A petroleum hydrocarbon multi-stage fluid catalytic reaction method and reactor are described. The method implements a sectional multi-stage reaction in one reactor and comprises primary-stage and secondary-stage catalytic cracking reactions of feedstock oil and primary-stage and secondary-stage catalytic cracking reactions of light hydrocarbons and/or cycle oil, which occur in different reaction regions of the reactor. The primary-stage reaction of the light hydrocarbon and/or circulation oil is carried out in an independent reaction region. The reactor comprises a first reaction section, a catalyst splitter, a third reaction section, a second reaction section and a settler.

The present invention discloses an integrated process scheme for producing (i) high-octane gasoline blending stream (ii) high aromatic heavy naphtha stream which is a suitable feedstock for benzene, toluene, and xylene (BTX) production and (iii) high cetane ultra-low sulphur diesel (ULSD) stream suitable for blending in refinery diesel pool.

A process for upgrading a hydrocarbon feed includes passing the hydrocarbon feed and an aromatic bottoms stream to an FCC unit including an FCC reactor and a catalyst regenerator. The hydrocarbon feed is hydrogen-rich having at least 12 wt. % hydrogen, and the aromatic bottoms stream is a bottoms stream produced from an aromatics recovery complex for processing reformate from naphtha reforming. The hydrocarbon feed and aromatic bottoms stream are cracked over the FCC catalysts to produce an effluent and spent FCC catalysts having coke deposits. The spent FCC catalyst is regenerated through combustion of the coke deposits. The hydrogen-rich hydrocarbon feed does not produce enough coke to satisfy the heat demand of the FCC reactor. Cracking the aromatic bottoms stream increases the amount of coke so that combustion of the additional coke during regeneration produces additional heat to satisfy the heat demand of the FCC reactor.

Provided is a process capable of converting the cokes on spent catalysts in a fluid catalytic cracking (FCC) process into synthesis gas. The produced synthesis gas contains high concentrations of CO and H.sub.2 and may be utilized in many downstream applications such as syngas fermentation for alcohol production, hydrogen production and synthesis of chemical intermediates. A reducer/regenerator reactor for a fluid catalytic process comprising a chemical looping system to produce synthesis gas is also described.

Provided is a process capable of converting the cokes on spent catalysts in a fluid catalytic cracking (FCC) process into synthesis gas. The produced synthesis gas contains high concentrations of CO and H.sub.2 and may be utilized in many downstream applications such as syngas fermentation for alcohol production, hydrogen production and synthesis of chemical intermediates. A reducer/regenerator reactor for a fluid catalytic process comprising a chemical looping system to produce synthesis gas is also described.

In accordance with the present subject matter there is provided a catalyst composition including 70-98% of a non-zeolitic material; and 2-30% of at least one zeolite material, the percentage being based on weight of the catalyst composition. The subject matter also relates to a method for preparation of the catalyst composition. The subject matter further relates to a process for the fluid catalytic cracking of a hydrocarbon feedstock.

In accordance with the present subject matter there is provided a catalyst composition including 70-98% of a non-zeolitic material; and 2-30% of at least one zeolite material, the percentage being based on weight of the catalyst composition. The subject matter also relates to a method for preparation of the catalyst composition. The subject matter further relates to a process for the fluid catalytic cracking of a hydrocarbon feedstock.

A method of cracking a hydrocarbon feed under fluid catalytic cracking conditions includes adding FCC compatible inorganic particles having a first particle type including one or more boron oxide components and a first matrix component into a FCC unit and adding cracking microspheres having a second particle type including a second matrix component, a phosphorus component and 20% to 95% by weight of a zeolite component into the FCC unit.

A method of cracking a hydrocarbon feed under fluid catalytic cracking conditions includes adding FCC compatible inorganic particles having a first particle type including one or more boron oxide components and a first matrix component into a FCC unit and adding cracking microspheres having a second particle type including a second matrix component, a phosphorus component and 20% to 95% by weight of a zeolite component into the FCC unit.

A multi-zoned fluidized bed reactor system may include a multi-zoned fluidized bed reactor and at least one catalyst regeneration loop. The multi-zoned fluidized bed reactor comprising a housing, a fluid bed distributor plate positioned at the bottom of the housing, a fluidized catalyst bed disposed vertically above the fluid bed distributor plate and a condensation zone disposed vertically above the fluidized catalyst bed. The at least one catalyst regeneration loop may be fluidly coupled to the stripping zone and a reaction zone. The at least one catalyst regeneration loop may be operable to withdraw a portion of spent catalyst from the stripping zone, regenerate the portion of spent catalyst to produce regenerated catalyst, and return the regenerated catalyst to the reaction zone. A method of regenerating catalyst in a multi-zoned fluidized bed reactor may include passing a portion of spent catalyst from a stripping zone to a catalyst regeneration loop.