Systems and methods for processing full range naphtha feeds to produce a light olefins stream and an aromatics stream are described. In particular, the invention concerns integration of catalytic cracking with steam cracking to maximize production of aromatics.

Systems and methods for producing olefins and/or aromatics via catalytically cracking a hydrocarbon feed are disclosed. The hydrocarbon feed is cracked in a reaction unit having one or more fluidized bed reactors. The catalyst particles are then separated from at least some of the gas product in a solid-gas separation unit to form separated catalyst particles. Methane is injected into the catalyst regeneration unit. The methane is burnt in the regeneration unit to provide additional heat to the regenerated catalyst such that the regenerated catalyst particles are at a temperature sufficient for the cracking when the regenerated catalyst particles are flowed to the reaction unit.

An improved process and catalyst composition for cracking hydrocarbons in a fluidized cracking process are disclosed. The process employs circulating inventory of a regenerated cracking having a minimal carbon content. The regenerated catalyst comprises a catalyst/additive composition which contains a pentasil zeolite, iron oxide, and a phosphorous compound. In accordance with the present disclosure, the catalyst/additive contains controlled amounts of iron oxide which is maintained in an oxidized state by maintaining low amounts of carbon on the regenerated catalyst inventory. In this manner it was discovered that the catalyst composition greatly enhances the production and selectivity of light hydrocarbons, such as propylene.

This invention provides a fluidized catalytic cracking apparatus and process for converting a hydrocarbon feedstock containing higher concentrations of Conradson Carbon Residue (CCR), metal impurities, etc into lighter products by employing two riser reactors in which the feed impurities are removed using an adsorbent in a first riser reactor and cracking a portion of first riser reactor liquid product in a second riser reactor to lighter products using the active catalyst thus eliminating the catalyst deactivation due to metal, impurities and FCC catalyst activity dilution effect to achieve a better conversion and higher catalyst longevity.

One exemplary embodiment can be a process for fluid catalytic cracking. The process can include sending a first catalyst from a first riser reactor and a second catalyst from a second riser reactor to a regeneration vessel having a first stage and a second stage. The first catalyst may be sent to the first stage and the second catalyst may be sent to the second stage of the regeneration vessel. Generally, the first stage is positioned above the second stage.

A method is provided for increasing production of middle distillate hydrocarbons from conversion of a heavy hydrocarbon feed in a fluid catalytic cracking system having a primary riser and a secondary riser, wherein the method comprises providing regenerated catalyst to the primary riser and operating the primary riser under severe conditions and providing spent catalyst to the secondary riser and operating the secondary riser under moderate conditions.

A naphtha and methanol mixed catalytic cracking reaction process involves a simultaneous cracking reaction of naphtha and methanol using a circulating fluidized-bed reactor comprising a reactor, a stripper, and a regenerator. The naphtha is supplied from the bottom part of the reactor at a position between 0%˜5% of the total length of the reactor, and the methanol is supplied from the bottom part of the reactor at a position between 10%˜80% of the total length of the reactor. The catalytic cracking reaction process uses the circulating fluidized-bed reactor and can crack naphtha and methanol simultaneously by having different introduction positions for the naphtha and methanol in the reactor, which is advantageous for heat neutralization, so that energy consumption can be minimized and also the yield of light olefins can be improved by suppressing the production of light saturated hydrocarbons such as methane, ethane and propane.

Systems and methods are provided for using a reverse flow reactor (or another reactor with flows in opposing directions at different parts of a process cycle) for pyrolysis of hydrocarbons. The systems and methods can include a reactor that includes a combustion catalyst to initiate and/or maintain combustion within the reactor in a controlled manner during the heating and/or regeneration portion(s) of the reaction cycle. A fuel can also be used that has a greater resistance to auto-combustion, such as a fuel that is composed primarily of methane and/or other hydrocarbons. During operation, the temperature in at least an initial portion of the reactor can be maintained at a temperature so that auto-ignition of the auto-combustion resistant fuel injected during the heating step(s) is reduced or minimized. This can allow combustion to be initiated when the auto-combustion resistant fuel comes into contact with the catalyst. Additionally, the amount and positioning of the catalyst within the reactor can be controlled so that combustion of the fuel takes place over a substantially longer period of time than combustion during a conventional reactor heating step. Because the fuel is moving within the reactor during combustion, extending the combustion time results in a substantial expansion of the volume where combustion occurs. Optionally in combination with an improved reaction cycle, this can expand the portion of the reactor that is directly heated by combustion, allowing for an improved temperature distribution within the reactor during the pyrolysis step.

A process for upgrading a naphtha feed includes separating the naphtha feed into at least a light naphtha fraction, contacting the light naphtha fraction with hydrogen in the presence of at least one cyclization catalyst, and contacting the cyclization effluent with at least one cracking catalyst. Contacting the light naphtha fraction with hydrogen in the presence of at least one cyclization catalyst may produce a cyclization effluent comprising a greater concentration of naphthenes compared to the light naphtha fraction. Contacting the cyclization effluent with at least one cracking catalyst under conditions sufficient to crack at least a portion of the cyclization effluent may produce a fluid catalytic cracking effluent comprising light olefins, gasoline blending components, or both. A system for upgrading a naphtha feed includes a naphtha separation unit, a cyclization unit disposed downstream of the naphtha separation unit, and a fluid catalytic cracking unit disposed downstream of the cyclization unit.

An advanced regulatory controller for a converter of a catalytic olefins unit is disclosed. A Fluid Catalytic Cracking (FCC) type converter (i.e., reactor-regenerator) is combined with an ethylene style cold-end for product recovery. The regulatory controller operates using an Advanced Regulatory Control (ARC) application using variables, such as a controlled variable, four disturbance variables, associated variable, and a manipulated variable. The ARC application manipulates fuel oil or tail gas flow to a regenerator in response to an expected future steady state value of a regenerator bed temperature resulting from changes in the values of a selected set of the variables.