NZ792307B2 - Fluid catalytic cracking process and apparatus for maximizing light olefin yield and other applications - Google Patents

Abstract

The present invention relates to a particle separator for separating catalysts or other particles based on size and/or density. The separator comprises an inlet for providing a mixture comprising a carrier gas, a first particle type, and a second particle type. Each particle type has a particle size distribution, an average particle size and an average density, the second particle type having an average particle size and/or average density greater than the first particle type. The separator includes a chamber for receiving the mixture. The chamber is configured to separate at least a portion of the second particle type from the carrier gas and the first particle type. A first outlet is provided to recover the second particle type. A second outlet is provided to recover the carrier gas and the first particle type. A distributor is disposed within or proximate the first outlet for introducing a fluidizing gas, facilitating additional separation of the first particle type from the second particle type. The second particle type is returned, without being regenerated, to a reactor.

Claims (5)

1. A process for the conversion of hydrocarbons, comprising: feeding a first catalyst to a reactor; feeding a second catalyst to the reactor, wherein the first catalyst has a smaller average particle size and/or is less dense than the second catalyst; feeding a hydrocarbon feedstock to the reactor; recovering an overhead effluent from the reactor, the effluent including cracked hydrocarbon, the first catalyst, and the second catalyst; separating the second catalyst from the overhead product to provide a first stream comprising the first catalyst and the hydrocarbon effluent and a second stream comprising the separated second catalyst; returning the separated second catalyst in the second stream, unregenerated, to the reactor.

2. The process of claim 1, wherein separating the second catalyst from the overhead effluent to provide a first stream comprising the first catalyst and the hydrocarbon effluent and a second stream comprising the separated second catalyst comprises: separating the second catalyst and the first catalyst using a particle separation system.

3. The process of claim 2, further comprising operating the particle separation system at a superficial gas velocity sufficient to carry over a portion of the second catalyst in the first stream.

4. The process of claim 3, wherein the reactor and particle separation system are operated at a superficial gas velocity that is sufficient to carry over a portion of second catalyst in the first stream to maintain a catalyst inventory balance in the reactor.

5. A process for the conversion of hydrocarbons, comprising: regenerating a catalyst mixture comprising a first catalyst and a second particle in a regenerator, wherein the first catalyst has a smaller average particle size and/or is less dense than the second particle, and wherein the second particle may be catalytic or non-catalytic;