Petrochemical products may be produced from a hydrocarbon material by a process that may include separating the hydrocarbon material into at least a lesser boiling point fraction and a greater boiling point fraction, cracking the lesser boiling point fraction in a first reactor in the presence of a catalyst at a reaction temperature of from 500° C. to 700° C. to produce a first cracking reaction product, and cracking the greater boiling point fraction in a second reactor in the presence of the catalyst at a reaction temperature of from 500° C. to 700° C. to produce a second cracking reaction product. The hydrocarbon material may be crude oil. The first reactor may be a riser, and the second reactor may be a downer. The catalyst may be passed from the first reactor to the second reactor, from the second reactor to a regenerator, and from the regenerator to the first reactor, such that the catalyst is circulated between the first reactor, second reactor, and regenerator. An amount of coke may be reduced on the catalyst in the regenerator.

A catalyst regenerator for regenerating a coked catalyst produced along with a olefin by mixing naphtha and a catalyst with each other to cause a naphtha cracking reaction, and falling from a cyclone which separates the coked catalyst and the olefin produced from the naphtha cracking reaction, includes: a vessel accommodating a catalyst layer formed by stacking the catalyst; a partial oxidation burner producing a high-temperature gas containing solid carbon; and supply nozzles connected to the partial oxidation burner, installed on a bottom of the vessel toward the falling catalyst and the catalyst layer, and spraying the high-temperature gas containing the solid carbon to the catalyst and the catalyst layer.

Systems and methods for enhancing the processing of hydrocarbons in a FCC unit by introduction of the coked FCC catalyst from the FCC reactor and a renewable feedstock to the FCC regenerator to facilitate regeneration of the coked FCC catalyst. The renewable feedstock can contain biomass-derived pyrolysis oil. The biomass-derived pyrolysis oil and coke from the coked FCC catalyst are oxidized by oxygen to provide a regenerated catalyst that is recycled to the FCC reactor.

A composition of fuel gas that when mixed with spent catalyst and oxygen has an induction time that allows bubbles to break up while combusting in the regenerator. Bubble breakage in a dense bed avoids generation of a flame that can generate hot spots in the regenerator which can damage equipment and catalyst. The fuel gas can be obtained from paraffin dehydrogenation products, so it can sustain operation of the unit even in remote locations. Heavier streams can be mixed with lighter streams to obtain a fuel gas composition with a desirable induction time to avoid such hot spots. Mixing of a depropanizer bottom stream and/or deethanizer overhead stream with lighter gas streams such as cold box light gas or PSA tail gas can provide the desired fuel gas composition.

The present invention provides a method of cooling a regenerated catalyst and a device thereof, which employs low-line-speed operation, wherein a range of the superficial gas velocity is 0.005-0.7 m/s, wherein at least one fluidization wind distributor is provided, wherein the main fluidization wind enters the dense bed layer of the catalyst cooler from the distributor, and the heat removal load of the catalyst cooler and/or the temperature of the cold catalyst is controlled by adjusting the fluidization wind quantity. The method and a device thereof of the present invention has an extensive application range, and can be extensively used for various fluid catalytic cracking processes, including heavy oil catalytic cracking, wax oil catalytic cracking, light hydrocarbon catalytic conversion and the like, or used for other gas-solid fluidization reaction charring processes, including residual oil pretreating, methanol to olefin, methanol to aromatics, fluid coking, flexicoking and the like.

Processes of catalytically pyrolyzing solid hydrocarbonaceous materials in a downflow fluid bed reactor and regenerating the catalyst in an upflow fluidized bed reactor are described. Systems and compositions useful in the catalytic pyrolysis of plastics are also described.

A two-step process that includes a pyrolytic first step carried out in a mechanically or gravitationally impelled reactor and a catalytic fluid bed second step that upgrades the resulting vapor, for the conversion of waste plastics, polymers, and other waste materials to useful chemical and fuel products such as paraffins, olefins, and aromatics such as BTX is described.

Systems and methods for producing light olefin(s) are disclosed. The method includes contacting a catalyst with a coke precursor to form a light olefin selective catalyst, and contacting the light olefin selective catalyst with a hydrocarbon feed under conditions sufficient to catalytically crack at least a portion of the hydrocarbon feed to form a products stream containing a light olefin, here the light olefin selective catalyst is more selective than the catalyst in catalyzing formation of the light olefin by the catalytic cracking of the hydrocarbon feed.

A cyclic metals deactivation system unit for the production of equilibrium catalyst materials including a cracker vessel configured for cracking and stripping a catalyst material; and a regenerator vessel in fluid communication with the cracker vessel, the regenerator vessel configured for regeneration and steam deactivation of the catalyst material.

Processes involving the use of a dry sorbent injection (DSI) unit or slurry reagent injection (SRI) unit to remove sulfur compounds form flue gas are described. Flue gas from an FCC regenerator, for example, is used to make superheated steam and saturated steam. The flue gas is then sent to a DSI unit to remove the sulfur compounds, and then to an economizer (or heat exchanger) to heat boiler feed water or combustion air. Because the temperature is not reduced as much as with a wet scrubber process, additional energy can be recovered in the economizer.