The present disclosure relates to fluid bed processes that utilize silica particles as a fluidization aid. The process comprises reacting one or more reactants in a reactor comprising a fluid bed to form a product. The fluid bed comprises a catalyst composition comprising a catalyst and an inert additive composition comprising silica particles from 0.5 wt % to 30 wt %, based on the total weight of the catalyst composition. The silica particles are discrete, inert particles that are mixed with the catalyst in the fluid bed.

A system for separating first reactor effluent product by means of an intermediate separator, and sending the unconverted slurry material from the separator to further reactors. Such intermediate separation decreases the required size of downstream reactors.

An erosion monitoring system of components exposed to wear for use in systems equipped with a fluidized catalyst comprising a bundle of fiber optic sensors, said optical fibers being provided with one or more Bragg gratings, a processing unit and the fiber optic sensors depart off from the bundle and are positioned transversely to the wall exposed to erosion wear due to the erosion of the components to be monitored.

A method for fluid catalytic cracking (FCC) of petroleum oil feedstock includes reacting the petroleum oil feedstock with a catalyst mixture in a reaction zone of an FCC unit to obtain a product stream including desulfurized hydrocarbon product, unreacted petroleum oil feedstock, and spent catalyst. During the reacting a process control system develops a process model based on data collected during the reacting, the process model characterizing a relationship among the feed rate of the base cracking catalyst, the feed rate of the FCC additive, the operating conditions, the composition of the product stream, and emissions from the reaction; and one or more of (i) a target feed rate of the base cracking catalyst, (ii) a target feed rate of the FCC additive, and (iii) one or more target operating conditions of the reaction in the reaction zone to reduce the emissions from the FCC unit and to increase a yield of the desulfurized hydrocarbon product in the product stream are determined.

Systems for separating a contaminant trapping additive from a cracking catalyst may include a contaminant removal vessel having one or more fluid connections for receiving contaminated cracking catalyst, contaminated contaminant trapping additive, fresh contaminant trapping additive, and a fluidizing gas. In the contaminant removal vessel, the spent catalyst may be contacted with contaminant trapping additive, which may have an average particle size and/or density greater than the cracking catalyst. A separator may be provided for separating an overhead stream from the contaminant removal vessel into a first stream comprising cracking catalyst and lifting gas and a second stream comprising contaminant trapping additive. A recycle line may be used for transferring contaminant trapping additive recovered in the second separator to the contaminant removal vessel, allowing contaminant trapping additive to accumulate in the contaminant removal vessel. A bottoms product line may provide for recovering contaminant trapping additive from the contaminant removal vessel.

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.

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.

A rotary feeder having a stationary, cylindrical housing having disposed therein a number of injection nozzles, and within which rotate a plurality of vanes about a central axis, wherein pairs of adjacent vanes of the plurality of vanes define wedge volumes, wherein the housing extends a width along the central axis, wherein each of the vanes has a length along the central axis, and wherein the injection nozzles are positioned across the width of the housing, such that a spray pattern of a gas injected via the number of injection nozzles spans substantially the entire length of the vanes.

In an apparatus for fluid catalytic cracking a riser having a top and a bottom for fluidizing and cracking a hydrocarbon feed stream by contact with catalyst exits an outlet at the top of the riser. A downer in communication with the outlet of the riser receives cracked hydrocarbon product and catalyst. A swirl duct in communication with the downer has a discharge opening below the outlet for discharging said cracked hydrocarbon product and catalyst. A stream of hydrocarbon feed and a catalyst is passed upwardly in a riser. A stream of gaseous hydrocarbon products and catalyst is directedly downwardly and then the stream of gaseous hydrocarbon products and catalyst are directed to flow in an angular direction to separate gaseous hydrocarbon products from the catalyst.

The present application discloses a molecular sieve-based catalyst modification apparatus. The apparatus comprises a feed unit 1, a modification unit 2 and a cooling unit 3 connected in sequence; the feed unit comprises a catalyst feed unit 11 and a modifier feed unit 12, a catalyst and a modifier are introduced into the modification unit 2 respectively by the catalyst feed unit and the modifier feed unit and are discharged from the modification unit after sufficient reaction in modification unit, and then enter the cooling unit 3 for cooling. The present application further discloses a use method for the molecular sieve-based catalyst modification apparatus. The use method comprises: introducing a catalyst and a modifier into the modification unit 2 respectively through the feed unit 1; wherein the catalyst is modified by the modifier in the modification unit 2, and then discharged to the cooling unit 3 to cool until the temperature is lower than 50 C., and then the cooled modified catalyst is transferred to any storage device.