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.

Processes for producing olefins include integration of steam cracking with a dual catalyst metathesis process. The processes include steam cracking a hydrocarbon feed to form a cracking reaction effluent containing butenes, separating the cracking reaction effluent to produce a cracking C4 effluent including normal butenes, isobutene, and 1,3-butadiene, subjecting the cracking C4 effluent to selective hydrogenation to convert 1,3-butadiene in the cracking C4 effluent to normal butenes, removing isobutene from a hydrogenation effluent to produce a metathesis feed containing normal butenes, and contacting the metathesis feed with a metathesis catalyst and a cracking catalyst directly downstream of the metathesis catalyst to produce a metathesis reaction effluent. Contacting with the metathesis catalyst causes metathesis of normal butenes to produce ethylene, propene, and C5+ olefins, and contacting with the cracking catalyst causes C5+ olefins produced through metathesis to undergo cracking reactions to produce additional propene, ethylene, or both.

A method for processing a hydrocarbon feed to produce olefins may comprise introducing the hydrocarbon feed to a first fluid catalytic cracking system, which may cause at least a portion of the hydrocarbon feed to undergo catalytic cracking and produce a spent first cracking catalyst and a first cracked effluent comprising one or more olefins. The method may further comprise passing the first cracked effluent to a separation system downstream of the first fluid catalytic cracking system, which may separate the first cracked effluent to produce at least a naphtha effluent comprising one or more olefins. Additionally, the method may comprise passing the naphtha effluent to a second fluid catalytic cracking system downstream of the separation system, which may cause at least a portion of the naphtha effluent to undergo catalytic cracking and produce a spent cracking catalyst mixture and a second cracked effluent comprising one or more olefins.

Petrochemical products may be produced from a hydrocarbon material by a process that may include separating the hydrocarbon material into at least a lesser boiling point fraction and a greater boiling point fraction, cracking the lesser boiling point fraction in a first reactor in the presence of a catalyst at a reaction temperature of from 500° C. to 700° C. to produce a first cracking reaction product, and cracking the greater boiling point fraction in a second reactor in the presence of the catalyst at a reaction temperature of from 500° C. to 700° C. to produce a second cracking reaction product. The hydrocarbon material may be crude oil. The first reactor may be a riser, and the second reactor may be a downer. The catalyst may be passed from the first reactor to the second reactor, from the second reactor to a regenerator, and from the regenerator to the first reactor, such that the catalyst is circulated between the first reactor, second reactor, and regenerator. An amount of coke may be reduced on the catalyst in the regenerator.

The invention is directed to a process to prepare propylene from a mixture of hydrocarbons having an olefin content of between 5 and 50 wt. % and boiling for more than 90 vol. % between 35 and 280° C. or from a hydrocarbon feed comprising paraffins, naphthenics, aromatics and optionally up to 10 wt. % of olefins, by first contacting the feed with a low acidic density cracking catalyst in a fixed bed reactor, separating propylene and subsequently contacting the residue with a high acidic density cracking catalyst in a fixed bed reactor at a more elevated temperature, separating propylene and recycling the residue to first and second cracking reactors. Aromatics may be added to first and second cracking step to improve cycle length.

The invention is directed to a process to prepare propylene from a mixture of hydrocarbons having an olefin content of between 5 and 50 wt. % and boiling for more than 90 vol. % between 35 and 280 ?C or from a hydrocarbon feed comprising paraffins, naphthenics and/or aromatics and optionally up to 10 wt. % of olefins, by first contacting the feed with a low acidic density cracking catalyst in a reactor, separating propylene and subsequently contacting the residue with a high acidic density cracking catalyst in a reactor at a more elevated temperature, separating propylene and recycling the residue to first and second cracking reactors. Aromatics may be added to first and second cracking step to improve cycle length.

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 subject matter provides a process for hydrocarbon residue upgradation. The combination of the hydrocarbon residue along with aromatic rich hydrocarbons, catalysts and surfactants allow the operation of visbreaking unit at higher temperature while producing a stable bottom product.

The present invention relates to a process for obtaining fuel from biomass which comprises the introduction of the catalyst (3) in the base of an cracking section (4), wherein said catalyst (3) at high temperature comes in contact with a gas stream of light hydrocarbons rich in hydrogen (1), wherein the catalyst (3) and hydrocarbon (1) then come in contact with a lignocellulosic liquid stream (2) in the same cracking section (4), creating the reaction mixture (5) that, soon after, comes into contact with the main stream containing the traditional fossil load of a FCC (6) in a second cracking section (7).

Light olefins may be produced from hydrocarbons by a method including passing a hydrocarbon feed stream into a feed inlet of a reactor. The reactor may include an upper reactor portion defining an upper reaction zone and a lower reactor portion defining a lower reaction zone. The catalyst may move in a generally downward direction through the upper reactor portion and the lower reactor portion, and the hydrocarbon feed stream may move in a generally upward direction through the upper reactor portion and lower reactor portion such that the hydrocarbon feed stream and the catalyst move with a counter-current orientation. Contacting the catalyst with the hydrocarbon feed stream may crack one or more components of the hydrocarbon feed stream and form a hydrocarbon product stream. The method may further include passing the hydrocarbon product stream out of the upper reaction zone through the hydrocarbon product outlet.