In a catalytic reaction, after a reaction product leaves a catalyst bed, an inert substance with a low temperature is sprayed, and through heat absorption and vaporization processes of the inert substance, the temperature of the reaction product drops rapidly when staying in a catalyst cushion layer at a discharge end of a fixed bed reactor, or in a space formed by the catalyst cushion layer at the discharge end of the fixed bed reactor and a reactor head, or in a space formed by a tube plate at the discharge end of the fixed bed reactor and the reactor head. The residence time of the reaction product is shortened due to the entrance of the inert substance in a gaseous state.

Apparatus and processes herein provide for converting hydrocarbon feeds to light olefins and other hydrocarbons. The processes and apparatus include, in some embodiments, feeding a hydrocarbon, a first catalyst and a second catalyst to a reactor, wherein the first catalyst has a smaller average particle size and is less dense than the second catalyst. A first portion of the second catalyst may be recovered as a bottoms product from the reactor, and a cracked hydrocarbon effluent, a second portion of the second catalyst, and the first catalyst may be recovered as an overhead product from the reactor. The second portion of the second catalyst may be separated from the overhead product, providing a first stream comprising the first catalyst and the hydrocarbon effluent and a second stream comprising the separated second catalyst, allowing return of the separated second catalyst in the second stream to the reactor.

A method of revamping vertical converters having a bolt-on flanged pressure shell extension for housing an internal heat exchanger is performed by replacing an existing pressure shell extension with a larger pressure shell extension for housing a plurality of internal heat exchangers.

A hydroprocessing system having a processing vessel that discharges a high temperature effluent that must be cooled prior to collection in a reflux drum. One or more gas assisted spray nozzle are provided that utilize light atomizing gas having a density of 8-15 times less than air, such as hydrogen, which preferably is the processing or recycle gas of the system. The spray nozzles are designed for the efficient atomization and direction of cooling water into a micron sized droplet distribution utilizing the light atomizing gas for affecting higher mass and heat transfer from the effluent. The spray nozzles each include a unique atomizing gas and cooling liquid passageway systems, a downstream impingement post, and a plurality of discharge orifices which sequentially breakdown the liquid into micron sized droplets as low as 500 microns and less.

A process for large scale and energy efficient production of oxygenates from sugar is disclosed in which a sugar feedstock is introduced into a thermolytic fragmentation reactor including a fluidized stream of heat carrying particles. The heat carrying particles may be separated from the fluidized stream prior to cooling the fragmentation product and may be directed to a reheater to reheat the particles and recirculate the heated particles to the fragmentation reactor.

Apparatus and processes herein provide for converting hydrocarbon feeds to light olefins and other hydrocarbons. The processes and apparatus include, in some embodiments, feeding a hydrocarbon, a first catalyst and a second catalyst to a reactor, wherein the first catalyst has a smaller average particle size and is less dense than the second catalyst. A first portion of the second catalyst may be recovered as a bottoms product from the reactor, and a cracked hydrocarbon effluent, a second portion of the second catalyst, and the first catalyst may be recovered as an overhead product from the reactor. The second portion of the second catalyst may be separated from the overhead product, providing a first stream comprising the first catalyst and the hydrocarbon effluent and a second stream comprising the separated second catalyst, allowing return of the separated second catalyst in the second stream to the reactor.

The present disclosure provides a system for energy recycling using mechanical vapor recompression in combined chemical process, the system including a heat exchange reactor for generating an intermediate material by means of an exothermic reaction and discharging the generated intermediate material, and heat-exchanging heat generated in the exothermic reaction with water supplied from outside so as to generate water vapor; an absorption tank for receiving the intermediate material, and mixing the intermediate material with water, so as to generate an intermediate material aqueous solution; a stripper for receiving the intermediate material aqueous solution, and separating the intermediate material into an intermediate material gas and an intermediate material water-rich aqueous solution; an endothermic reactor for receiving the intermediate material water-rich aqueous solution, and reacting the intermediate material with water, so as to generate a final product aqueous solution; an evaporation concentrator for receiving the final product aqueous solution, and heat-exchanging heat of the water vapor from the heat exchange reactor with the final product aqueous solution so as to generate steam; a dehydrating distillation tower for receiving, dehydrating, and purifying the final product aqueous solution discharged from the evaporation concentrator; and a mechanical vapor recompressor for compressing the steam from the evaporation concentrator, and providing the compressed steam as a source of heat or a source of steam supply.

Apparatus and processes herein provide for converting hydrocarbon feeds to light olefins and other hydrocarbons. The processes and apparatus include, in some embodiments, feeding a hydrocarbon, a first catalyst and a second catalyst to a reactor, wherein the first catalyst has a smaller average particle size and is less dense than the second catalyst. A first portion of the second catalyst may be recovered as a bottoms product from the reactor, and a cracked hydrocarbon effluent, a second portion of the second catalyst, and the first catalyst may be recovered as an overhead product from the reactor. The second portion of the second catalyst may be separated from the overhead product, providing a first stream comprising the first catalyst and the hydrocarbon effluent and a second stream comprising the separated second catalyst, allowing return of the separated second catalyst in the second stream to the reactor.

A hydroprocessing system having a processing vessel that discharges a high temperature effluent that must be cooled prior to collection in a reflux drum. One or more gas assisted spray nozzle are provided that utilize light atomizing gas having a density of 8-15 times less than air, such as hydrogen, which preferably is the processing or recycle gas of the system. The spray nozzles are designed for the efficient atomization and direction of cooling water into a micron sized droplet distribution utilizing the light atomizing gas for affecting higher mass and heat transfer from the effluent. The spray nozzles each include a unique atomizing gas and cooling liquid passageway systems, a downstream impingement post, and a plurality of discharge orifices which sequentially breakdown the liquid into micron sized droplets as low as 500 microns and less.

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.