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.

A fuel tank inerting system includes a primary catalytic reactor comprising an inlet, an outlet, a reactive flow path between the inlet and the outlet, and a catalyst on the reactive flow path. The catalytic reactor is arranged to receive fuel from the fuel tank and air from an air source that are mixed to form a combined flow, and to react the combined flow along the reactive flow path to generate an inert gas. The system also includes an input sensor that measures a property of the combined flow before it enters the primary catalytic reactor and an output sensor that measures the property of the combined flow after it exits the primary catalytic reactor.

A process and system for maintaining optimum polymerization production in a loop polymerization reactor by continuously and periodically obtaining polymerization results, such as melt index (MI), production rate and ash content of the polymer produced, determining whether each of the results is within desired ranges, storing and averaging recently obtained results in a database within a reaction rate controller program, and when one of the results is out of the desired range modifying at least one reaction parameter set-point such as monomer concentration, catalyst feed rate and reactor temperature to drive any out-of-range polymerization result(s) toward the desired range for that result.

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.

A fuel tank inerting system includes a primary catalytic reactor comprising an inlet, an outlet, a reactive flow path between the inlet and the outlet, and a catalyst on the reactive flow path. The catalytic reactor is arranged to receive fuel from the fuel tank and air from an air source that are mixed to form a combined flow, and to react the combined flow along the reactive flow path to generate an inert gas. The system also includes an input sensor that measures a property of the combined flow before it enters the primary catalytic reactor and an output sensor that measures the property of the combined flow after it exits the primary catalytic reactor.

The present disclosure relates generally to methods and systems for achieving enhanced catalytic performance via the strategic arrangement of multiple catalyst beds in series, where each catalyst bed comprises a compositionally-distinct catalyst, and each catalyst facilitates the conversion of the same structural moieties on the reactant to form the same product. Arranging multiple catalyst beds according to the methods and systems disclosed herein allows a predictable enhancement of conversion of the reactant to product without the need for time-consuming experimentation to test all possible catalysts configurations.

A Fluid Catalytic Cracking process converts heavy crude oil fractions into lighter hydrocarbon products at high temperature and moderate pressure in the presence of a catalyst. During this process, catalyst particles stay entrained in the descending gas stream. An inlet scroll on the cyclone may be used to keep the inlet gas stream and the entrained particles away from the entrance to the gas outlet tube. Refractory material may applied to the interior of the wall of the cyclone to form an abrasion resistant lining to insulate the walls of the cyclone from the gas flow contents. The inlet feed velocity may be used as a predictive factor to determine a wear rate of the cyclones. Thus, lining erosion can be predicted so that the lining can be repaired or replaced during a planned turnaround.

Devices and methods for controlling the properties of chemical species during time-dependent processes. A device includes a reactor for containing one or more chemical species of a time-dependent process, an extraction pump for automatically and continuously extracting an amount of the one or more chemical species from the reactor, one or more detectors for measuring property changes of the one or more extracted chemical species and generating a continuous stream of data related to the one or more property changes to the one or more chemical species during a time interval, and a process controller configured to fit the continuous stream of data to a mathematical function to predict one or more properties of the one or more chemical species at a future time point and make one or more process decisions based on the prediction of one or more properties at the future time point.

A Fluid Catalytic Cracking process converts heavy crude oil fractions into lighter hydrocarbon products at high temperature and moderate pressure in the presence of a catalyst. During this process, catalyst particles stay entrained in the descending gas stream. An inlet scroll on the cyclone may be used to keep the inlet gas stream and the entrained particles away from the entrance to the gas outlet tube. Refractory material may applied to the interior of the wall of the cyclone to form an abrasion resistant lining to insulate the walls of the cyclone from the gas flow contents. The inlet feed velocity may be used as a predictive factor to determine a wear rate of the cyclones. Thus, lining erosion can be predicted so that the lining can be repaired or replaced during a planned turnaround.

Systems and methods of dehydrogenating a hydrocarbon in a fixed bed dehydrogenation unit. A method for dehydrogenating a hydrocarbon is applied to a fixed bed reactor. The hydrocarbon flows to a fixed bed reactor to be dehydrogenated in presence of a catalyst in the fixed bed reactor. The catalyst in the fixed bed reactor is then regenerated. The period for dehydrogenation, the period for catalyst regeneration and the period for total slack time are controlled such that total slack time is less than both half of the period for dehydrogenation and half of the period for regeneration. One of the advantages of the process comes from optimization of the slack time, thereby increasing the catalyst utilization rate and number of reactors concurrently online.