[0001] There are a number of continuous cyclical processes employing fluidized solid techniques
in which an at least partially liquid phase stream containing hydrocarbon compounds
contacts the fluidized solids in a contacting zone and carbonaceous or other fouling
materials are deposited on the solids. The solids are conveyed during the course of
the cycle to another zone where foulants are removed in a rejuvenation section or,
more specifically, in most cases carbon deposits are at least partially removed by
combustion in an oxygen-containing medium. The solids from the rejuvenation section
are subsequently withdrawn and reintroduced in whole or in part to the contacting
zone.
[0002] One of the more important processes of this nature is the fluid catalytic cracking
(FCC) process for the conversion of relatively high-boiling hydrocarbons to lighter
hydrocarbons. The hydrocarbon feed is contacted in one or more reaction zones with
the particulate cracking catalyst maintained in a fluidized state under conditions
suitable for the conversion of hydrocarbons.
[0003] The processing of increasingly heavier feeds in FCC type processes and the tendency
of such feeds to elevate coke production and yield undesirable products has led to
new methods of contacting feeds with catalyst. Recently, methods of contacting FCC
catalyst for very short contact periods have been of particular interest. In US-A
4,985,136, an FCC feed contacts a falling-curtain of catalyst for a contact time of
less than 1 second followed by a quick separation. The ultra short contact time system
improves selectivity to gasoline while decreasing coke and dry gas production by using
high activity catalyst that previously contacted the feed for a relatively short period
of time. The inventions are specifically directed to zeolite catalysts having high
activity. Arrangements for performing such feed contacting are known from US-A-2,935,466,
US-A-4,435,272, US-A 4,944,845, US-A-5,296,131 and US-A 5,462,652.
[0004] The type of injection desired for short contact time arrangements has received particular
attention in the above referenced patents. The feed may be formed into a jet by an
array of identical feed injection streams or by an extended orifice that uniformly
contacts a stream of catalyst flowing in a compatible pattern. The feed injection
is arranged to shoot the feed into a relatively thin band of catalyst that falls in
a direction perpendicular to the flow of jets.
[0005] Aside from uniform feed and catalyst contacting, short contact time also requires
good separation between the catalyst and hydrocarbons. The above described prior art
typically directs the catalyst and vapor mixture into a conduit that communicates
with a downstream separation device. Therefore, contact of the hydrocarbons with the
catalyst will continue for a substantial period of time as it flows to the separation
device and while it is in the separation device.
SUMMARY OF THE INVENTION
[0006] This invention further limits contact time between catalyst and hydrocarbon in an
arrangement for contacting relatively heavy hydrocarbon feeds and fluidized catalyst
particles for ultra short periods of time.
[0007] This invention provides rapid separation of a feed from a catalyst stream by injecting
the catalyst stream together with the contacted vapors into a disengaging zone in
a substantially horizontal direction under dilute catalyst phase conditions and by
immediately withdrawing cracked vapors from an upper portion of the dilute phase zone.
Horizontal dilute phase injection into a disengaging vessel combined with the upper
draw-off of vapors initiates an immediate gravity separation of the catalyst from
the hydrocarbons vapors. By this method a significant portion of the contacting between
the catalyst and hydrocarbons ceases immediately upon injection of the catalyst stream
into the disengaging vessel. Contacting of the feed with the catalyst stream can occur
at about the same location or near the same location as the injection of the catalyst
stream into the disengaging vessel. In this manner ultra short contact times may be
controlled from minimal times that approach zero to longer times. Unlike the prior
art, this invention does need to maintain contact while the catalyst and hydrocarbon
mixture travels together vertically or horizontally to a stage of separation.
[0008] Accordingly, in one embodiment this invention is a process for the fluidized catalytic
cracking of a hydrocarbon feed. The process injects catalyst particles and hydrocarbons
from an injection point into a disengaging zone in a substantially horizontal direction.
A collection zone collects descending catalyst particles below the injection point.
A distance of at least 5 feet in the disengaging zone between the injection point
and the collection zone provides a settling zone for continued separation of the catalyst
and hydrocarbons vapors. The process collects rising vapors and entrained catalyst
particles from an upper portion of the discharge zone and transfers them to an inertial
separation zone. The inertial separation zone separates entrained catalyst from the
rising vapors to provide a separated vapor stream and separated catalyst. The process
recovers hydrocarbons from a lower portion of the disengaging zone and the separated
vapor stream.
[0009] Typically, a jet of a hydrocarbon-containing feed is injected - in a principally
transverse direction - into a flowing layer of catalyst particles upstream of the
injection point and at the periphery of the disengaging zone or outside of the disengaging
zone. A particularly useful form of this invention uses a standpipe as a location
for a distributor nozzle arrangement that performs contacting of a hydrocarbon-containing
stream with a falling layer of particulate material. Generally the injection of the
jet of hydrocarbon-containing feed into the flowing layer of catalyst particles takes
place in the confined conduit, but near the outlet of the conduit into the disengaging
vessel. Location of the distributor in the standpipe will typically allow the discharge
of the fluid and solids mixture directly from the distributor into the disengaging
vessel at a suitable elevation for the practice of this invention. A standpipe distributor
arrangement can fit compactly near the junction of most standpipes with the disengaging
vessel.
[0010] In an apparatus embodiment this invention comprises a disengaging vessel portion
and catalyst and a feed contactor for injecting the feed and catalyst from an injection
point into the disengaging vessel portion in a substantially horizontal direction.
The feed contactor injects a hydrocarbon-containing feed into a flowing stream of
catalyst to supply the feed and catalyst to the injection point. A collector vessel
portion, located subjacent to the disengaging vessel portion and at least 5 feet below
the injection point, collects a dense bed of catalyst from the disengaging vessel
portion. An inertial separator, located superjacent to the disengaging vessel portion,
communicates directly with an upper portion of the disengagement vessel portion to
separate hydrocarbons from catalyst particles that rise with the hydrocarbons from
the disengaging vessel portion. A catalyst outlet, defined by the inertial separator,
recovers separated hydrocarbons from the inertial separator.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011]
Figure 1 is a schematic illustration of an FCC apparatus that incorporates a short
contact time arrangement of this invention.
Figure 2 is a schematic section taken across lines 2-2 of Figure 1.
Figure 3 is a schematic illustration of an FCC apparatus that incorporates an alternate
short contact time arrangement of this invention.
Figure 4 is a schematic section taken across lines 4-4 of Figure 3.
Figure 5 is a section of standpipe conduit portion that contains a contactor for use
in this invention.
Figure 6 is a section of the standpipe conduit portion taken at lines 6-6 of Figure
5.
Figure 7 is a front view of a feed distributor taken at lines 7-7 of Figure 5.
DETAILED DESCRIPTION OF THE INVENTION
[0012] This invention can be used in combination with any type of particulate material.
The material may be inert or reactive in the presence of the particular fluid material.
A wide variety of inert and catalytic material is suitable for this invention. For
example in destructive distillation processes a suitable inert material comprises
an alpha alumina. FCC applications of this process can include any of the well-known
catalysts that are used in the art of fluidized catalytic cracking. These compositions
include amorphous-clay type catalysts which have, for the most part, been replaced
by high activity, crystalline alumina silica or zeolite-containing catalysts. Zeolite-containing
catalysts are preferred over amorphous-type catalysts because of their higher intrinsic
activity and their higher resistance to the deactivating effects of high temperature
exposure to steam and exposure to the metals contained in most feedstocks. Zeolites
are the most commonly used crystalline alumina silicates and are usually dispersed
in a porous inorganic carrier material such as silica, alumina, or zirconium. These
catalyst compositions may have a zeolite content of 30% or more. Zeolite catalysts
used in the process of this invention will preferably have a zeolite content of from
25-80 wt. % of the catalyst. The zeolites may also be stabilized with rare earth elements
and contain from .1 to 10 wt. % of rare earths.
[0013] Although primarily intended for use in FCC units, this invention may be useful for
any process that seeks to contact hydrocarbon-containing streams with a fluidized
particulate stream for short periods of time. The types of processes in which this
invention may be useful include the contacting of catalyst with residual feeds and
the destructive contacting of high asphaltene-containing feed with high temperature
inert or catalytic particles. Suitable liquid media for this invention include any
liquid stream that will enter the distributor at least partially as a liquid and that
is further vaporized by contact with the particulate material. Feed for destructive
contacting will comprise highly refractory crudes having boiling points that extend
over wide ranges and having high concentrations of metals and coke. For example, one
typical crude has a boiling point that ranges from 116 °-815 ° C (240° - 1575° F)
with more than half of the liquid volume boiling above 1000° F. For the FCC process,
feedstocks suitable for processing by the method of this invention include conventional
FCC feeds and higher boiling or residual feeds. The most common of the conventional
feeds is a vacuum gas oil which is typically a hydrocarbon material having a boiling
range of from 343 ° -552 °C (650° - 1025° F) and which is prepared by vacuum fractionation
of atmospheric residue. These fractions are generally low in coke precursors and the
heavy metals which can deactivate the catalyst. Heavy or residual feeds, i.e., which
have a boiling range above 500 ° C (930° F). and which have a high metals content,
are also finding increased usage in FCC units.
[0014] When applied in catalyst operations both the metals and coke serve to deactivate
the catalyst by blocking active sites on the catalysts. To overcome its deactivating
effects, coke can be removed to a desired degree by regeneration.
[0015] Figure 1 shows an FCC arrangement that is arranged in accordance with this invention.
The FCC arrangement shown in Figure 1 consists of a reactor 10 that includes a disengaging
vessel portion 11, a collection vessel portion 14, and a separator 13. Separator 13
includes a separator vessel portion 12 and a riser 15. The arrangement circulates
catalyst and contacts feed in the manner hereinafter described.
[0016] Looking then at the operation of the reaction zone, fresh regenerated catalyst, spent
catalyst, or a mixture thereof enters the reactor through a nozzle 16 which typically
communicates with the end of a regenerated catalyst standpipe. Feed is injected into
standpipe nozzle 16 through a feed injection nozzle 17 that contacts the catalyst,
preferably through a contactor as further described herein. After or simultaneously
with the contact between the feed and the hydrocarbons, the feed and catalyst particles
enter the disengaging vessel portion 11 from an injection point 18.
[0017] Contact of the catalyst and the feed will produce a concentrated stream of catalyst
that flows into the disengaging vessel portion 11 along a substantially horizontal
flow path. The substantially horizontal flow path is defined to mean a flow path that
has at least a principal horizontal component. The principal direction of the catalyst
stream as it enters the disengaging vessel will primarily dictate the entering trajectory
of the feed and hydrocarbon stream. Therefore, the hydrocarbon stream will be directed
into the disengaging vessel at an angle, shown in Figure 1 as A, of 60 ° or less to
ensure that the momentum of the catalyst moves the mixture of catalyst and hydrocarbon
in a substantial horizontal direction across disengaging vessel portion 11. The substantial
horizontal discharge from the disengaging point promotes a quick disengagement of
the vaporous hydrocarbon stream from the relatively heavier catalyst particles. Rapid
disengagement also requires a vertical space for unrestricted passage of the rising
vapors upwardly through the disengaging vessel 11. For this purpose, the disengaging
vessel portion will have a substantially open volume 19 above the injection point
and perhaps, more importantly, an open volume 20 below the injection point. Open volume
20 is defined as a region of the dilute catalyst density above a catalyst interface
21 and shown as dimension B in Figure 1. Dimension B will be at a minimum of at least
1.5 m and, more typically, will be from 2 to 3.6 m. Dilute phase conditions refer
to a catalyst density of less than 300 kg/m
3 and, more typically, will refer to a density of less than 150 kg/m
3. Catalyst density in open volumes 19 and 20 will vary with proximity to the feed
and catalyst contact point. Usually the density of the open volume will not exceed
an average of 80 kg/m
3; and typically, it will have an average catalyst density of less than 48.4 kg/m
2. Catalyst from open volumes 19 and 20 collects in a dense bed 22 within collection
zone 14. Dense phase conditions are characterized by an apparent bulk density of the
catalyst in a range of from 240 to 800 kg/m
3. Thus the dense bed of collection zone 22 typically retains catalyst particles at
a density of at least 240 kg/m
3 and, more typically, catalyst particles are retained at a density of 730 kg/m
3 or more. The distance B over the disengaging zone 11 may also serve as a settling
zone where catalyst disengages and settles from the rising vapors.
[0018] Collection zone 14 may serve as a stripping zone for the recovery of entrained and
adsorbed hydrocarbons from catalyst entering collection zone 14. Stripping gas enters
the collection zone 14 through a nozzle 23 and a distributor 24. A dispersed stripping
gas, such as steam, rises upwardly through the catalyst. The series of grids 25 may
provide redistribution of the stripping medium and stripped hydrocarbons as they pass
upwardly through the bed 22. A nozzle 26 withdraws the stripped catalyst for regeneration
in a regenerator vessel (not shown) and/or recycle to nozzle 16 for recontacting of
catalyst with the feed. The optional addition of hot regenerated catalyst to bed 22
can facilitate stripping by raising the temperature in the stripping zone. Hot catalyst
may enter the stripping zone above bed interface 21 through a nozzle 27. Alternately,
an extended bed portion 22' with a higher catalyst interface 21' may be maintained
to keep the dense phase catalyst above the entry point of the regenerated catalyst
through nozzle 27, provided the minimum disengagement length is provided between injection
point 18 and bed level 21'.
[0019] It is also possible through baffling not shown, to isolate recovered stripped hydrocarbons
from a lower portion of bed 22. Segregation of the stripped hydrocarbons can provide
different product streams for downstream separation and recovery. The longer contact
time of the hydrocarbons that enter the collection can substantially alter the properties
of the cracked hydrocarbons recovered from this zone. Separate recovery of a stream
from the stripping zone may facilitate independent recovery of an isolated product
stream from an upper portion of the disengaging vessel 11.
[0020] However, the stripping medium as well as the stripped hydrocarbons will ordinarily
rise through the disengaging vessel 11 and combine with the disengaged hydrocarbons
that enter with the catalyst stream from nozzle 16. As the vapors and entrained catalyst
rise through disengaging zone 19, a transition section in the form of a truncated
cone 28 reduces the fluid flow area and increases the velocity of the gases as they
enter riser 15. The conditions within disengaging zone 19, cone 28, and riser 15 are
often referred to as fast fluidized conditions in which the upward catalyst transfer
velocity may range between 6 to 18 m/sec with a density range of from 65 to 550 kg/m
3.
[0021] The rising hydrocarbons and any additional entrained catalyst will rise upwardly
into an inertial separation device provided by a pair of arms 29 each having tangentially
directed openings 30. Arms 29 provide an inertial separation by centripetal acceleration
of the relatively heavy catalyst particles that quickly removes most of the catalyst
from the hydrocarbon vapors. The depiction of tangentially oriented openings to provide
a centripetal or cyclonic type separation is not meant to preclude other inertia separation
devices such as those that use a ballistic separation of particles from the hydrocarbon
vapors. Cracked hydrocarbons with trace amounts of catalyst exit separator 13 through
an outlet 31.
[0022] Hydrocarbon vapors from outlet 31 will, in most cases, undergo further separation
for the recovery of the trace amounts of catalyst particles. Cyclone separators will
normally provide the secondary recovery of the residual catalyst particles. Catalyst
particles recovered from additional separators may return to the collection zone 14
via a nozzle 32. After any additional catalyst recovery, products are typically transferred
to a separation zone (not shown) for the removal of light gases and heavy hydrocarbons
from the products.
[0023] Catalyst recovered from the inertial separator 13 collects in a bed 33 for return
to bed 22 in the collection zone 14. Catalyst may pass from bed 33 to the collection
zone 14 through one or more internal or external standpipes 34. Figure 1 shows an
arrangement of internal standpipes 34 that return catalyst from bed 33 in isolation
from the open volumes 19 and 20 of disengagement zone 11. The bottoms 35 of standpipes
34 are typically submerged in bed 22. The submersion of standpipe bottoms 35 prevents
the backflow of stripped vapors through the standpipes and into the separated vapors
that collect at the top of separation zone 13.
[0024] Internal standpipes 34 have an arrangement that leaves a clear trajectory for the
injected hydrocarbon and catalyst particles as it enters disengaging zone 11 from
injection point 18. As shown more clearly in Figure 2, the spacing of internal conduits
34 is increased in the area of nozzle 16 to provide a spacing between conduits 34
equal to dimension C. Dimension C will, preferably, at least equal the diameter of
nozzle 16. By this layout the injected hydrocarbons and catalyst particles have a
clear trajectory path that extends at least to the center of the disengaging zone
11 as shown by dimension T.
[0025] The configuration of the inertial separator 13 and the return of catalyst to the
collection zone 14 may be accomplished in a variety of different ways. Figure 3 shows
an alternate arrangement that uses a downwardly extended conduit 36 together with
a separation shroud 40 to increase the recovery of separated catalyst from the inertial
separation device and return of the catalyst to a dense bed 22" by an external standpipe
38. The apparatus of Figure 3 operates in a similar manner to the apparatus described
in conjunction with Figure 1. The major differences are the introduction of an additional
change in vapor direction as vapor passes upwardly in disengaging vessel portion 11'
and further separation of catalyst particles from the hydrocarbon vapors before the
mixture leaves the separation zone 13'. More specifically, hydrocarbons entering disengaging
vessel portion 11' from injection point 18' are further separated from the entering
catalyst particles as the vapors flow to an opening 39 that receives the initially
separated hydrocarbon vapors. Opening 39 serves as separator inlet and faces a side
of the disengaging zone that is opposite the side from which the catalyst particles
and hydrocarbons are injected through injection point 18'. In this manner, the hydrocarbons
exit the disengaging zone on a side opposite from which the catalyst particles and
hydrocarbons are injected.
[0026] Hydrocarbons and entrained catalyst from inlet 39 continue upwardly through riser
section 15'. Arms 29' again tangentially discharge the catalyst and entrained catalyst
particles through openings 30'. A shroud 40 provides a restricted opening 41 for recovered
vapors that pass upwardly into a secondary section 42 of separator 13'. Recovered
hydrocarbons together with any residual catalyst again leave the separation zone 13'
through a nozzle 31'.
[0027] External standpipe 38 recovers catalyst from a bed 33' that collects catalyst from
inertial separator 13'. Conduit 38 passes catalyst around disengaging zone 11' and
into catalyst bed 22" of collection zone 14'. External standpipe 38' leaves disengaging
zone 11' completely open for disengagement of hydrocarbon vapors from the catalyst
stream.
[0028] The open section of the disengaging zone may be further segregated to confine the
separation of the hydrocarbons from the stream of catalyst particles. As shown in
Figure 4, a pair of baffles 43 may be placed in proximity to a catalyst conduit 16'
that discharges the catalyst particles and feed mixture into a central portion 44
of the disengaging zone 11'. Disengaging zone 11' may be further modified to provide
conduits for returning the catalyst particles that are located outside of the area
44'. Catalyst conduits 46 may be located in the circular sectors to the outside of
baffles 43.
[0029] The process and apparatus of this invention may initially contact the feed with regenerated
catalyst, carbonized catalyst, or a mixture of the two. The process can use any type
of regeneration for the removal of coke. Coke removal which ordinarily operates to
completely remove coke from the catalyst is generally referred to as "complete regeneration".
Complete regeneration removes coke from the catalyst to a level of less than .2 wt%,
or preferably to less than .1wt%, and or more preferably, to less than 0.05 weight
percent coke.
[0030] Regenerated catalyst will have a substantially higher temperature than carbonized
catalyst. Regenerated catalyst that usually enters the regenerated conduit 16 will
have a temperature in a range from 590 to 760 °C and, more typically, the temperature
will be in a range of from 650 to 760 °C. Once the catalyst mixture contacts the feed,
the catalyst accumulates coke on the catalyst particles and has a lower temperature.
The temperature of the carbonized catalyst will usually be in a range of from 480
to 620°C, but its temperature will vary depending on its source.
[0031] A preferred standpipe and feed injection arrangement for this invention is shown
in Figure 5. Figure 5 illustrates a contactor 115 that atomizes the feed into streams
of fine liquid droplets. A flange 111 at the end of conduit 17 usually retains contactor
115 in conduit 17. Collectively the streams produced by contactor 115 provide a linear
array of catalyst that contacts a falling curtain of catalyst formed by an outlet
114 of a chute 113.
[0032] Contact of the feed with the catalyst causes a rapid vaporization and a high velocity
discharge of catalyst into the disengaging vessel. Contact between the feed and catalyst
cracks the heavier hydrocarbons into lighter hydrocarbons and produces coking of the
most active catalyst sites on the catalyst. The transverse contacting of the feed
with the vertically falling catalyst curtain creates a beneficial trajectory of the
catalyst and feed mixture into the disengaging vessel. The feed preferably contacts
the curtain of falling catalyst in a transverse direction to obtain a quick contacting
between the feed and the catalyst particles. For the purposes of this description
the expression "transversely contacting" means the feed does not flow parallel to
the direction of the falling curtain. The catalyst particles, after injection of the
jet of hydrocarbons, typically flow less than 1.5m through conduit 17 and, preferably
flow less than .3m before injection into the disengaging zone from the injection point.
[0033] As shown by Figures 5 and 6 chute 113 is fixed to the inside of conduit 116 and opening
114 usually has a rectilinear shape. The chute will usually have a width equal to
or greater than about half the width of conduit 16. Catalyst for discharge enters
conduit 16 from a control valve, i.e. typically a slide valve (not shown). The control
valve regulates the flow rate of catalyst into chute 113. The discharge velocity of
the catalyst from outlet 114 may be controlled by the addition of fluids upstream
of chute 113.
[0034] Contactor 115 will produce a spray pattern that is compatible with the geometry of
the falling curtain. Where the falling curtain has a linear shape as depicted in the
figures, the feed injector will generally produce a horizontal pattern of atomized
liquid. Accordingly, in a typical arrangement, the feed is discharged in a substantially
transverse direction with respect to the catalyst curtain. Substantially transverse
contact is used to describe the case where the principal direction of catalyst flow
has an included angle of at least 30° and preferably at least 45° between the principal
direction by which contactor 115 injects the feed into the layer or curtain of catalyst.
Preferably the feed flows perpendicularly into contact with a downwardly moving curtain
of catalyst. When contacting the falling curtain of catalyst, the feed will typically
have a velocity greater than .3m/sec and a temperature in the range of 150 to 320°C.
[0035] The nozzles of contactor 115 are sized to create jets having a fluid velocity out
of the openings in a range of 9 to 120m per second and preferably, the velocity will
be in the range of 30 to 90m/sec. In accordance with typical FCC practice, the feed
exits the nozzle openings in contactor 115 as a spray.
[0036] The dispersion of the feed into fine droplets is promoted by imparting sufficient
energy into the liquid. In some cases, this invention will be practiced with some
addition of a gaseous diluent, such as steam, to the feed before discharge through
the orifices. The addition of the gaseous material can aid in the atomization of the
feed. A minimum quantity of gaseous material, usually equal to about 0.2 wt.% of the
combined liquid and gaseous mixture, is typically commingled with the liquid before
its discharge through the nozzles. Typically the quantity of any added steam is 5
wt% or less of the combined gaseous and liquid mixture. Atomization will, for most
liquids, produce droplets in a size range of from 50 to 750 microns.
[0037] Figure 7 shows a linearly extended array of nozzles 123 extending across the front
face of contactor 115. Nozzles 123 are orientated to inject an atomized mixture of
fluids directly out from contactor 115 in a straight flow pattern from the more centrally
located nozzles. Those nozzles 123 that are located more to the outside of the array
may be angled to orient the injected atomized liquid over a wider pattern and to maintain
an even spacing between jets. Nozzles 123 may be angled in this manner to cover any
length or configuration of catalyst flow pattern or catalyst dispersion.
1. A process for the fluidized catalytic cracking of a hydrocarbon-containing feed, said
process comprising:
a) injecting a jet of a hydrocarbon-containing feed in a principally transverse direction,
into a flowing layer of catalyst particles upstream of an injection point (18) located
at the periphery of a disengaging zone (20) or outside of a disengaging zone (20);
b) injecting catalyst particles and hydrocarbons from the injection point (18) into
a disengaging zone (20) in a substantially horizontal direction wherein the disengaging
zone (20) has a substantially open volume (19) above and below the injection point
(18) and an average catalyst density of less than 80 kg/m3;
c) collecting descending catalyst particles in a collection zone (22) below the injection
point (18) and maintaining a settling distance (13) of at least 1.5m in 5.13m the
disengaging zone between the injection point (18) and the collection zone (22) wherein
the collection zone has a catalyst density of at least 240 kg/m3;
d) collecting rising vapors and entrained catalyst particles from the substantially
open volume (19) located above the injection point (18) and transferring the rising
vapors and entrained catalyst particles to an inertial separation zone (29) and separating
entrained catalyst from the rising vapors to provide a separated vapor stream and
separated catalyst; and,
e) recovering hydrocarbons from a lower portion of the disengaging zone (20) and the
separated vapor stream.
2. The process of claim 1 wherein the hydrocarbons recovered from the lower portion of
the disengaging zone (20) pass upwardly to the inertial separator (29) and are recovered
as part of the separated vapor stream.
3. The process of claim 1 wherein separated catalyst collects with the descending catalyst
in a common stripping zone (22).
4. The process of claim 1 wherein separated catalyst is collected above the disengaging
zone (20) and passes downwardly to the collection zone (22) in isolation from the
rising vapors.
5. The process of claim 2 wherein the injection of the jet of hydrocarbon-containing
feed into the flowing layer of catalyst particles takes place in a confined conduit
(16, 17) and the catalyst particles after injection of the jet of hydrocarbons flow
less than 1.5m through the conduit before injection into the disengaging zone (20)
from the injection point (18)
6. The process of claim 1 wherein a regenerated catalyst stream enters the disengaging
zone (20) or the collection zone (22) below the injection point (18) through a regenerated
catalyst inlet (27) and wherein the settling of the catalyst takes place in a settling
(22) zone that extends below the regenerated catalyst inlet (27).
7. The process of claim 1 wherein the rising vapors and entrained catalyst particles
enter the inertial separator (29) through a separator inlet (39) having an opening
that faces a side of the disengaging zone (20) opposite the side from which the catalyst
particles and hydrocarbons are injected.
8. An apparatus for quick contacting of particulate catalyst with a hydrocarbon-containing
feed, the apparatus comprising:
A disengaging vessel portion (20);
A catalyst and feed contactor (114, 115) for injecting a hydrocarbon-containing feed
into a flowing stream of catalyst and injecting the feed and catalyst into the disengaging
vessel portion (20) in a substantially horizontal direction from an injection point
(18) defined by the feed contractor (114, 115) wherein the catalyst and feed contactor
(114, 115) injects the hydrocarbon feed into a flowing layer of catalyst in a substantially
transverse direction at a location upstream, with respect to catalyst flow, of the
injection point (18);
A collector vessel portion (22) located subjacent to the disengaging vessel portion
and at least 1.5m below the injection point (18) for collecting a dense bed of catalyst;
An inertial separator (29) located superjacent to the disengaging vessel portion (20)
and in direct communication with an upper portion of the disengaging vessel portion
(20) to separate hydrocarbons from the catalyst particles that rise with the hydrocarbons
from the disengaging vessel portion (20); and,
A catalyst outlet (31) for recovering separated hydrocarbons from the inertial separator.
9. The apparatus of claim 8 wherein a plurality of conduits (34) extend vertically through
the disengaging poriton (20) and are spaced with an orientation that leaves a clear
trajectory for at least half the diameter of the disengaging vessel portion (20) in
front of the injection point (18).
10. The apparatus of claim 8 wherein the inertial separator (29) defines a horizontally
projected inlet (39) that opens to a side of the disengaging zone (20) opposite the
side from which the catalyst particles and hydrocarbons are injected.