zone, and the axial solids fraction ε of the catalyst is adjusted within the range of about 0.1 to about 0.2 throughout the full dense phase reaction zone.

According to the present application, by using a reactor containing a completely dense phase reaction zone, the distribution of the catalyst from rarefied to dense state in the reaction zone from top to bottom is prevented, and the actual ratio of catalyst to oil products is maintained at a stable level in the reaction zone from top to bottom, so that can be reduced the yield of dry gas and coke, and the yield of the desired product can be increased.

According to a preferred embodiment of the present application, the process is used to produce light olefins such as ethylene and propylene from heavy petroleum feedstocks, and the process further comprises the following steps:

i) contacting a heavy feed oil, such as a low grade heavy oil, with a catalytic cracking catalyst in a fully dense phase reactor reaction zone under effective conditions to produce light olefins, wherein the axial solids fraction ε of the catalyst is controlled within a range of about 0.1 to about 0.2 in the entire fully dense-phase reaction zone of the reactor;

ii) separating the reactor effluent to form a light olefin rich reaction product and a spent catalyst;

iii) regenerating the spent catalyst and recycling at least a portion of the resulting regenerated catalyst to step (i) as a catalytic cracking catalyst; And

iv) optionally separating the reaction products to produce dry gas, liquefied petroleum gas, naphtha, diesel fuel and catalyst slurry.

As used herein, the term "effective for the production of light olefins" means that at least a portion of the feedstock is subjected to efficient cracking, for example, deep catalytic cracking, in a fast fluidized bed to obtain light olefins, such as ethylene and propylene, as products, resulting in a product mixture enriched in light olefins.

As used herein, the expression "enriched in light olefins" means that the total content of light olefins (eg, ethylene and propylene) in the product or mixture of reaction products is more than about 10 wt. %, preferably more than about 15 wt. % and more preferably more than about 20 wt. % product mixture of reaction products.

According to a further preferred embodiment of the present application, the method further comprises the following steps:

i) contacting a preheated low-grade heavy oil product in a fully dense-phase reaction zone of the reactor with a catalytic cracking catalyst introduced into the reaction zone from below, and introducing it into the catalytic cracking reaction in the process of passing through the reaction zone from the bottom up, and the axial solid fraction ε of the catalyst in the entire fully dense-phase reaction zone is regulated in such a way as to satisfy the condition: 0.1 ≤ ε ≤ 0.2;

ii) separating the reactor effluent to form a light olefin rich reaction product and a spent catalyst;

iii) sending the spent catalyst to a regenerator for regeneration by burning off the coke and recycling at least a portion of the resulting regenerated catalyst to step (i) as a catalytic cracking catalyst; And

iv) separating the resulting reaction product to produce dry gas, liquefied petroleum gas, naphtha, diesel fuel and catalyst slurry.

In some embodiments, prior to said step (i) and/or after said step (ii), the process of the present application may further include one or more additional reaction steps, such as catalytic cracking and/or catalytic isomerization, carried out in other types of reaction zones, such as rarefied phase transport fluidized bed, dense phase fluidized bed, traditional fast fluidized bed, etc.

According to some other embodiments of the present application, the method does not include any additional reaction step before or after said step (i).

According to a preferred embodiment of the present application, the method further comprises introducing one or more additional catalyst streams into the fully dense phase reaction zone at a position downstream of the position at which the catalytic cracking catalyst is introduced into the fully dense phase reaction zone to contact an existing stream in a fully dense phase reaction zone. reaction zone for the catalytic cracking reaction.

According to the present application, the total amount of one or more streams of additional catalyst may be from approximately 0 to 50 wt. %, preferably from about 5 to 45 wt. %, preferably from about 10 to 40 wt. % with respect to the catalyst circulation rate in the reactor.

Preferably, the single or each of the multiple additional catalyst streams may independently have a carbon content of from about 0 to about 1.0 wt. %. For example, the single or multiple additional catalyst streams may be independently selected from reclaimed catalysts, spent catalysts, and semi-reclaimed catalysts, including reclaimed, spent, and semi-reclaimed catalytic cracking catalysts.

According to the present application, by introducing additional catalyst into a fully dense phase reaction zone, the ratio of catalyst to oil products can be controlled over a wider range and more active sites for the cracking reaction can be present. At the same time, by introducing an additional catalyst, the flexibility of controlling the reaction temperature can be increased, and it becomes possible to effectively control the temperature gradient and catalyst activity in the fully dense phase reaction zone. In addition, by introducing an additional catalyst into the fully dense-phase reaction zone, it is possible to maintain the highest possible density uniformity of the catalyst in the reaction zone, it becomes possible to effectively control the density distribution of the catalyst, so that the cracking reaction can be carried out completely and efficiently, and the selectivity of the desired product.

According to the present application, the catalytic cracking catalyst is generally introduced into the full dense phase reaction zone from below, for example, through the outlet end of the preliminary riser section into the lower section of the fully dense phase reaction zone. Typically, a single or each of multiple additional catalyst streams are independently introduced at a position spaced from the lower end of the fully dense phase reaction zone within a range of greater than 0% to about 90% of the respective overall height. Preferably, a single or multiple additional catalyst streams are independently introduced at a level of from about 20 to 80%, more preferably from about 30 to 75%, of the height of the fully dense phase reaction zone. The temperature of the additional catalyst may be adjusted according to the desired reaction temperature, for example, cold and/or hot regenerated catalyst may be introduced, or cold and/or hot spent catalyst may be introduced.

According to the present application, liquid oil feedstocks such as a heavy feedstock, in particular a low grade heavy oil product, may be introduced into the reactor entirely at one injection position, or they may be introduced into the reactor at two or more injection positions in the same or different proportions. . The feed nozzle may be located at the outlet end of the pre-lift section, or at a position in the pre-lift section less than or equal to about 1/3 of the height of the pre-lift section from its outlet end, or in the lower section of the fully dense phase reaction zone.

According to the present application, a low grade heavy oil product means a heavy oil product that is less suitable for use in catalytic cracking processing than traditional heavy oil products. For example, the properties of a low grade heavy oil product may satisfy at least one, including one, two, three, or four of the following criteria: density at 20°C is about 850 to 1000 kg/m ³ , preferably about 890 to 940 kg / m ³ ; the carbon residue is approximately from 2 to 10 wt. %, preferably from about 2 to 8 wt. %; the total nickel and vanadium content is from about 2 to 30 ppm, preferably from about 5 to 20 ppm; the characteristic factor K is less than about 12.1, preferably less than about 12.0. Carbon residue in a low grade heavy oil product is measured by the Conradson carbon residue test according to ASTM D-189.

For example, the low grade heavy oil may be heavy petroleum hydrocarbons and/or other mineral oils; heavy oil hydrocarbon may be selected from the group consisting of vacuum distillation residue (VR), low grade atmospheric distillation residue (AR), low grade hydrogenated residue, coking gas oil, deasphalted oil, vacuum gas oil having a high acid number crude oil having a high metal content crude oil and combinations thereof; wherein said other mineral oil may be selected from the group consisting of coal liquefaction oil, oil sand bitumen, shale oil, and combinations thereof.

The catalytic cracking catalyst used in the present invention is not particularly limited, and may be, for example, a variety of catalytic cracking catalysts known to those skilled in the art and suitable for producing light olefins from liquid petroleum feedstocks such as heavy feedstocks. According to a preferred embodiment, the catalytic cracking catalyst contains, based on the dry weight of the catalytic cracking catalyst, from about 1% to about 50%, preferably from about 5% to about 45%, more preferably from about 10% to about 40% by weight of zeolite, from about 5% to about 99%, preferably from about 10% to about 80%, more preferably from about 20% to about 70% by weight of inorganic oxide and from about 0% to about 70%, preferably from about 5% to about 60 %, preferably from about 10% to about 50% by weight of the clay; wherein the active zeolite may comprise a mesoporous zeolite and optionally a macroporous zeolite. Preferably, the mesoporous zeolite may be from about 0 to 50 wt. %, preferably from about 0 to 20 wt. % in relation to the total weight of the zeolite in terms of dry weight.

According to the present application, mesoporous and macroporous zeolites are zeolites that are well known in the art, i. the mesoporous zeolite has an average pore size of about 0.5 to 0.6 nm, and the macroporous zeolite has an average pore size of about 0.7 to 1.0 nm.

For example, the macroporous zeolite may be one or more zeolites selected from the group consisting of rare earth substituted Y (REY) zeolites, rare earth substituted H-Y (REHY) zeolites, ultrastable Y zeolites, and high silica zeolites of the Y type. Y obtained in various ways. The mesoporous zeolite may be selected from zeolites having an MFI structure such as ZSM zeolites and/or ZRP zeolites. Optionally, the mesoporous zeolite may be modified with a non-metallic element such as phosphorus and/or a transition metal element such as iron, cobalt, nickel. A more detailed description of ZRP zeolites can be found in US Pat. No. US5,232,675A. The ZSM zeolite is preferably a mixture of one or more zeolites selected from ZSM-5, ZSM-11, ZSM-12, ZSM-23, ZSM-35, ZSM-38, ZSM-48 and other zeolites having a similar structure. A more detailed description of ZSM-5 zeolites can be found in US Pat. No. US3,702,886A.

According to the present application, the inorganic oxide acting as a binder is preferably silicon dioxide (SiO ₂ ) and/or alumina (Al ₂ O ₃ ). The clay acting as the matrix (ie the carrier) is preferably kaolin and/or halloysite.

The catalytic cracking reaction conditions used according to the present invention are not strictly limited and may be, for example, conditions that are well known to those skilled in the art and suitable for producing light olefins from liquid petroleum feedstocks such as heavy feedstocks. According to a preferred embodiment, the catalytic cracking reaction in a fully dense phase reaction zone can be carried out under the following conditions: the reaction temperature (at the outlet) is from about 510 to 700°C, the reaction time is from about 1 to 20 seconds, the mass ratio of catalyst to oil is from about 3:1 to about 50:1, the weight ratio of water to oil is from about 0.03:1 to about 0.8:1, the density of the catalyst is from about 120 to 290 kg/m ³ , the vapor velocity is from about 0.8 to 2.5 m/s, the reaction pressure is about 130 to 450 kPa, and the mass velocity G _s of the catalyst flow is about 15 to 150 kg/(m ² s). More preferably, the reaction in a fully dense phase reaction zone can be carried out under the following conditions: the reaction temperature is from about 550 to 650°C, the reaction time is from about 3 to 15 seconds, the weight ratio of catalyst to oil is from about 10:1 to about 30: 1, the weight ratio of water to oil is from about 0.05:1 to about 0.5:1, the density of the catalyst is from about 150 to 250 kg/m ³ , the steam velocity is from about 1 to 1.8 m/s, and the mass flow rate G _s of the catalyst flow is about 20 to 130 kg/(m ² s).

According to the present application, the separation of the reaction product from the spent catalyst can be carried out in a manner known to those skilled in the art, for example, in a separator using a cyclone. The method of subsequent separation of the reaction products to obtain dry gas, liquefied petroleum gas, naphtha, diesel fuel and catalyst slurry is also well known to those skilled in the art. According to a preferred embodiment, the dry gas and LPG can then be separated using a separation device commonly used in the art to obtain the desired product such as ethylene, propylene, etc.

According to a preferred embodiment of the present application, the method further comprises introducing a C4 hydrocarbon cut and/or a C5-C6 light gasoline cut into the reactor at one or more positions for the catalytic cracking reaction. More preferably, at least a portion of said C4 hydrocarbon cut and/or C5-C6 light naphtha cut is introduced at a position upstream of the position at which the liquid oil feed, such as low grade heavy oil, is introduced into the reactor.

According to the present application, the term "C4 hydrocarbon fraction" means a light hydrocarbon fraction that is present in gaseous form at normal temperature and pressure and contains C4 hydrocarbons as a main component, including alkanes, alkenes and alkynes containing 4 carbon atoms in the molecule. This fraction may contain gaseous hydrocarbon products (for example, liquefied petroleum gas) obtained by the method according to this application and enriched in C4 hydrocarbon fraction, or gaseous hydrocarbons produced by other plants and enriched in C4 fraction, preferably C4 hydrocarbon fraction, obtained by the method according to this application. The C4 hydrocarbon fraction is preferably an olefin-rich C4 hydrocarbon fraction that may have a C4 olefin content of greater than about 50 wt. %, preferably more than about 60 wt. %, preferably more than about 70 wt. %.

According to the present application, the term "C5-C6 light gasoline fraction" means a component of gasoline containing 5 or 6 carbon atoms, which may contain gasoline obtained in the cracking reaction according to the method according to this application, and may also contain gasoline fractions produced by other installations, for example, at least one C5-C6 fraction selected from the group consisting of deep catalytic cracking gasoline, catalytic cracking gasoline, straight run gasoline, coking gasoline, thermal cracking gasoline and hydrogenated gasoline.

According to the present application, the spent catalyst can be regenerated using means well known to those skilled in the art, for example regenerated in a regenerator by burning coke. In particular, an oxygen-containing gas such as air may be introduced into the regenerator to contact the spent catalyst. The off-gas resulting from coke-burning regeneration can be separated from the catalyst in the regenerator and then sent to a downstream power recovery system.

According to some preferred embodiments of the present application, the regenerated catalyst resulting from regeneration by burning coke in the regenerator may be cooled to a temperature of about 600 to 680° C. in a catalyst cooler before being recycled to the reactor. Recirculation to the reactor after cooling the hot regenerated catalyst is advantageous for lowering the contact temperature of the oil and the catalyst, improving the contact state of the feed oil and the catalyst, and further reducing the dry gas and coke selectivity.

According to the second aspect of the present application, a reactor suitable for use in the catalytic cracking of liquid petroleum products, in particular, heavy initial petroleum products, which consists of an optional preliminary riser section, a fully dense phase reaction zone, a transition section and an outlet zone, located from the bottom up, is provided. the zone is present in the form of a hollow column having an approximately circular cross-section with a constant diameter or a variable diameter, an open lower end and an open upper end, an optional preliminary riser section is in communication with the lower end of the fully dense phase reaction zone, the upper end of the fully dense phase reaction zone is in communicating with the outlet zone via a transition section, the optional pre-lift section and/or bottom section of the full dense phase reaction zone comprises at least one catalytic cracking catalyst inlet, and the optional pre-lift section and/or bottom section of the full dense phase reaction zone comprises at least one feed inlet,

wherein the cross-sectional diameter of the lower end of the fully dense phase reaction zone is greater than or is the same as the diameter of the optional pre-lift section and the cross-sectional diameter of the upper end of the fully dense phase reaction zone is greater than the diameter of the outlet zone, and the side wall of the fully dense phase reaction zone comprises one or more additional catalyst inlets, each inlet independently located at a height within the range of greater than 0% to about 90%, preferably about 20 to 80%, more preferably about 30 to 75% of the total height of the fully dense phase reaction zone.

According to the present application, the preliminary riser section is optional, for example, when the reactor of the present application is used in series with one or more other reactors, such as vertical reactors, and a completely dense-phase reaction zone can be in direct communication with the upstream outlet of the reactor, without the need for a preliminary lifting section.

According to the present application, a fully dense-phase reaction zone may be present in the form of a hollow column having an approximately circular cross section with a constant diameter or a variable diameter, an open lower end and an open upper end, such as a hollow cylinder with a constant diameter or a hollow column whose diameter is continuous or incrementally increases from bottom to top.

According to the present application, the expression "diameter continuously increases" means that the diameter increases continuously in a linear or non-linear manner. An inverted hollow truncated cone can be mentioned as an example of "a hollow column whose diameter increases continuously from bottom to top".

According to the present application, the expression "diameter discontinuously increases" means that the diameter increases in a discontinuous manner, for example, increases in a stepped manner. As an example of a "hollow column whose diameter increases in a discontinuous manner from bottom to top", there may be mentioned a hollow column that consists of two or more cylindrical sections with successively increasing diameters.

For example, a fully dense-phase reaction zone may be in the form of a hollow cylinder, an inverted hollow truncated cone, a hollow column consisting of two or more cylindrical sections with successively increasing diameters, a hollow column consisting of two or more sections of inverted truncated cones with successively increasing diameters, or a hollow column consisting of one or more cylindrical sections and one or more sections of inverted truncated cones.

In some preferred embodiments, the bottom section of the fully dense phase reaction zone contains a catalyst distributor plate.

According to a preferred embodiment, the diameter of the pre-lift section is from about 0.2 to 5 meters, preferably from about 0.4 to 4 meters, more preferably from about 0.6 to 3 meters; the ratio of its height to the overall height of the reactor is from about 0.01:1 to about 0.2:1, preferably from about 0.03:1 to about 0.18:1, more preferably from about 0.05:1 to about 0 ,15:1.

In a preferred embodiment, the ratio of the diameter of the maximum cross section of the fully dense phase reaction zone to the overall height of the reactor is from about 0.005:1 to about 1:1, preferably from about 0.01:1 to about 0.8:1, more preferably from about 0, 05:1 to about 0.5:1; the ratio of the height of the fully dense phase reaction zone to the total height of the reactor is from about 0.1:1 to about 0.9:1, preferably from about 0.15:1 to about 0.8:1, more preferably from about 0.2:1 up to about 0.75:1.

In some preferred embodiments, the fully dense-phase reaction zone is in the form of an inverted hollow truncated cone with an isosceles trapezoid longitudinal section that has a lower cross-sectional diameter of about 0.2 to 10 meters, preferably about 0.5 to 8 meters. , preferably about 1 to 5 meters; the ratio of the diameter of the upper cross section and the diameter of the lower cross section is from more than 1 to about 50, preferably from about 1.2 to about 10, more preferably from about 1.5 to about 5; the ratio of the diameter of the maximum cross section to the overall height of the reactor is from about 0.005:1 to about 1:1, preferably from about 0.01:1 to about 0.8:1, more preferably from about 0.05:1 to about 0.5 :1; the ratio of the height of the fully dense phase reaction zone to the total height of the reactor is from about 0.1:1 to about 0.9:1, preferably from about 0.15:1 to about 0.8:1, more preferably from about 0.2:1 up to about 0.75:1.

According to some other preferred embodiments, the fully dense-phase reaction zone is in the form of a hollow column, which consists of an inverted truncated cone section and a cylindrical section, with the truncated cone preferably located below the cylinder, while the truncated cone has a longitudinal section in the form of an isosceles trapezoid, in which the diameter of the lower cross section is about 0.2 to 10 meters, preferably about 0.5 to 8 meters, more preferably about 1 to 5 meters; and the ratio of the diameter of the upper cross section and the diameter of the lower cross section is from more than 1 to about 50, preferably from about 1.2 to about 10, more preferably from about 1.5 to about 5; the diameter of the cylinder is approximately the same as the diameter of the upper cross-section of the frustum, and the ratio of the height of the cylinder to the height of the frustum is from about 0.4:1 to about 2.5:1, preferably from about 0.8:1 to about 1 .5:1; the ratio of the diameter of the maximum cross section of the fully dense phase reaction zone to the overall height of the reactor is from about 0.005:1 to about 1:1, preferably from about 0.01:1 to about 0.8:1, more preferably from about 0.05:1 to about 0.5:1; the ratio of the height of the fully dense phase reaction zone to the total height of the reactor is from about 0.1:1 to about 0.9:1, preferably from about 0.15:1 to about 0.8:1, more preferably from about 0.2:1 up to about 0.75:1.

In other preferred embodiments, the fully dense phase reaction zone is in the form of a hollow cylinder having a diameter of about 0.2 to 10 meters, preferably about 1 to 5 meters; the ratio of the diameter of the fully dense phase reaction zone to the total height of the reactor is from about 0.005:1 to about 1:1, preferably from about 0.01:1 to about 0.8:1, more preferably from about 0.05:1 to about 0, 5:1; the ratio of the height of the fully dense phase reaction zone to the total height of the reactor is from about 0.1:1 to about 0.9:1, preferably from about 0.15:1 to about 0.8:1, more preferably from about 0.2:1 up to about 0.75:1. Preferably, the fully dense phase reaction zone comprises a catalyst distribution plate at the bottom.

In a preferred embodiment, the fully dense phase reaction zone has a height of about 2 to 50 meters, preferably about 5 to 40 meters, and more preferably about 8 to 20 meters.

According to the present application, the catalyst distributor plate may be present in a position where the catalytic cracking catalyst is introduced into the lower section of the fully dense phase reaction zone, for example, at the outlet end of the pre-lift section.

According to the present application, the catalyst distributor plate may be any type of distributor plate that is commonly used in the industry, such as one or more flat, arcuate, cupped, annular and umbrella shaped plates. The use of a catalyst distributor plate is advantageous because it allows the catalyst to come into contact with the feed oil at a uniform concentration along the axial direction of the fully dense-phase reaction zone for the catalytic cracking reaction, thereby reducing the formation of vented coke and coke from thermal reaction due to excessively high or excessive low catalyst concentration.

In a preferred embodiment, the ratio of the height of the transition section to the overall height of the reactor is from about 0.01:1 to about 0.1:1, preferably from about 0.02:1 to about 0.05:1. Preferably, the transition section is in the form of a hollow truncated cone with a longitudinal section in the form of an isosceles trapezoid with sides having an internal inclination angle a of about 25 to 85°, preferably about 30 to 75°.

According to a preferred embodiment, the outlet zone has a diameter of about 0.2 to 5 meters, preferably about 0.4 to 4 meters, more preferably about 0.6 to 3 meters, and a ratio of its height to the overall reactor height of about 0.05:1 to about 0.2:1, preferably about 0.08:1 to about 0.18:1, more preferably about 0.1:1 to about 0.15:1, outlet end of outlet zone may be open or may be directly connected to the cyclone inlet.

In some embodiments, the reactor of the present application may further comprise one or more reaction zones having other forms, such as a rarefied phase transport fluidized bed, a dense phase fluidized bed, a traditional fast fluidized bed, etc., located relatively completely upstream. dense phase reaction zone (eg, between the optional pre-lift section and the fully dense phase reaction zone), and/or downstream of the fully dense phase reaction zone (eg, between the transition section and the outlet zone).

According to some other embodiments of the present application, the reactor does not have any additional reaction zone upstream of or downstream of the fully dense phase reaction zone.

According to the present application, the reactor may contain one or more, for example, one, two or more inlets of the source material, each of which may independently be located at the outlet end of the preliminary riser section, in the preliminary riser section at a distance from its outlet end, which is less than or equal to approximately 1/3 of the height of the pre-lift section, or in the lower section of the fully dense phase reaction zone.

Optionally, when a feed inlet is present in the bottom section of the fully dense phase reaction zone, a gas distributor may be present at the feed inlet.

A third aspect of the present application also provides a system suitable for use in the catalytic cracking of liquid petroleum products, in particular heavy crude oils, and comprising a catalytic cracking reactor, a catalyst separating device, an optional reaction product separator and a regenerator,

wherein the catalytic cracking reactor comprises a catalyst inlet in the lower part, a feedstock inlet in the lower part and an outlet in the upper part, a catalyst separating device contains an inlet, a catalyst outlet and an outlet of reaction products, an optional reaction product separator contains an inlet of reaction products, an outlet of dry gas, liquefied petroleum gas outlet, naphtha outlet, diesel fuel outlet and catalyst slurry outlet, and the regenerator comprises a catalyst inlet and a catalyst outlet,

the catalytic cracking reactor inlet is in fluid transfer communication with the regenerator catalyst outlet, the catalytic cracking reactor outlet is in fluid transfer communication with the catalyst separating device inlet, the catalyst separating device reaction product outlet is in fluid transfer capability communication with the reaction products inlet of an optional reaction product separator, and the catalyst outlet of the catalyst separating device is in fluid communication with the catalyst inlet of the regenerator.

According to a preferred embodiment, the catalytic cracking reactor comprises a reactor according to the present application.

According to some additional preferred embodiments, the catalytic cracking reactor further comprises one or more reactors having other shapes and connected in series and/or in parallel with the reactor according to the present application, such as a fluidized bed with transport in rarefied phase, dense phase fluidized bed, traditional fast fluidized bed etc.

According to other additional preferred embodiments, the catalytic cracking reactor consists of the reactor according to the present application.

According to some embodiments of the present application, the catalytic cracking reactor used may be located coaxially with the separator, or it may be located in parallel with the separator.

According to the present application, the catalyst separating device and the reaction product separator can be any device known to those skilled in the art. For example, the catalyst separating device may include a cyclone, separator, stripper, etc., and the reaction product separator may be a fractionator, etc.

The present application will be further described with the presentation of preferred embodiments, which are illustrated in the figures, but the present application is not limited to them.

In FIG. 1 shows a preferred embodiment of the present application, according to which the pre-lift medium enters the bottom of the pre-lift section 1 of the catalytic cracking reactor through the pre-lift medium conduit 8, which may be dry gas, steam, or a mixture thereof. The regenerated catalyst from the regenerated catalyst riser 5 enters the lower part of the pre-lift section 1 and moves upward by the lifting action of the pre-lift medium. The low grade heavy oil product enters the top of the preliminary lift section 1 through the feed line 9, mixes and contacts the material in the catalytic cracking reactor, and then enters the catalytic cracking reaction while passing through the reactor from bottom to top. One or more additional catalyst streams enter the full dense phase reaction zone 2 via auxiliary conduit 6 and/or auxiliary conduit 7 and come into contact with streams in the fully dense phase reaction zone to carry out the catalytic cracking reaction. The position of the auxiliary conduit 6 and the auxiliary conduit 7 are in each case independently at a height within the range of more than 0% to about 90%, preferably about 20 to 80%, more preferably about 30 to 75% of the total height of the fully dense phase reaction zone. The reaction product and the deactivated catalyst generated during the reaction enter the cyclone 11 in the separator 10 through the transition section 3 and the outlet zone 4, so that the spent catalyst and the reaction product are separated. The separated reaction product enters the pressure chamber 12, and the steam from the reactor in the pressure chamber 12 enters the subsequent reaction product separation system (not shown) through the reactor steam line 13. The separator 10 enters the stripper 14. After the stripper, the spent catalyst enters the regenerator 16 through the vertical spent catalyst pipeline 15, and the air enters the regenerator 16 after being distributed by the air distributor 17 to burn coke on the spent catalyst in a dense bed at the bottom of the regenerator 16, thus that the deactivated catalyst is regenerated to form a regenerated catalyst. The regenerated catalyst is recycled to the pre-lift section 1 through the regenerated catalyst riser 5, and the exhaust gas enters the downstream power recovery system (not shown) through the exhaust gas pipeline 18.

In FIG. 2 shows another preferred embodiment of the present application which is substantially the same as the embodiment shown in FIG. 1, except that a heat exchanger (also referred to as a catalyst cooler) is present on the regenerated catalyst riser 5 for the purpose of cooling the regenerated catalyst; at the same time, the low grade heavy oil product enters the upper part of the preliminary lifting section 1 and/or the lower section of the fully dense phase reaction zone 2 through the supply pipeline 9.

In FIG. 3 shows a preferred embodiment of the reactor according to the present application, according to which the reactor consists of bottom-up preliminary riser section 1, a fully dense phase reaction zone 2, a transition section 3 and an outlet zone 4. A fully dense phase reaction zone 2 is present in the form of an inverted hollow truncated cone with a longitudinal section in the form of an isosceles trapezoid. The transition section 3 is in the form of a hollow truncated cone with a longitudinal section in the form of an isosceles trapezoid with sides having an internal inclination angle a of approximately 25 to 85°, preferably approximately 30 to 75°. The bottom of the pre-lift section 1 contains a catalytic cracking catalyst inlet, and the top of the pre-lift section 1 and/or the bottom section of the fully dense phase reaction zone 2 contains a feed inlet. The cross-sectional diameter of the lower end of the fully dense phase reaction zone is greater than the diameter of the pre-lift section, and the cross-sectional diameter of the upper end of the fully dense phase reaction zone is greater than the diameter of the outlet zone. The side wall of the fully dense-phase reaction zone contains one or more, for example, one, two or more additional catalyst inlets, such as additional catalyst inlets for auxiliary pipeline 6 or auxiliary pipeline 7. A single or each of several additional catalyst inlets is independently located at a height within the range from more than 0% to about 90%, preferably from about 20 to 80%, more preferably from about 30 to 75%, relative to the full height of the fully dense phase reaction zone.

In FIG. 4 shows another preferred embodiment of the reactor according to the present application, in which the reactor consists of bottom-up preliminary riser section 1, a fully dense phase reaction zone 2, a transition section 3 and an outlet zone 4. The fully dense phase reaction zone 2 is present in the form of a hollow column, which is an inverted truncated cone section and a cylindrical section from bottom to top. The transition section 3 is in the form of a hollow truncated cone with a longitudinal section in the form of an isosceles trapezoid with sides having an internal inclination angle a of approximately 25 to 85°, preferably approximately 30 to 75°. The bottom of the pre-lift section 1 contains a catalytic cracking catalyst inlet, and the top of the pre-lift section 1 and/or the bottom section of the fully dense phase reaction zone 2 contains a feed inlet. The cross-sectional diameter of the lower end of the fully dense phase reaction zone is greater than the diameter of the pre-lift section, and the cross-sectional diameter of the upper end of the fully dense phase reaction zone is greater than the diameter of the outlet zone. The side wall of the fully dense-phase reaction zone contains one or more, for example one, two or more, additional catalyst inlets, such as additional catalyst inlets for auxiliary pipeline 6 or auxiliary pipeline 7. A single or each of several additional catalyst inlets is independently located at a height of within a range of more than 0% to about 90%, preferably about 20 to 80%, more preferably about 30 to 75% of the total height of the fully dense phase reaction zone, and each can be independently located in a truncated cone section or a cylindrical section fully dense-phase reaction zone.

In FIG. 5 shows a further preferred embodiment of the reactor according to the present application, in which the reactor is constituted from bottom to top by a preliminary riser section 1, a fully dense phase reaction zone 2, a transition section 3 and an outlet zone 4. The fully dense phase reaction zone 2 is present in the form of a hollow column. The transition section 3 is in the form of a hollow truncated cone with a longitudinal section in the form of an isosceles trapezoid with sides having an internal inclination angle a of approximately 25 to 85°, preferably approximately 30 to 75°. The bottom of the pre-lift section 1 contains a catalytic cracking catalyst inlet, and the top of the pre-lift section 1 and/or the bottom section of the fully dense phase reaction zone 2 contains a feed inlet. The catalyst distributor is present at the outlet of the pre-lift section in the lower section of the full dense phase reaction zone 2. The diameter of the full dense phase reaction zone is greater than the diameter of the pre-lift section and the outlet zone. The side wall of the fully dense-phase reaction zone contains one or more, for example one, two or more, additional catalyst inlets, such as additional catalyst inlets for auxiliary pipeline 6. A single or each of several additional catalyst inlets is independently located at a height within a range of more than 0% to about 90%, preferably from about 20% to 80%, more preferably from about 30% to 75%, relative to the full height of the fully dense phase reaction zone.

According to some preferred embodiments, the following technical solutions are proposed in this application:

1. The method of catalytic cracking using a fast fluidized bed, including the following stages:

i) bringing the preheated low grade heavy oil into the fast fluidized bed from the bottom into contact with the catalytic cracking catalyst and introducing it into the catalytic cracking reaction in an upward flow process to obtain a reaction product and a spent catalyst; moreover, the catalyst in the fast fluidized bed is distributed in a completely dense-phase manner, and the distribution of the axial solid fraction ε in the fast fluidized bed satisfies the condition: 0.1 ≤ ε ≤ 0.2;

ii) separating the resulting reaction product to produce dry gas, liquefied petroleum gas, gasoline, diesel fuel and a catalyst slurry; And

iv) sending the spent catalyst to a regenerator for regeneration by coke burnout and recycling the resulting regenerated catalyst to the bottom of the fast fluidized bed as a catalytic cracking catalyst.

2. The method according to claim 1, in which the properties of low-grade heavy oil satisfy one, two, three or four of the following criteria: density at 20°C is from 900 to 1000 kg/m ³ , carbon residue is from 2 to 10 wt. %, the total content of nickel and vanadium is from 2 to 30 ppm, and the value of the characteristic factor K is less than 12.1.

3. The method according to claim 1, in which the properties of low-grade heavy oil satisfy one, two, three or four of the following criteria: density at 20°C is from 910 to 940 kg/m ³ , carbon residue is from 3 to 8 wt. %, the total content of nickel and vanadium is from 5 to 20 ppm, and the value of the characteristic factor K is less than 12.0.

4. The method according to paragraph 1, in which the low-grade heavy oil product is a heavy petroleum hydrocarbons and/or other mineral oils;

wherein the heavy petroleum hydrocarbon is one or more materials selected as vacuum distillation residue, low grade atmospheric distillation residue, low grade hydrogenated residue, coking gas oil, deasphalted oil, vacuum gas oil, high acid number crude oil, and high content crude oil, and said other mineral oil is one or more of coal liquefaction oil, oil sand bitumen and shale oil.

5. The method according to paragraph 1, in which the catalytic cracking catalyst contains, in relation to the dry weight of the catalytic cracking catalyst, from 1 to 50 wt. % zeolite, from 5 to 99 wt. % inorganic oxide and from 0 to 70 wt. % clay;

wherein the zeolite contains a mesoporous zeolite, which is a ZSM zeolite and/or a ZRP zeolite, and optionally a macroporous zeolite, which is one or more zeolites, which are Y-type zeolite substituted with rare earth elements, H-Y type zeolite substituted with rare earth elements, ultra-stable zeolite type Y and a high silica content type Y zeolite.

6. The method according to paragraph 5, in which the mesoporous zeolite is from 0 to 50 wt. % relative to the total weight of the zeolite in terms of dry weight.

7. The method according to paragraph 5, in which the mesoporous zeolite is from 0 to 20 wt. % relative to the total weight of the zeolite in terms of dry weight.

8. The method according to claim 1, wherein the catalytic cracking reaction is carried out under the following conditions: the reaction temperature is from 510 to 650°C, the reaction time is from 1 to 20 seconds, the mass ratio of catalyst and oil is from 3:1 to 50:1 , the mass ratio of water and oil is from 0.03:1 to 0.8:1, the density of the catalyst is from 120 to 290 kg/m ³ , the steam velocity is from 0.8 to 2.5 m/s, the reaction pressure is from 130 to 450 kPa, and the mass flow rate G _s of the catalyst flow is from 15 to 150 kg/(m ² s).

9. The method according to claim 1, wherein the catalytic cracking reaction is carried out under the following conditions: the reaction temperature is from 550 to 620°C, the reaction time is from 3 to 15 seconds, the mass ratio of catalyst and oil is from 10:1 to 30:1 , the mass ratio of water and oil is from 0.05:1 to 0.5:1, the density of the catalyst is from 150 to 250 kg/m ³ , the vapor velocity is from 1 to 1.8 m/s, and the mass velocity G _s the catalyst flow is from 20 to 130 kg/(m ² s).

10. The process of claim 1, further comprising introducing a C4 hydrocarbon cut and/or a C5-C6 light gasoline cut to the fast fluidized bed for the catalytic cracking reaction.

11. The method of claim 10, wherein the C4 hydrocarbon cut and/or the C5-C6 light naphtha cut is introduced before the position where the low grade heavy oil product is introduced into the fast fluidized bed.

12. The method of claim 1, further comprising adding an additional catalyst to the fast fluidized bed for carrying out the catalytic cracking reaction together with a low grade heavy oil product and a catalytic cracking catalyst; while in which the carbon content of the additional catalyst is from 0 to 1.0 wt. %.

13. The method according to paragraph 12, in which the additional catalyst is from 0 to 50 wt. % circulation rate of the fast fluidized bed catalyst.

14. The method according to paragraph 12, in which the additional catalyst is from 5 to 30 wt. % circulation rate of the fast fluidized bed catalyst.

15. The method of claim 12, wherein the additional catalyst is introduced into the fast fluidized bed at a position at a distance from the bottom of the fast fluidized bed between 0 and 2/3 of the full height of the fast fluidized bed.

16. The method according to claim 1, wherein the regenerated catalyst obtained by regeneration in the regenerator by burning coke is cooled to a temperature of 600 to 680°C in a cooler and then recycled to the bottom of the fast fluidized bed.

17. A catalytic cracking system comprising a fast fluidized bed, a catalyst separating device, a reaction product separator and a regenerator;

At the same time, the fast fluidized bed contains a catalyst inlet in the lower part, an inlet of a low-grade heavy oil product in the lower part and an outlet in the upper part, a catalyst separating device contains an inlet, a catalyst outlet and an outlet of reaction products, a reaction product separator contains an inlet of reaction products, an outlet of dry gas, an LPG outlet, a gasoline outlet, a diesel fuel outlet, and a catalyst slurry outlet, and the regenerator comprises a catalyst inlet and a catalyst outlet;

the fast fluidized bed catalyst inlet is in fluid transfer capability communication with the regenerator catalyst outlet, the fast fluidized bed outlet is in fluid transfer capability communication with the catalyst separating device inlet, the catalyst separating device reaction product outlet is in fluid transfer capability communication with the reaction product inlet of the reaction product separator, and the catalyst outlet of the catalyst separating device is in fluid communication with the catalyst inlet of the regenerator.

The definition and calculation of each parameter in the present application is carried out as follows:

(1) Axial catalyst solids ε = pressure difference between two positions in the reaction zone along the axial direction, measured by a pressure difference sensor / distance between two positions along the axial direction / catalyst particle density;

where the pressure drop is expressed in kg/m ² , the distance between two positions along the axial direction is expressed in meters (m), and the density of the catalyst particles is expressed in kg/m ³ .

Catalyst particle density = theoretical density / (catalyst pore volume × theoretical density + 1),

where the theoretical density is expressed in kg/m ³ and the pore volume of the catalyst is expressed in m ³ and the theoretical density and pore volume of the catalyst are determined by the methods of pycnometric study and water titration, respectively.

(2) Reaction time = volume of the reaction zone / average logarithmic volume flow rate of the vapor of the petroleum product;

where the volume of the reaction zone is expressed in m ³ and the average logarithmic volumetric flow rate of the vapor of the petroleum product is expressed in m ³ /s.

Average logarithmic volume flow rate of oil vapor = (V _out - V _in ) / 1n(V _out /V _in ),

where V _out and V _in are the volumetric flow rates of vapor oil at the outlet and inlet of the reaction zone, respectively;

the volumetric flow rate of the vapor of the oil product at the outlet of the reaction zone V _out = m/ρ ₃ ;

the volume flow rate of the vapor of the oil product at the inlet of the reaction zone V _in = m/ρ ₄ ;

where m is the input mass of the original oil and atomizing steam per unit time, expressed in kg/s; ρ ₃ is the oil vapor density at the outlet of the reaction zone, expressed in kg/m ³ ; ρ ₄ is the oil vapor density at the inlet of the reaction zone, expressed in kg/m ³ .

(3) Catalyst density in the reaction zone (or its top, middle, or bottom) = pressure difference between two positions in the reaction zone (or its top, middle, or bottom) along the axial direction, measured by a differential pressure transducer / distance between the two positions along the axial direction;

where the pressure drop is expressed in kg/m ² , the reaction zone is divided into three equal parts, representing the upper part, the middle part and the lower part, along the axial direction, and the distance between the two positions along the axial direction is expressed in meters (m).

(4) Vapor velocity = average logarithmic volumetric vapor flow rate of the oil product / cross-sectional area of the reaction zone;

when the reaction zone is non-cylindrical, the vapor velocity means the average logarithmic value of the vapor velocity at the bottom of the reaction zone and the vapor velocity at the top of the reaction zone.

(5) Catalyst mass flow rate G _s = reactor catalyst circulation rate / cross-sectional area of the reaction zone;

when the reaction zone has a non-cylindrical shape, the mass flow rate G _{s of} the catalyst flow means the average logarithmic value of G _s at the bottom of the reaction zone and G _s at the top of the reaction zone;

where the catalyst circulation rate is expressed in kg/s;

reactor catalyst circulation rate = coke formation rate / (carbon content of spent catalyst - carbon content of regenerated catalyst);

where the rate of formation of coke is expressed in kg/s, and the carbon content of the spent catalyst and the carbon content of the regenerated catalyst are mass content;

coke formation rate = amount of off-gas / (CO ₂ % + CO%)/V _m ×M;

where V _m is the molar volume of the gas, which is 22.4×10 ^-3 m ³ /mol, and M is the molar mass of the element carbon, which is 12×10 ^-3 kg/mol;

exhaust gas quantity = (air velocity × 79% vol.%) / (1 - CO ₂ % - CO% - O ₂ %);

where the air velocity is expressed in m ³ /s, the amount of exhaust gas is expressed in m ³ /s, and CO ₂ %, CO% and O ₂ % represent the volume percentage of CO ₂ , CO and O ₂ in the exhaust gas, respectively.

Examples

The present application will be further illustrated by presenting the following examples, but the present application is not limited to them.

All starting oils used in the following examples and comparative examples are hydrogenated residue, the properties of which are shown in Table 1. The catalyst used is an industrial catalytic cracking catalyst, which was purchased under the trade name DMMC-2 from a catalyst subsidiary of Sinopec Co., Ltd. .

Example 1

This example was carried out in accordance with the process flow diagram shown in FIG. 1 in a medium size plant using a hydrogenated residue as the feed oil, a DMMC-2 catalyst as the catalyst, and a full dense phase catalytic cracking reactor as the reactor. The preheated feed oil was contacted with a catalytic cracking catalyst in a catalytic cracking reactor for the catalytic cracking reaction, with the hot regenerated catalyst stream (with a carbon content of 0.05 wt %) being introduced into the fully dense phase reaction zone at 60% full height completely dense-phase reaction zone, and the additional catalyst was 15 wt. % catalyst circulation rate in the reactor. The distribution of the catalyst in the fully dense phase reaction zone was set in the fully dense phase configuration such that the axial solids fraction ε of the catalyst in the fully dense phase reaction zone ranged from 0.1 to 0.2 from bottom to top. The reactor effluent was passed into a closed cyclone where the reaction product and the spent catalyst were quickly separated, and the reaction product was further separated in a product separation system according to the distillation range. The spent catalyst was passed into the stripper by gravity, the hydrocarbon vapors that were adsorbed on the spent catalyst were separated by steam stripping, the stripper-cleaned catalyst was directly passed into the regenerator without heat exchange, and brought into contact with air for regeneration by coke burning, and the regenerated catalyst was recycled into the reactor for reuse. The process conditions used and the distribution of products are shown in Table 2.

As can be seen in Table 2, in this example, the ethylene yield is 5.2 wt. %, the yield of propylene is 21.1 wt. %, the yield of light aromatic compounds is 11.3 wt. %, and the yields of dry gas and coke are 10.2 wt. % and 8.0 wt. %, respectively.

Example 2

This example was carried out in accordance with the process flow diagram shown in FIG. 1 in a medium size plant using a hydrogenated residue as the feed oil, a DMMC-2 catalyst as the catalyst, and a full dense phase catalytic cracking reactor as the reactor. The preheated feed oil was contacted with a catalytic cracking catalyst in a catalytic cracking reactor for the catalytic cracking reaction, with the hot regenerated catalyst stream (with a carbon content of 0.05 wt %) being introduced into the fully dense phase reaction zone at 60% full height completely dense-phase reaction zone, and the additional catalyst was 15 wt. % catalyst circulation rate in the reactor. The distribution of the catalyst in the fully dense phase reaction zone was set in the fully dense phase configuration such that the axial solids fraction ε of the catalyst in the fully dense phase reaction zone ranged from 0.1 to 0.2 from bottom to top. The reactor effluent was passed into a closed cyclone where the reaction product and the spent catalyst were quickly separated, and the reaction product was further separated in a product separation system according to the distillation range. The spent catalyst was passed into the stripper by gravity, the hydrocarbon vapors that were adsorbed on the spent catalyst were separated by steam stripping, the stripper-cleaned catalyst was directly passed into the regenerator without heat exchange, and brought into contact with air for regeneration by coke burning, and the regenerated catalyst was recycled into the reactor for reuse. The mixed fraction C4 obtained after separation of the reaction products was recycled to the lower section of the fully dense phase reaction zone for the subsequent reaction. The process conditions used and the distribution of products are shown in Table 2.

As can be seen in Table 2, in this example, the ethylene yield is 5.7 wt. %, the yield of propylene is 21.0 wt. %, the yield of light aromatic compounds is 11.5 wt. %, and the yields of dry gas and coke are 10.3 wt. % and 8.1 wt. %, respectively.

Comparative Example 1

The study was carried out in a medium size plant using a hydrogenated residue as the feed oil, a DMMC-2 catalyst as a catalyst, and a combined reactor containing a vertical reactor and a fluidized bed connected in series as a reactor. The preheated feed oil was introduced into the bottom of the vertical reactor to contact the catalyst for the catalytic cracking reaction. The resulting reaction vaporous hydrocarbons, steam and spent catalyst were passed into the dense phase fluidized bed reactor through the outlet of the vertical reactor for subsequent reaction. The reactor effluent was passed into a closed cyclone where the reaction product and the spent catalyst were quickly separated, and the reaction product was further separated in a product separation system according to the distillation range. The spent catalyst was passed into the stripper by gravity, the hydrocarbon vapors that were adsorbed on the spent catalyst were separated by steam stripping, the catalyst purified in the stripper was directly passed into the regenerator without heat exchange and brought into contact with air for regeneration by coke burning, and the regenerated catalyst ( 705°C) was recycled to the vertical reactor for reuse. The process conditions used and the distribution of products are shown in Table 2.

As can be seen in Table 2, in this comparative example, the yield of ethylene is 3.7 wt. %, the yield of propylene is 12.8 wt. %, the yield of light aromatic compounds is 5.5 wt. %, and the yields of dry gas and coke are 12.9 wt. % and 13.3 wt. %, respectively.

Comparative Example 2

Comparative Example 2 was essentially the same as Example 1, except that no additional catalyst was introduced into the fully dense phase reaction zone, and the axial solid fraction ε of the catalyst in the fully dense phase reaction zone exhibited a gradient of 0.1 → 0.2 → 0 ,3 from top to bottom. The process conditions used were the same as in Example 1 and the product distribution is shown in Table 2.

Example 3

This example was carried out according to the process flow diagram of FIG. 1 in a medium size plant using a hydrogenated residue as the feed oil, a DMMC-2 catalyst as a catalyst, and a fully dense phase catalytic cracking reactor as a reactor. The preheated feed oil was introduced into the catalytic cracking reactor to contact the catalytic cracking catalyst for the catalytic cracking reaction, with two additional catalyst streams being introduced into the fully dense phase reaction zone, with one stream of hot regenerated catalyst (with a carbon content of 0.05 wt.%) was introduced at a height of 70% of the total height of a completely dense-phase reaction zone in an amount of 13 wt. % catalyst circulation rate in the reactor; and another spent catalyst stream (with a carbon content of 0.9 wt. %) was introduced at the level of 50% of the full height of the fully dense-phase reaction zone in an amount of 3 wt. % catalyst circulation rate in the reactor. The distribution of the catalyst in the fully dense phase reaction zone was set in the fully dense phase configuration such that the axial solids fraction ε of the catalyst in the fully dense phase reaction zone ranged from 0.1 to 0.2 from bottom to top. The reactor effluent was passed into a closed cyclone where the reaction product and the spent catalyst were quickly separated, and the reaction product was further separated in a product separation system according to the distillation range. The spent catalyst was passed into the stripper by gravity, the hydrocarbon vapors that were adsorbed on the spent catalyst were separated by steam stripping, the stripper-cleaned catalyst was directly passed into the regenerator without heat exchange, and brought into contact with air for regeneration by coke burning, and the regenerated catalyst was recycled into the reactor for reuse. The process conditions used and the distribution of products are shown in Table 3.

As can be seen in Table 3, in this example, the ethylene yield is 5.3 wt. %, the yield of propylene is 20.6 wt. %, the yield of light aromatic compounds is 11.5 wt. %, and the yields of dry gas and coke are 10.4 wt. % and 8.2 wt. %, respectively.

Example 4

This example was carried out in accordance with the process flow diagram shown in FIG. 1 in a medium size plant using a hydrogenated residue as the feed oil, a DMMC-2 catalyst as the catalyst, and a full dense phase catalytic cracking reactor as the reactor. The preheated feed oil was introduced into the catalytic cracking reactor to contact the catalytic cracking catalyst for the catalytic cracking reaction, with two streams of hot regenerated catalysts (with a carbon content of 0.05 wt. %) additionally introduced into a fully dense phase reaction zone, at this one stream of hot regenerated catalyst was introduced at the level of 70% of the total height of the fully dense-phase reaction zone in an amount of 13 wt. % catalyst circulation rate in the reactor; and another stream of hot regenerated catalyst was introduced at the level of 50% of the total height of the fully dense-phase reaction zone in an amount of 3 wt. % catalyst circulation rate in the reactor. The distribution of the catalyst in the fully dense phase reaction zone was set in the fully dense phase configuration such that the axial solids fraction ε of the catalyst in the fully dense phase reaction zone ranged from 0.1 to 0.2 from bottom to top. The reactor effluent was passed into a closed cyclone where the reaction product and the spent catalyst were quickly separated, and the reaction product was further separated in a product separation system according to the distillation range. The spent catalyst was passed into the stripper by gravity, the hydrocarbon vapors that were adsorbed on the spent catalyst were separated by steam stripping, the stripper-cleaned catalyst was directly passed into the regenerator without heat exchange, and brought into contact with air for regeneration by coke burning, and the regenerated catalyst was recycled into the reactor for reuse. The mixed fraction C4 obtained after separation of the reaction products was recycled to the lower section of the fully dense phase reaction zone for the subsequent reaction. The process conditions used and the distribution of products are shown in Table 3.

As can be seen in Table 3, in this example, the ethylene yield is 5.7 wt. %, the yield of propylene is 20.9 wt. %, the yield of light aromatic compounds is 11.7 wt. %, and the yields of dry gas and coke are 10.4 wt. % and 8.3 wt. %, respectively.

Example 5

This example was carried out in accordance with the process flow diagram shown in FIG. 2 in a medium size plant using a hydrogenated residue as the feed oil, a DMMC-2 catalyst as the catalyst, and a fully dense phase catalytic cracking reactor as the reactor. The preheated feed oil was introduced into the catalytic cracking reactor to contact the cooled catalytic cracking catalyst for the catalytic cracking reaction, the cooled regenerated catalyst stream (with a carbon content of 0.05 wt %) being introduced into the fully dense phase reaction zone at 60% of the total height of the fully dense phase reaction zone, and the additional catalyst was 15 wt. % catalyst circulation rate in the reactor. The distribution of the catalyst in the fully dense phase reaction zone was set in the fully dense phase configuration such that the axial solids fraction ε of the catalyst in the fully dense phase reaction zone ranged from 0.1 to 0.2 from bottom to top. The reactor effluent was passed into a closed cyclone where the reaction product and the spent catalyst were quickly separated, and the reaction product was further separated in a product separation system according to the distillation range. The spent catalyst was passed into the stripper by gravity, the hydrocarbon vapors that were adsorbed on the spent catalyst were separated by steam stripping, the purified catalyst in the stripper was directly passed into the regenerator without heat exchange, and brought into contact with air for regeneration by coke burning, while the regenerated catalyst cooled with a condenser and then returned to the reactor for reuse. The process conditions used and the distribution of products are shown in Table 4.

As can be seen in table 4, in this example, the yield of ethylene is 5.3 wt. %, the yield of propylene is 21.6 wt. %, the yield of light aromatic compounds is 11.5 wt. %, and the yields of dry gas and coke are 9.9 wt. % and 8.1 wt. %, respectively.

Example 6

This example was carried out in accordance with the process flow diagram shown in FIG. 2 in a medium size plant using a hydrogenated residue as the feed oil, a DMMC-2 catalyst as the catalyst, and a fully dense phase catalytic cracking reactor as the reactor. The preheated feed oil was introduced into the catalytic cracking reactor to contact the cooled catalytic cracking catalyst for the catalytic cracking reaction, the cooled regenerated catalyst stream (with a carbon content of 0.05 wt %) being introduced into the fully dense phase reaction zone at 60% of the total height of the fully dense phase reaction zone, and the additional catalyst was 15 wt. % catalyst circulation rate in the reactor. The distribution of the catalyst in the fully dense phase reaction zone was set in the fully dense phase configuration such that the axial solids fraction ε of the catalyst in the fully dense phase reaction zone ranged from 0.1 to 0.2 from bottom to top. The reactor effluent was passed into a closed cyclone where the reaction product and the spent catalyst were quickly separated, and the reaction product was further separated in a product separation system according to the distillation range. The spent catalyst was passed into the stripper by gravity, the hydrocarbon vapors that were adsorbed on the spent catalyst were separated by steam stripping, the purified catalyst in the stripper was directly passed into the regenerator without heat exchange, and brought into contact with air for regeneration by coke burning, while the regenerated catalyst cooled with a condenser and then returned to the reactor for reuse. The mixed fraction C4 obtained after separation of the reaction products was recycled to the lower section of the fully dense phase reaction zone for the subsequent reaction. The process conditions used and the distribution of products are shown in Table 4.

As can be seen in Table 4, in this example, the ethylene yield is 5.7 wt. %, the yield of propylene is 22.0 wt. %, the yield of light aromatic compounds is 11.7 wt. %, and the yields of dry gas and coke are 10.0 wt. % and 8.2 wt. %, respectively.

From the results of Examples 1-6, it can be seen that the process of the present application provides higher yields of ethylene, propylene and light aromatics while providing lower dry gas and coke yields.

Preferred embodiments according to the present application have been described in detail above, but the present application is not limited to the details of the above embodiments. Various modifications of the technical solution according to this application can be made within the scope of the corresponding inventive concept, and these modifications should be within the scope of this application.

It should be noted that the various features described in the present embodiments may be combined in any suitable manner, as long as there is no conflict. To avoid unnecessary repetition, these possible combinations are not described in this application.

In addition, the various embodiments of the present application may also be combined arbitrarily, and these combinations should also be considered part of the present application, provided that they do not deviate from the spirit of the present application.

Claims (42)

1. The method of catalytic cracking of liquid petroleum products, including the step of introducing the original liquid petroleum products, in particular heavy source oil products, into contact with a catalytic cracking catalyst for reaction in a reactor containing one or more fast fluidized reaction zones, and at least one of the fast fluidized reaction zones of the reactor is a fully dense phase reaction zone, and the axial solids ε of the catalyst, measured in the upper, middle and lower parts of the reaction zone, divided into equal parts in the axial direction, in each case are not less than about 0.1 and not more than about 0.2 so that the axial solids fraction ε of the catalyst is controlled within the range from about 0.1 to about 0.2 in the entire fully dense phase reaction zone from bottom to top, where the axial solid fraction of the catalyst ε = pressure difference between two positions in the reaction zone along the axial direction, measured by the pressure difference sensor / distance between the two positions along the axial direction / catalyst particle density; where the pressure drop is expressed in kg/m ² , the distance between two positions along the axial direction is expressed in meters (m), and the density of the catalyst particles is expressed in kg/m ³ ; catalyst particle density = theoretical density / (catalyst pore volume × theoretical density + 1), where the theoretical density is expressed in kg/m ³ and the pore volume of the catalyst is expressed in m ³ , and the theoretical density and pore volume of the catalyst are determined by methods of pycnometric study and water titration, respectively, wherein the process is used to produce light olefins from heavy feedstocks and further comprises the following steps: i) contacting a heavy feed oil, such as a low grade heavy oil, with a catalytic cracking catalyst in a fully dense phase reaction zone of the reactor to react under efficient conditions to produce light olefins, wherein the axial solids fraction ε of the catalyst is controlled within a range of about 0, 1 to about 0.2 throughout the entire dense phase reaction zone of the reactor from bottom to top; ii) separating the reactor effluent to form a light olefin rich reaction product and a spent catalyst; iii) regenerating the spent catalyst and recycling at least a portion of the resulting regenerated catalyst to step (i) as a catalytic cracking catalyst; And iv) optionally separating the reaction product to produce dry gas, liquefied petroleum gas, naphtha, diesel fuel and catalyst slurry. 2. The process of claim 1, wherein the process further comprises, before said step (i) and/or after said step (ii), one or more additional reaction steps selected from catalytic cracking and catalytic isomerization carried out in other types of reaction zones selected from a rarefied phase transport fluidized bed, a dense phase fluidized bed, and a traditional fast fluidized bed. 3. The method according to any one of the preceding claims, further comprising: introducing one or more additional catalyst streams into the fully dense phase reaction zone at a position downstream of the position where the catalytic cracking catalyst is introduced into the fully dense phase reaction zone, and contacting the additional catalyst with material in a fully dense phase reaction zone for a catalytic cracking reaction, wherein the one or more co-catalyst streams independently have a carbon content of from about 0 to about 1.0 wt %, each independently selected from reclaimed, spent, or semi-reclaimed catalytic cracking catalysts, and the total amount of the one or more co-catalyst streams is from about 5 up to 50 wt.% in relation to the catalyst circulation rate in the reactor, and wherein one or more additional catalyst streams are independently introduced at a height within the range of about 20 to 90% of the total height of the fully dense phase reaction zone. 4. The method according to any one of the preceding claims, further comprising: introducing a C4 hydrocarbon cut and/or a C5-C6 light gasoline cut into the reactor at one or more positions for the catalytic cracking reaction. 5. The method according to any one of the preceding paragraphs, in which the catalytic cracking catalyst contains, in relation to the dry weight of the catalytic cracking catalyst, from about 1 to 50 wt.% zeolite; from about 5 to 99 wt.% inorganic oxide and from about 0 to 70 wt.% clay; wherein the zeolite comprises a mesoporous zeolite selected from the group consisting of ZSM zeolites, ZRP zeolites and combinations thereof, and optionally a macroporous zeolite selected from the group consisting of rare earth substituted Y type zeolite, rare earth substituted HY type zeolite, ultrastable Y type zeolite , having a high content of silicon dioxide zeolite type Y and combinations thereof. 6. The process according to any one of the preceding claims, wherein the following reaction conditions exist in the fully dense phase reaction zone: the reaction temperature is from about 510 to 700°C, the reaction time is from about 1 to 20 seconds, the weight ratio of catalyst to oil is from about 3:1 to about 50:1, water to oil weight ratio from about 0.03:1 to about 0.8:1, catalyst density from about 120 to 290 kg/m ³ , steam velocity from about 0.03:1 to about 0.8:1 8 to 2.5 m/s, the reaction pressure is about 130 to 450 kPa, and the mass flow rate Gs of the catalyst is about 15 to 150 kg/(m ² s). 7. The process according to any one of the preceding claims, wherein the feed liquid oil is a heavy feed oil whose properties meet at least one of the following criteria: density at 20°C is about 850 to 1000 kg/m ³ , carbon residue is from about 2 to 10 wt.%, the total content of nickel and vanadium is from about 2 to 30 ppm, and the characteristic factor K is less than about 12.1. 8. The method according to any one of the preceding paragraphs, in which the original liquid oil is a heavy source oil selected from heavy petroleum hydrocarbons, other mineral oils and combinations thereof; wherein the heavy petroleum hydrocarbon is selected from the group consisting of vacuum distillation residue, low grade atmospheric distillation residue, low grade hydrogenated residue, coker gas oil, deasphalted oil, vacuum gas oil, high acid number crude oil, high metal crude oil, and combinations thereof. ; And wherein said other mineral oil is selected from the group consisting of coal liquefaction oil, oil sand bitumen, shale oil, and combinations thereof. 9. A reactor suitable for use in the catalytic cracking of liquid petroleum products, in particular heavy crude oil products, which consists of a bottom-up preliminary riser section, a fully dense phase reaction zone, a transition section and an outlet zone, the fully dense phase reaction zone being in the form of a hollow column , having an approximately circular cross-section with a constant diameter or a variable diameter, an open lower end and an open upper end, and the preliminary riser section is in communication with the lower end of the fully dense phase reaction zone, the upper end of the fully dense phase reaction zone is in communication with the outlet zone through the transition section, pre-lift section and/or lower section of the fully dense phase reaction zone contains at least one catalytic cracking catalyst inlet, and the preliminary lift section and/or lower section of the fully dense phase reaction zone contains at least one source material inlet, wherein the diameter of the cross section of the lower end of the fully dense phase reaction zone is greater than or is the same as the diameter of the pre-lift section, and the diameter of the cross section of the upper end of the fully dense phase reaction zone is greater than the diameter of the outlet zone, and the side wall of the fully dense phase reaction zone contains one or more additional catalyst inlets, each inlet independently located at a height within a range of about 20 to 90% of the total height of the fully dense phase reaction zone, where the constant-diameter or variable-diameter hollow column is a constant-diameter hollow cylinder or a hollow column whose diameter continuously or discontinuously increases from bottom to top, and where the fully dense phase reaction zone is in the form of a hollow cylinder of constant diameter, and the lower section of the fully dense phase reaction zone contains a distribution plate for the catalyst. 10. The reactor of claim 9, wherein said one or more additional catalyst inlets are each independently located at a height within the range of about 30 to 75% of the total height of the fully dense phase reaction zone. 11. Reactor according to claim 9, wherein the reactor further comprises one or more reaction zones of other forms selected from a fluidized bed with transport in a rarefied phase, a dense phase fluidized bed and a traditional fast fluidized bed, upstream of a relatively dense phase reaction zone and/or downstream of a relatively fully dense phase reaction zone. 12. The reactor according to any one of paragraphs. 9-11, in which the fully dense-phase reaction zone is present in the form of an inverted hollow truncated cone, and the hollow column consists of two or more cylindrical sections with successively increasing diameters, the hollow column consists of two or more sections of inverted truncated cones with successively increasing diameters, or a hollow column consists of one or more cylindrical sections and one or more sections of inverted truncated cones. 13. The reactor according to any one of paragraphs. 9-12, wherein the pre-lift section has a diameter of approximately 0.2 to 5 meters; and a ratio of its height to the overall height of the reactor, which is from about 0.01:1 to about 0.2:1. 14. The reactor according to any one of paragraphs. 9-13, in which the ratio of the diameter of the maximum cross section of the fully dense phase reaction zone and the overall height of the reactor is from about 0.005:1 to about 1:1; and the ratio of the height of the fully dense phase reaction zone to the total height of the reactor is from about 0.1:1 to about 0.9:1. 15. The reactor according to any one of paragraphs. 9-14, wherein the fully dense-phase reaction zone is present in the form of an inverted hollow truncated cone with an isosceles trapezoid longitudinal section that has a lower cross-sectional diameter of approximately 0.2 to 10 meters; the ratio of the diameter of the upper cross-section and the diameter of the lower cross-section, ranging from more than 1 to about 50; and the ratio of the diameter of the maximum cross section and the overall height of the reactor, comprising from about 0.005:1 to about 1:1; and a ratio of the height of the fully dense phase reaction zone to the total height of the reactor of from about 0.1:1 to about 0.9:1. 16. The reactor according to any one of paragraphs. 9-14, in which the fully dense-phase reaction zone is present in the form of a hollow column, consisting of bottom-up sections in the form of an inverted truncated cone and a cylindrical section, and the truncated cone has a longitudinal section in the form of an isosceles trapezoid, the diameter of the lower cross section is approximately 0 ,2 to 10 meters;; the ratio of the diameter of the upper cross section and the diameter of the lower cross section is from more than 1 to about 50; the diameter of the cylinder is approximately the same as the diameter of the upper cross-section of the truncated cone, the ratio of the height of the cylinder to the height of the truncated cone is from about 0.4:1 to about 2.5:1; the ratio of the diameter of the maximum cross-section of the fully dense-phase reaction zone and the total height of the reactor is from about 0.005:1 to about 1:1; and the ratio of the height of the fully dense phase reaction zone to the total height of the reactor is from about 0.1:1 to about 0.9:1. 17. The reactor according to any one of paragraphs. 9-14, in which the fully dense phase reaction zone is in the form of a hollow cylinder having a diameter of about 0.2 to 10 meters and a ratio of the diameter of the fully dense phase reaction zone to the overall height of the reactor is from about 0.005:1 to about 1: 1, and the ratio of the height of the fully dense phase reaction zone to the total height of the reactor is from about 0.1:1 to about 0.9:1. 18. The reactor according to any one of paragraphs. 9-17, wherein the ratio of the height of the transition section to the overall height of the reactor is from about 0.01:1 to about 0.1:1; and the transition section is in the form of a hollow truncated cone with a longitudinal section in the form of an isosceles trapezoid with sides having an internal inclination angle α of approximately 25° to 85°. 19. The reactor according to any one of paragraphs. 9-18, wherein the outlet zone has a diameter of about 0.2 to 5 meters and a ratio of its height to the overall height of the reactor of about 0.05:1 to about 0.2:1, and the outlet the end of the outlet zone may be open or may be directly connected to the inlet of the cyclone. 20. The reactor according to any one of paragraphs. 9-19, wherein at least one feed inlet is in each case independently positioned in the pre-lift section at a position less than or equal to about 1/3 of the height of the pre-lift section from its outlet end, at the outlet end of the pre-lift section. section or in the lower section of a fully dense-phase reaction zone, optionally, when a feed inlet is present in the lower section of the fully dense phase reaction zone, a gas distributor may be present at said feed inlet. 21. A system suitable for use in the catalytic cracking of liquid petroleum products, in particular heavy feedstocks, comprises a catalytic cracking reactor, a catalyst separating device, an optional reaction product separator, and a regenerator, the catalytic cracking reactor comprising a catalyst inlet at the bottom, a feed inlet at the bottom and an outlet at the top, the catalyst separating device comprises a catalyst inlet and outlet and a reaction products outlet, an optional reaction product separator comprises a reaction products inlet, a dry gas outlet, an LPG outlet, a naphtha outlet, a diesel fuel outlet, and a catalyst slurry outlet and the regenerator comprises a catalyst inlet and a catalyst outlet, the catalytic cracking reactor inlet is in fluid transfer communication with the regenerator catalyst outlet, the catalytic cracking reactor outlet is in fluid transfer communication with the catalyst separating device inlet, the catalyst separating device reaction product outlet is in fluid transfer capability communication with the reaction products inlet of the optional reaction product separator, the catalyst outlet of the catalyst separating device is in fluid transfer communication with the regenerator catalyst inlet, wherein the catalytic cracking reactor comprises a reactor according to any one of paragraphs. 9-20.

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