Processing of different feeds in a fluid catalytic cracking unit
An apparatus and method for processing different feeds in a fluid catalytic cracking unit are disclosed which result in improved yields of C 3 , C 4 and gasoline range hydrocarbons as compared to conventional systems. The process comprises injecting a main hydrocarbon feed into a catalyst-containing riser reactor through a plurality of main feed injectors, and injecting a light hydrocarbon feed into the riser reactor at a location upstream from the main feed injectors and downstream from a control valve such as a regenerated catalyst slide valve, the light feed being injected in a region having a high density of catalyst particles. The light feed is injected in a dispersed way such the amount of feed injected corresponds to the density of catalyst particles at that particular point, with greater amounts of feed being injected at locations having a large number of catalyst particles. Also, a heavy hydrocarbon feed or a heavy recycle stream from the same FCC unit can be injected at the same elevation as the main feed injectors but through separate injectors.
1. A fluid catalytic cracking apparatus, comprising:
a catalyst regenerator;
a riser reactor having a set of main hydrocarbon feed injectors connected thereto and including a conduit portion fluidly connected to said catalyst regenerator for receiving regenerated catalyst, said conduit portion including an angled section located upstream from said set of main hydrocarbon feed injectors, said riser reactor including a vertical portion disposed downstream from said angled section,
a plurality of light hydrocarbon feed injectors fluidly connected to a light hydrocarbon feed source; and
a plurality of heavy hydrocarbon feed injectors fluidly connected to a heavy hydrocarbon feed source,
wherein the plurality of heavy hydrocarbon feed injectors and the main hydrocarbon feed injectors are disposed at approximately the same predetermined elevation on the riser reactor and, together, are slanted in the same direction relative to a flow of catalyst.
2. The fluid catalytic cracking apparatus according to claim 1 , wherein said riser reactor is configured to generate a region of relatively higher catalyst density in said flow of catalyst as compared to an average catalyst density in said flow of catalyst.
3. The fluid catalytic cracking apparatus according to claim 2 , wherein at least one of said plurality of light hydrocarbon feed injectors are disposed at said region of relatively higher catalyst density.
4. The fluid catalytic cracking apparatus according to claim 1 , wherein said angled section of said conduit portion is configured to change the direction of said flow of catalyst.
5. The fluid catalytic cracking apparatus according to claim 1 , further comprising:
a control valve disposed between said catalyst regenerator and said riser reactor.
6. The fluid catalytic cracking apparatus according to claim 5 , wherein said control valve is regenerated catalyst slide valve.
7. The fluid catalytic cracking apparatus according to claim 1 , wherein said catalyst regenerator is configured to regenerate a zeolite catalyst.
8. The fluid catalytic cracking apparatus according to claim 1 , wherein said plurality of light hydrocarbon feed injectors include a first light hydrocarbon feed injector and a second light hydrocarbon feed injector.
9. The fluid catalytic cracking apparatus according to claim 8 , wherein said first light hydrocarbon feed injector is disposed at a lower end of said riser reactor and said second light hydrocarbon feed injector being disposed at said angled section and upstream from said first light hydrocarbon feed injector.
10. The fluid catalytic cracking apparatus according to claim 9 , wherein said riser reactor is configured to generate a region of relatively higher catalyst density in said flow of catalyst as compared to an average catalyst density in said flow of catalyst.
11. The fluid catalytic cracking apparatus according to claim 10 , wherein at least one of said plurality of light hydrocarbon feed injectors are disposed at said region of relatively higher catalyst density.
12. The fluid catalytic cracking apparatus according to claim 8 , wherein said angled section of said conduit portion is configured to change the direction of the flow of catalyst.
13. The fluid catalytic cracking apparatus according to claim 8 , further comprising:
a control valve disposed between said catalyst regenerator and said riser reactor.
14. A fluid catalytic cracking apparatus, comprising:
a catalyst regenerator;
a riser reactor having a set of main hydrocarbon feed injectors connected thereto and including a conduit portion fluidly connected to said catalyst regenerator for receiving regenerated catalyst, said conduit portion including an angled section located upstream from said set of main hydrocarbon feed injectors, said riser reactor including a vertical portion disposed downstream from said angled section; and
a plurality of light hydrocarbon feed injectors,
wherein the plurality of light hydrocarbon feed injectors comprises a plurality of first light hydrocarbon feed injectors and a plurality of second light hydrocarbon feed injectors fluidly connected to a light hydrocarbon source,
wherein the plurality of first light hydrocarbon feed injectors are disposed at a first predetermined elevation that is on a lower end of said riser reactor,
wherein the plurality of second light hydrocarbon feed injectors are disposed at a second predetermined elevation on the angled section and upstream from the plurality of first light hydrocarbon feed injectors;
wherein the plurality of light hydrocarbon feed injectors further comprises a plurality of third light hydrocarbon feed injectors fluidly connected to the light hydrocarbon source; and
wherein the plurality of third light hydrocarbon feed injectors are disposed at a third predetermined elevation that is on an upper end of the riser reactor.