Methods for separating gaseous components, such as unreacted hydrocarbon monomer and/or solvent, from polyolefin solids are provided. The methods include contacting a first stream including polyolefin solids and gaseous unreacted hydrocarbon monomer and/or solvent with a first purge gas in a gas-solid separation vessel to separate the gaseous unreacted hydrocarbon monomer and/or solvent from the polyolefin solids to produce a second stream including polyolefin solids substantially free of gaseous unreacted hydrocarbon monomer and/or solvent and a third stream including the gaseous unreacted hydrocarbon monomer and/or solvent. The first purge gas includes hydrocarbon monomer and/or solvent and has a temperature of at least about 70° C. when entering the gas-solid separation vessel. Systems for carrying out such methods are also provided.

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.

The present disclosure relates generally processes and systems for converting a C2-C7 light alkanes feed to liquid transportation fuels or value-added chemicals. The feed is contacted with an aromatization catalyst at a temperature and pressure that selectively converts C4 and larger alkanes to an intermediate product comprising monocyclic aromatics and olefins. Following separation of the aromatics and C5+ hydrocarbons from the intermediate product, unconverted C2-C3 alkanes are thermally-cracked to produce olefins that are subsequently oligomerized to produce a liquid transportation fuel blend stock or value-added chemicals.

A reactor system configured for efficiently removing contaminants (CCR, nickel, vanadium, nitrogen, sodium, iron, calcium, chlorine etc.) from a heavy portion of the crude oil. The products are routed to a common main fractionation section. The heavy feed with lower contaminants may then be processed in a fluid catalytic cracking (FCC) unit, the overall concept employing a fluid catalytic reaction platform with carbon rejection approach. Also disclosed is a reactor system for efficiently processing crude oil in a fluid catalytic cracking unit with a dual-reactor and dual catalyst system to maximize petrochemical building blocks such as ethylene, propylene, butylenes, BTX (benzene, toluene and xylene) rich naphtha from a variety of crude oils.

A system for processing a hydrocarbon feed has a final stage reactor and internal separator with cyclone that forms a substantially gas stream and a substantially non-gas stream. The substantially gas stream is sent directly from the final stage reactor and separator to further downstream processing.

A system for processing a hydrocarbon feed has a final stage reactor and internal separator that forms a substantially gas stream and a substantially non-gas stream. The substantially gas stream is sent directly from the final stage reactor to a separator or for other processing.

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.

Apparatus and processes herein provide for converting hydrocarbon feeds to light olefins and other hydrocarbons. The processes and apparatus include a conventional riser reactor in combination with a mixed flow (e.g., including both counter-current and co-current catalyst flows) fluidized bed reactor designed for maximizing light olefins production. The effluents from the riser reactor and mixed flow reactor are processed in a catalyst disengagement vessel, and the catalysts used in each reactor may be regenerated in a common catalyst regeneration vessel. Further, integration of the two-reactor scheme with a catalyst cooler provides a refinery the flexibility of switching the operation between the two-reactor flow scheme, a catalyst cooler only flow scheme, or using both simultaneously.

In an FCC apparatus and process gas and catalyst exit from a riser, are disengaged from each other and the catalyst is stripped. Product gases are evacuated from catalyst that can over crack the product gases to other undesired products. A baffle in or above the stripping section can direct product gases into a passage that evacuates the product gases to product recovery in isolation from the catalyst.

A dehydrogenation process and apparatus contact a paraffinic stream with dehydrogenation catalyst to product olefinic product gases. The olefinic product gases are separated from spent dehydrogenation catalyst and contained in a confined space that has a smaller volume than the reactor particularly at the same elevation. The containment of the olefinic product gases facilitates quenching the olefinic product gases to terminate reaction and improve selectivity to propylene.