A process and apparatus for fluidizing a catalyst cooler with fluidization gas fed to the cooler below the catalyst bed is disclosed. Fluidization headers extend through an outlet manifold and deliver fluidization gas through distributors protruding through an outlet tube sheet defining said outlet manifold. The outlet manifold collects heated water vapor from the catalyst cooler and discharges it from the catalyst cooler.

Apparatus and processes herein provide for converting hydrocarbon feeds to light olefins and other hydrocarbons. The processes and apparatus include, in some embodiments, feeding a hydrocarbon, a first catalyst and a second catalyst to a reactor, wherein the first catalyst has a smaller average particle size and is less dense than the second catalyst. A first portion of the second catalyst may be recovered as a bottoms product from the reactor, and a cracked hydrocarbon effluent, a second portion of the second catalyst, and the first catalyst may be recovered as an overhead product from the reactor. The second portion of the second catalyst may be separated from the overhead product, providing a first stream comprising the first catalyst and the hydrocarbon effluent and a second stream comprising the separated second catalyst, allowing return of the separated second catalyst in the second stream to the reactor.

Provided is a process capable of converting the cokes on spent catalysts in a fluid catalytic cracking (FCC) process into synthesis gas. The produced synthesis gas contains high concentrations of CO and H.sub.2 and may be utilized in many downstream applications such as syngas fermentation for alcohol production, hydrogen production and synthesis of chemical intermediates. A reducer/regenerator reactor for a fluid catalytic process comprising a chemical looping system to produce synthesis gas is also described.

The present invention refers to an integrated operation method of conventional and residue FCC units that applies a model developed for predicting the catalytic performance of residue FCC units with any content and quality of flushing for the correct prediction and optimization of process simulators for residue FCC units and refining production planning models. The application can be for individual studies in process simulators or in digital twins to mitigate the unreliability in the prediction of the original simulator for studies with wide alteration in the content and quality of the flushing. The other application consists of modifying the refining production planning models based on the simulation result obtained in the modified process simulators to predict the performance of the waste units operating for any variation in the content and quality of the flushing catalyst used. The refining production planning model allows: 1. Indicative of potential profitability gain; 2. Optimum replacement of virgin and flushing catalysts in the conventional and residue FCC units; 3. Better distribution of the flushing content and flushing quality for FCC consumer units of the flushing system; 4. Quantifies the marginal value of flushing generated in the FCCs units that produce flushing; 5. Defines the best virgin catalyst budget and predicts the logistical costs of transporting flushing between the FCC units producing flushing and consuming flushing, considering all viable routes.

A process for power generation using a chemical looping combustion concept is integrated with heavy liquid fuel coking in a cracking reactor, and is configured such that petcoke deposits on metal oxide particles from the cracking reactor are used as fuel in the chemical looping combustion reaction. The process is also configured such that metal oxide particles provide the heat necessary for the cracking reaction to be initiated in the cracking reactor.

Methods and systems for producing a hydrocarbon are provided. The method can include cracking one or more C.sub.2-C.sub.10 hydrocarbons in the presence of a catalyst under conditions sufficient to produce an effluent containing ethylene, propylene, gasoline, and a coked-catalyst, wherein the catalyst includes a first catalytic component having an average pore size of less than 6.4 Å and a second catalytic component having an average pore size of 6.4 Å or more, separating the effluent to provide a recovered coked-catalyst and a cracked product; and regenerating the recovered coked-catalyst to produce heat and the catalyst.

The present invention relates to catalyst product, a method of making a catalyst and its use in fluid catalytic conversion process. In particular, this invention relates to a process for the preparation of CO-combustion promoter microspheres, comprising a large crystallite low surface area alumina; a composite binder comprising nano-crystallite alumina and dispersant; and platinum or palladium or both. The large crystallite low surface area alumina is bound together by the composite binder in the said particulate composition.

Disclosed is a catalytic cracking process for producing isobutane and/or light aromatics in high yield, comprising the steps of: a) providing a catalytic cracking feedstock oil having a polycyclic naphthene content of greater than about 25 wt %; b) subjecting the catalytic cracking feedstock oil to a first catalytic cracking reaction and a second catalytic cracking reaction sequentially under different reaction conditions to obtain a catalytic cracking product; c) separating the resulting catalytic cracking product to obtain a liquefied gas fraction comprising isobutane and a gasoline fraction comprising light aromatics; and d) optionally, recovering isobutane from the liquefied gas fraction and/or recovering light aromatics from the gasoline fraction. The process can enable the production of isobutane and/or light aromatics in high yield.

A process and apparatus is for recycling LCO and/or HCO to an FCC unit to recover additional distillate. Spent catalyst recycle in the FCC unit may be used to improve distillate yield. A hydroprocessing zone may saturate cycle oil aromatics for cracking in an FCC unit. The recycle cracked stream may be recycled to a downstream hydroprocessing zone to avoid a first hydroprocessing zone for hydrotreating feed to the FCC unit. Additional recovery of cycle oil for recycle is obtained by heating slurry oil prior to vacuum separation.

Light olefins may be produced from hydrocarbons by a method including passing a hydrocarbon feed stream into a feed inlet of a reactor. The reactor may include an upper reactor portion defining an upper reaction zone and a lower reactor portion defining a lower reaction zone. The catalyst may move in a generally downward direction through the upper reactor portion and the lower reactor portion, and the hydrocarbon feed stream may move in a generally upward direction through the upper reactor portion and lower reactor portion such that the hydrocarbon feed stream and the catalyst move with a counter-current orientation. Contacting the catalyst with the hydrocarbon feed stream may crack one or more components of the hydrocarbon feed stream and form a hydrocarbon product stream. The method may further include passing the hydrocarbon product stream out of the upper reaction zone through the hydrocarbon product outlet.