A fluidized catalytic reactor utilizes an ascending temperature profile. The apparatus and process deliver cooler spent catalyst to a first catalyst distributor and a hotter regenerated catalyst to a second catalyst distributor that are spaced apart from each other. The reactant stream first encounters the first stream of catalyst and then encounters the second stream of catalyst. The process and apparatus stage the addition of hot catalyst to the reactant stream. The process and apparatus may be particularly advantageous in an endothermic reaction because the hotter catalyst will encounter reactants that have cooled due to the progression of endothermic reactions.

According to one or more embodiments disclosed herein, methods for operating dehydrogenation processes during non-normal operating conditions, such as at start-up, shut-down, system recycle, or unit trip, are described. The methods may include contacting a feed stream with a catalyst in a reactor portion of a reactor system to form a reactor effluent stream, separating at least a portion of the reactor effluent stream from the catalyst, passing the catalyst to a catalyst processing portion and processing the catalyst, wherein processing the catalyst comprises contacting the catalyst with oxygen, passing the catalyst from the processing portion to the reactor portion, wherein the catalyst exiting the processing portion comprises at least 0.001 wt. % oxygen, and contacting the catalyst with supplemental hydrogen, the contacting removing at least a portion of the oxygen from the catalyst by a combustion reaction.

According to one or more embodiments disclosed herein, methods for operating dehydrogenation processes during non-normal operating conditions, such as at start-up, shut-down, system recycle, or unit trip, are described. The methods may include contacting a feed stream with a catalyst in a reactor portion of a reactor system to form a reactor effluent stream, separating at least a portion of the reactor effluent stream from the catalyst, passing the catalyst to a catalyst processing portion and processing the catalyst, wherein processing the catalyst comprises contacting the catalyst with oxygen, passing the catalyst from the processing portion to the reactor portion, wherein the catalyst exiting the processing portion comprises at least 0.001 wt. % oxygen, and contacting the catalyst with supplemental hydrogen, the contacting removing at least a portion of the oxygen from the catalyst by a combustion reaction.

An air lance for removing pellets from tubes includes a conduit body having an inlet end and a bottommost discharge opening, and a poker fixed relative to the conduit body and projecting beyond the bottommost discharge opening to serve as a spacer and poker; wherein a rigid member extends along said conduit body, such that that a hammering force applied to said rigid member where it extends outside of the tube will be transmitted through said rigid member to said poker for dislodging and breaking pellets.

The invention provides an improved system for separation technology intended to reduce unwanted catalyst/thermal reactions by minimizing contact of the hydrocarbons and the catalyst within the reactor.

A control system for automatic operation of a hydrocracking unit is shown. The control system includes a control device operable to affect at least one of a yield or a product quality of one or more output oil products provided as outputs of the hydrocracking unit. The control system further includes a controller configured to obtain an objective function that quantifies a value of operating the hydrocracking unit as a function of at least one of the yield or the product quality of the one or more output oil products, use a neural network model to generate a target control device setpoint predicted to optimize the objective function when the hydrocracking unit operates at the target control device setpoint, and operate the control device using the target control device setpoint to modulate at least one of the yield or the product quality of the one or more output oil products.

A process and reactor for contacting a feed stream with a catalyst stream comprises a reaction chamber comprising two spent catalyst inlets for delivering two spent catalyst streams to the reaction chamber and at least one regenerated catalyst inlet for delivering a regenerated catalyst stream to the reaction chamber. The reaction chamber may also include a second regenerated catalyst inlet for delivering a second regenerated catalyst stream to the reaction chamber. The second spent catalyst inlet enables thorough mixing of catalyst streams.

Processes and systems for the conversion of hydrocarbons herein may include separating an effluent from a moving bed reactor, the effluent including reaction product, first particulate catalyst, and second particulate catalyst. The separating may recover a first stream including the reaction product and first particulate catalyst and a second stream including second particulate catalyst. The second stream may be admixed with a regenerated catalyst stream including both first and second particulate catalyst at an elevated temperature. The admixing may produce a mixed catalyst at a relatively uniform temperature less than the elevated regenerated catalyst temperature, where the temperature is more advantageous for contacting light naphtha and heavy naphtha within the moving bed reactor to produce the effluent including the reaction product, the first particulate catalyst, and the second particulate catalyst.

Aqueous effluent treatment system including a separation reactor having a reactor chamber fluidly connected to an aqueous effluent source, connected via a pump to an inlet of the reactor chamber, a fluid extraction system connected to a liquid effluent outlet at a top of the reactor chamber, and a solid residue extraction system connected to a solid residue outlet at a bottom of the reactor chamber. The separation reactor is operable to generate pressures exceeding 22 MPa and temperatures exceeding 300° C. in the reactor chamber configured to generate a supercritical zone in an upper portion of the reactor chamber to which the liquid effluent outlet is connected, and a subcritical zone in a lower portion of the chamber within the reactor chamber to which the solid residue outlet is connected. The solid residue extraction system comprises an output circuit comprising a collector coupled to the solid residue outlet via a collector input valve (V1) and to a water output tank via a filter and a collector liquid output valve (V4) operable to be opened to cause a pressure drop at the solid residue outlet to draw solid residue out of the reactor chamber, the solid residue extraction system further comprising a gas feed circuit connected via a gas supply valve (V5) to the collector, the gas supply valve operable to be opened to extract solid residues in the collector to a solids output tank connected to the collector via a collector solids output valve (V6).

A method for processing a chemical stream includes contacting a feed stream with a catalyst in a reactor portion of a reactor system causing a reaction which forms a product stream. The method includes separating the product stream from the catalyst, passing the catalyst to a catalyst processing portion of the reactor system, processing the catalyst in the catalyst processing portion, and passing a portion of the catalyst from the catalyst processing portion of the reactor system into a catalyst withdrawal system that includes a catalyst withdrawal vessel and a transfer line coupling the catalyst withdrawal vessel to the catalyst processing portion. Each of the catalyst withdrawal vessel and the transfer line include an outer metallic shell and an inner refractory lining. The method further includes cooling the catalyst in the catalyst withdrawal vessel from greater than or equal to 680° C. to less than or equal to 350° C.