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This invention relates to an improved catalytic cracking reactor system and process for cracking hydrocarbon-containing materials. In accordance with another aspect, this invention relates to a transfer line catalytic cracking riser-reactor having a vertical section and a horizontal section wherein the cross-sectional area of the horizontal section is larger than the vertical section so as to provide a lower flow velocity in the horizontal section. In accordance with another aspect, this invention relates to a process for cracking hydrocarbon-containing materials in a riser-reactor system having a vertical section and a horizontal section wherein the flow velocity of reactant and catalyst in the vertical portion is at a higher rate than the flow rate of reactant and catalyst in the horizontal section so that the reaction effluent passed to the catalyst separation zone is introduced at a flow rate such that erosion of equipment is minimized.
In recent years the process of catalytic cracking of gas oils and heavier petroleum stocks to produce gasoline and light olefins has been significantly improved by the development of improved cracking systems. One such cracking system is the riser-type or transfer line reactors which have many advantages over other systems and are a well-known type of catalytic cracking operation. One problem encountered in the riser-type of transfer line reactors is attrition of catalyst and erosion of the catalyst separators to which the riser-reactor effluent is introduced for separation of catalyst for regeneration from the catalytic cracked product. The present invention is directed to an improved riser-reactor whereby erosion of equipment is minimized.
Accordingly, an object of this invention is to provide an improved riser-reactor apparatus useful for cracking hydrocarbon oils.
Another object of this invention is to provide an improved process whereby flow velocities through the riser-reactor are so controlled that erosion of equipment is minimized.
Other objects, aspects, and the several advantages of the invention will become apparent to those skilled in the art upon a study of the specification, the drawing, and the appended claims.
In accordance with the invention, an improved catalytic cracking process is provided having a riser-reactor wherein a high flow velocity of hydrocarbon reactant and catalyst is employed in the vertical portion of the riser and a lower velocity of reactant and catalyst in the lateral or horizontal portion of the reactor and introducing reactant effluent containing catalyst into the catalyst separation units under conditions whereby erosion is minimized.
In accordance with one specific embodiment, an elongated cylindrical transfer line catalytic cracking riser-reactor system is provided having a vertical section of a smaller cross-sectional area than the horizontal section for introduction of effluent into a catalyst separation unit so that erosion of the horizontal section and the catalyst separation is minimized.
In accordance with another specific embodiment, the flow velocity of catalyst and hydrocarbon reactant in the vertical section of a riser-reactor is in the range of about 65 to about 90 feet per second and the flow velocity in the horizontal section is less than about 65 feet per second and less than the flow velocity of the vertical section so that erosion of the horizontal section and, in particular, in catalyst separation units is minimized.
The apparatus of this invention allows a riser-type reaction zone to be designed in a manner which allows the effluent material from the riser-type reaction zone which comprises catalyst and cracked products to pass into cyclone separation units located within a separation vessel for the relatively quick separation of catalyst and hydrocarbons under conditions such that erosion of the catalyst separation units, e.g., cyclones, is minimized. The present invention employs two or more sets of cyclone separators to separate catalyst from cracked products.
The reaction zone, regeneration zone, and separation zones along with all inlet and outlet lines and all transfer lines which are included as part of the apparatus of the present invention can be constructed of any suitable material. The metals used in the construction of the various parts of the apparatus should be of such a nature as to withstand temperatures greater than 600.degree. F. and not be easily worn away by contact with the small particle size catalysts. Typical of the metals which can be used include carbon steel with erosion-resistant linings, stainless steel metals and various metals derived therefrom including metals containing chromium and nickel.
The present invention has its greatest advantage in application to catalytic cracking of heavy petroleum hydrocarbon stocks. Typical stocks are light and heavy gas oils obtained by primary distillation, vacuum distillation, and the like, from crude oils of various sources and reduced crudes. The boiling range, e.g., 450.degree. to 650.degree. F. for light gas oils and 650.degree. to 850.degree. F. or even higher for heavy gas oils.
Catalyst for catalytic cracking include known types including silica-alumina or silica-magnesia synthetic microspheres or ground gels and various natural clay type or synthetic gel type catalysts.
A better understanding of the invention will be obtained upon reference to the accompanying drawing which illustrates schematically the described process and apparatus.
Referring to the drawing, the apparatus depicted shows a regenerator 10, riser-reactor having a vertical tubular section 20 and horizontal tubular section 21 and a catalyst disengaging vessel 30 which is provided with catalyst separation units 22, e.g., cyclones. The separated used or spent catalyst is regenerated in regenerator 10 by contact with air introduced at 29 and 31 under suitable conditions to burn off the coke and hydrocarbon deposits remaining on the catalyst. Regenerator 10 is ordinarily operated at a temperature in the range of about 1100.degree.-1500.degree. F.
Regenerated catalyst is removed from a lower portion of regenerator 10 by way of line 11 and the rate of withdrawal is controlled by slide valve 12. At the elbow of withdrawal line 11 is an inlet conduit 13 for introduction of steam 13, if needed, to move catalyst through line 11 into a lower portion of vertical section 20 of the riser-reactor. Oil and steam are introduced through valved line 14 into the base or lower portion of vertical reaction section 20.
Hot regenerated catalyst, oil, and steam are contacted in the lower portion of vertical reaction section 20 and passed upwardly at a flow velocity in the range of about 65 to about 90 feet per second which is sufficient to minimize recirculation or backflow of catalyst in the vertical leg. The cross-sectional area or diameter of vertical riser-reactor 20 is sized such that the flow of reactant and catalyst through section 20 falls within the range of 65 to 90 feet per second. The reaction time, for example, for a topped crude oil feed to be in contact with catalyst in vertical riser-reactor 20 can be in the range of 1.6 to 2.2 seconds.
The top of vertical section 20 is connected to horizontal section 21 which is of greater cross-sectional area than the vertical section 20 so that the flow velocity of reactant and catalyst in the horizontal section is less than about 65 feet per second, preferably less than about 60 feet per second, but always less than the flow rate in vertical section 20. The horizontal velocity is sufficiently high to prevent catalyst drop out, but low enough to avoid erosion of the cyclone separator inlet. Horizontal section 21 is connected to vertical section 20 at a right angle. Preferably, sections 20 and 21 are cylindrical. In actual installation, the vertical section 20 and the horizontal section 21 can vary a few degrees from vertical and horizontal, respectively. A conventional erosion protected elbow 20' is used between vertical section 20 and horizontal section 21.
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The effluent from riser-reactor 20 and 21 is introduced into one or more cyclone separators 22 located within catalyst disengaging vessel 30. The reaction effluent is introduced into the cyclone separators in such a manner as to separate catalyst from the cracked hydrocarbon products. Catalyst is withdrawn from a lower portion of each cyclone 22 by way of dip leg 23 and cracked hydrocarbon product is passed via second cyclones 22' to fractionation (not shown) by way of line 24.
Used separated catalyst collects in a lower portion of vessel 30 in stripping section 25 and is countercurrently contacted with stripping steam introduced by line 26 for removal of residual amounts of occluded cracked hydrocarbon from the catalyst. Stripped materials and steam are removed overhead through cyclones 22' and by way of line 24.
Stripped used separated catalyst is passed by way of line 27 to a lower portion of regenerator 10 wherein it is contacted with preheated air introduced by line 31 which lifts catalyst from well 28 to the annulus wherein it is contacted with heated air introduced by line 29. The air in line 29 can be heated to a temperature of about 440.degree. F., or higher, and serves as combustion air for burning coke and other carbonaceous deposits from the catalyst surfaces in the annulus and lower portion of regenerator 10. Flue gas is removed from regenerator 10 via cyclones 32 and conduit 33 for disposal.
The conditions obtaining in riser-reactor 20 and 21 are well known and within the skill of the art. However, ordinarily, the temperature in riser-reactor 20 will be in the range of 880.degree. F. to 1030.degree. F. with a hydrocarbon to steam weight ratio of about 10:1 to about 25:1 and a catalyst to hydrocarbon weight ratio of about 5:1 to about 8:1. Pressure in riser-reactor 20 will be in the range of about 10 to about 60 psia. As indicated previously, the flow velocity in the vertical section of riser-reactor will be in the range of about 65 to 90 feet per second and the horizontal flow velocity will be in the range of 50 to 65 feet per second, but preferably less than 60 feet per second. In any event, the flow velocity in the vertical section will be at a higher rate than in the horizontal section.
The total reaction time in both the riser and horizontal runs depends on many factors, including:
(a) type of oil, e.g., light cycle or heavy cycle oil requiring more time than less refractory virgin gas oil or (still less) topped crude;
(b) type of catalyst (activity); and
(c) reaction temperature (catalyst temperature and catalyst-to-oil ratio).
Thus, broadly, the total reaction time for both the vertical and horizontal reaction sections can range from about 2 seconds for topped crude up to about 5 seconds for cycle oils.
The reaction time in a preferred embodiment employing a topped crude feed in the vertical portion will be in the range of 1.6 to 2.2 and in the horizontal section 0.43 to 0.56 seconds. The total reaction time in this embodiment for both the vertical and horizontal sections will be about 2 to about 3 seconds, more often 2.76 seconds.
The ratio of the cross-sectional area of the vertical riser to the cross-sectional area of the horizontal section based on the average flow velocities in both the vertical and horizontal sections ranges from at least about 0.5 up to about 1. Using average velocities set forth herein and wherein area of flow times time of flow is constant, the ratio can be determined as follows: ##EQU1##
In one specific embodiment of the invention, the vertical riser-reactor 20 and 21 described in the drawing has a length of 143 feet and the horizontal section has a length of 28 feet with the vertical section being 50 inches in diameter and the horizontal section being 56 inches in diameter.
The following calculated operation describes and sets forth various conditions for the reaction system set forth in the drawing:
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Calculated Operation
Ranges (Where
Appropriate)
Specific
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(14) Topped Crude, B/H -- 2,085
.degree.API at 60.degree. F.,
-- 19.3
Steam Added at 466.degree. F., lb/hr,
-- 40,000
Oil Temperature, .degree.F.,
-- 500
(13) Optional Steam, lb/hr,
-- 1,800
Temperature, .degree.F.
-- 466
(11) Regenerated Catalyst:
Tons/hour, -- 2,400
Temperature, .degree.F.,
1150-1450 1,400
(29) Air for Regeneration:
Pounds/hour, -- 957,700
Temperature, .degree.F.,
-- 440
Pressure, psia, -- 54.8
(31) Air to Lift Catalyst:
Pounds/hour, -- 4,600
Temperature, .degree.F.,
-- 200
Pressure, psia, -- 100
(10) Conditions in Regenerator:
Pressure, psia, 10-60 47.6
Temperature, .degree.F.
1150-1450 1,400
Diameter, feet, (I.D.,),
-- 48.83
Length, feet, (approximately),
-- 110
(20) Riser-Reactor:
Vertical Length, feet,
-- 143
Diameter, inches, (I.D.),
-- 50
Velocity, feet/sec.,
65 to 90 70
Reaction time, sec.,
1.6 to 2.2 2.04
(21) Horizontal Length, feet,
25 to 35 28
Diameter, inches, (I.D.),
-- 56
Velocity, feet/sec.,
50 to 65 60
Reaction time, sec.,
0.43 to 0.56
0.47
Total Reaction Time, sec.,
2.03 to 2.76
2.51
(30) Disengaging Vessel:
Pressure, psia, 10-60 42.3
Temperature, .degree.F.,
880-1030 970
Diameter, feet, (I.D.),
-- 27.33
Length, feet, (approximately),
-- 70
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Note:
There are 16 to 32 2-stage cyclones in the top zone of regenerator 10; there are 4 riser cyclones in parallel, and about 16 secondary cyclones, in cyclone vessel 30 to which riser-reactor is fed by reactor lateral conduit.
The invention gives desired total reactor contact time by adjusting vertical riser velocity and by maintaining horizontal velocity to a level so as to not erode to any great degree the primary cyclones 22. This horizontal velocity is preferably less than 65 feet/second, e.g., 60 feet/second, and still effects proper cyclones operations.
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