Process for processing hydrocarbons to produce light olefins using catalyst formulations or mixtures

Abstract

Light olefins may be produced from hydrocarbons using a catalyst formulation or mixture by a process that includes feeding a hydrocarbon feed stream to one or more feed inlets of a reactor. The catalyst formulation may include multi-zeolite composite particles, or a mixture that is a combination of physical mixing of individual particles of at least a first composite particle of a first type of zeolite and a second composite particle of a second type of zeolite. 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 lower reactor portion and the upper reactor portion such that the hydrocarbon feed stream and the catalyst move in a countercurrent orientation.

Description

Technical Field

[0001] Embodiments of the present disclosure generally relate to methods for processing hydrocarbons, and more particularly, to methods for using catalyst formulations or mixtures for processing hydrocarbons to produce olefins. Background Art

[0002] Light olefins, including ethylene, propylene, and butene, are basic intermediates used in most of the petrochemical industry. In particular, pure streams of light olefins can be used in the production of various polymers and chemicals. Traditionally, light olefins can be produced by thermal cracking of petroleum fractions such as naphtha, kerosene, or gas oil. Light olefins can also be produced by a fluid catalytic cracking (FCC) process. With the increasing demand for light olefins, improved methods for producing light olefins are needed.

[0003] Regarding these and other problems in the art, the present disclosure aims to provide a technical solution for an improved method for producing light olefins using catalyst formulations or mixtures. Summary of the Invention

[0004] Light olefins can be produced from hydrocarbons using a catalyst formulation or mixture by a method including: feeding a hydrocarbon feed stream into one or more feed inlets of a reactor. The catalyst formulation can include a multi-zeolite composite particle, or a combination as a physical mixture of separate particles of a first composite particle of at least a first type of zeolite and a second composite particle of a second type of zeolite. The reactor can include an upper reactor portion defining an upper reaction zone and a lower reactor portion defining a lower reaction zone. The catalyst can move through the upper reactor portion and the lower reactor portion in a generally downward direction, and the hydrocarbon feed stream can move through the lower reactor portion and the upper reactor portion in a generally upward direction such that the hydrocarbon feed stream and the catalyst move in a countercurrent orientation. Contacting the catalyst with the hydrocarbon feed stream can crack one or more components of the hydrocarbon feed stream and form a hydrocarbon product stream. The method can further include exiting the hydrocarbon product stream from the upper reaction zone through a hydrocarbon product outlet.

[0005] In certain embodiments, the catalyst particles comprise a mixture that is a physical blend of separate particles of at least a first composite particle and a second composite particle. The first composite particle comprises from about 5 to 70 weight percent of a 10-membered ring zeolite component, optionally modified with phosphorus, from about 5 to 70 weight percent of a first binder component, from about 10 to 60 weight percent of a first filler component; and from 0 to 40 weight percent of an optional first additive component. The second composite particle comprises from about 5 weight percent of a 12-membered ring zeolite component, from about 5 to 70 weight percent of a second binder component, from about 10 to 60 weight percent of a second filler component; and from about 0 to 40 weight percent of an optional second additive component. The first and second binder components are the same or different amorphous components selected from alumina (including γ-alumina), silica, alumina-silicates, silica-aluminates, alumina phosphates, and combinations comprising two or more of said amorphous binder components. The first and second optional filler components are the same or different components selected from kaolin, sepiolite, talc, palygorskite, montmorillonite, and combinations of two or more of said filler components. The first and second additive components are the same or different components selected from metal carbides (including silicon carbide), rare earth metals (including cerium and lanthanum), alkali metals (including sodium), alkaline earth metals, and metal oxides (including iron oxide and copper oxide).

[0006] In certain embodiments, the catalyst particles comprise a multi-zeolite composite particle. The multi-zeolite composite particle comprises: from about 5 to 75 weight percent of a 10-membered ring zeolite component modified with phosphorus, from about 5 to 75 weight percent of a 12-membered ring zeolite component, from about 5 to 70 weight percent of a binder component, from about 10 to 60 weight percent of a filler component; and from about 0 to 40 weight percent of an optional additive component. The binder component is an amorphous component selected from alumina (including γ-alumina), silica, alumina-silicates, silica-aluminates, alumina phosphates, and combinations comprising two or more of said amorphous binder components. The filler component is selected from kaolin, sepiolite, talc, palygorskite, montmorillonite, and combinations of two or more of said filler components. The additive component is selected from metal carbides (including silicon carbide), rare earth metals (including cerium and lanthanum), alkali metals (including sodium), alkaline earth metals, and metal oxides (including iron oxide and copper oxide).

[0007] Any combination of the various examples and embodiments disclosed herein may be used. These and other aspects and features will be understood from the following description of certain examples, as well as the drawings and claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The following detailed description of specific embodiments of the present disclosure can be best understood when read in conjunction with the following drawings, in which like structures are denoted by like reference numerals.

[0009] Figure 1Schematically depicts a reactor and a catalyst regenerator for producing light olefins in accordance with one or more embodiments disclosed herein.

[0010] Figure 2 Schematically depicts a reactor and a catalyst regenerator for producing light olefins in accordance with one or more other embodiments.

[0011] Figure 3 Schematically shows a lower reactor section of a reactor for producing light olefins in accordance with one or more additional embodiments disclosed herein.

[0012] Figure 4 Schematically depicts a cross-sectional view of an upper reactor section of a reactor for producing light olefins in accordance with one or more embodiments disclosed herein.

[0013] Figures 5A - 5C Is a graph of the C1-C4 yields of the total activity and product distribution of the catalyst of the examples herein.

[0014] Figure 6 Plots the yield of the catalyst of the examples herein as a function of time on stream. Specific embodiments

[0015] Embodiments of the present disclosure relate to systems and processes for using catalyst formulations or mixtures for processing hydrocarbons to produce light olefins. The present disclosure includes embodiments related to the methods and apparatuses described in the co-owned U.S. patent application 16 / 940,668, filed on July 28, 2020, and published as US20220033714A1, titled "Methods and apparatuses for processing hydrocarbons to produce light olefins", which is incorporated herein by reference in its entirety.

[0016] As used in the present disclosure, "reactor" refers to a vessel in which one or more chemical reactions can occur between one or more reactants in the presence of one or more catalysts. One or more "reaction zones" may be provided in the reactor. As used in the present disclosure, "reaction zone" refers to the region in the reactor where a specific reaction occurs. In certain embodiments, the reaction zone includes a region arranged as a countercurrent plug flow reactor. In certain embodiments, the reactor includes a reaction zone, and the reaction zone includes a region arranged as a dense bed fluidized reactor. In certain embodiments, the reactor includes one reaction zone and another reaction zone, the one reaction zone being a region arranged as a countercurrent plug flow reactor, and the other reaction zone being a separate region arranged as a dense bed fluidized reactor. In certain embodiments, the reactor includes a stripping zone to strip hydrocarbons adsorbed on the catalyst.

[0017] As used in the present disclosure, "hydrocarbon reactant" refers to hydrocarbons from the hydrocarbon feed stream passing through the reactor and may include one or more initial hydrocarbon feed streams, one or more recycle streams, and one or more hydrocarbon-containing co-feeds. In certain embodiments, "hydrocarbon reactant" refers to hydrocarbons from the main hydrocarbon feed stream or initial hydrocarbon feed stream passing through the reactor and may include one or more co-feeds, including steam and / or oxygenates. In certain embodiments, "hydrocarbon reactant" refers to hydrocarbons from the main hydrocarbon feed stream passing through the reactor and may include one or more recycle feeds, such as at least a portion of the recycle oil (light, heavy, or combined recycle oil stream) from the reactor effluent. In certain embodiments, "hydrocarbon reactant" refers to hydrocarbons from the main hydrocarbon feed stream passing through the reactor and may include one or more recycle feeds, such as at least a portion of the light recycle oil from the reactor effluent, and one or more co-feeds, including steam and / or oxygenates. In certain embodiments, "hydrocarbon reactant" refers to hydrocarbons from a first hydrocarbon feed stream fed through a first feed inlet of the reactor and a second hydrocarbon feed stream fed through a second feed inlet of the reactor, which pass through the reactor. In certain embodiments, "hydrocarbon reactant" refers to hydrocarbons from a first hydrocarbon feed stream fed through a first feed inlet of the reactor and a second hydrocarbon feed stream fed through a second feed inlet of the reactor, which pass through the reactor, and one or more co-feeds passing with the first and / or second hydrocarbon feed stream, including steam and / or oxygenates. In certain embodiments, "hydrocarbon reactant" refers to hydrocarbons from a first hydrocarbon feed stream fed through a first feed inlet of the reactor and a second hydrocarbon feed stream fed through a second feed inlet of the reactor, which pass through the reactor, and one or more recycle feeds, such as at least a portion of the recycle oil (light recycle oil, heavy recycle oil, or a combination thereof) from the reactor effluent, which passes with the first and / or second hydrocarbon feed stream. In certain embodiments, "hydrocarbon reactant" refers to hydrocarbons from a first hydrocarbon feed stream fed through a first feed inlet of the reactor and a second hydrocarbon feed stream fed through a second feed inlet of the reactor, which pass through the reactor, and one or more recycle feeds, such as at least a portion of the light recycle oil from the reactor effluent, and one or more co-feeds, including steam and / or oxygenates, wherein the recycle and co-feeds pass with the first and / or second hydrocarbon feed stream.

[0018] As used in the present disclosure, "catalyst" refers to any substance that increases the rate of a specific chemical reaction. The catalysts described in the present disclosure can be used to facilitate various reactions, such as, but not limited to, cracking. As used in the present disclosure, "cracking" generally refers to a chemical reaction in which a molecule having carbon-carbon bonds is broken into more than one molecule by the breaking of one or more carbon-carbon bonds, or a compound including a cyclic moiety (such as cycloalkanes, cycloolefins, naphthalene, etc.) is converted into a compound that does not include a cyclic moiety or contains fewer cyclic moieties than before cracking.

[0019] As used in the present disclosure, the term "spent catalyst" refers to a catalyst that has been introduced and passed through a reaction zone to crack a hydrocarbon feed, but has not been regenerated in a regenerator after being introduced into the reaction zone. A "spent catalyst" can have: coke deposited on the catalyst, and can include partially coked catalysts and fully coked catalysts; and hydrocarbons from the feed or reaction products adsorbed or otherwise deposited on the catalyst. The amount of coke and adsorbed hydrocarbons deposited on the "spent catalyst" can be greater than the amount of coke and hydrocarbons remaining on the regenerated catalyst after regeneration. As used in the present disclosure, a "spent catalyst" can have adsorbed hydrocarbons that are removed in a steam stripping zone in fluid communication with the reaction zone, and the spent catalyst containing coke is subjected to regeneration.

[0020] As used in the present disclosure, the term "regenerated catalyst" refers to a catalyst that has been introduced into a reaction zone and then regenerated in a regenerator to heat the catalyst to a higher temperature, oxidize and remove at least a portion of the coke from the catalyst to restore at least a portion of the catalytic activity of the catalyst, or both. Compared with the spent catalyst, the "regenerated catalyst" can have less coke, a higher temperature, or both, and can have higher catalytic activity compared with the spent catalyst. Compared with fresh catalyst that has not passed through a cracking reaction zone and a regenerator, the "regenerated catalyst" can have more coke and lower catalytic activity.

[0021] As used in the present disclosure, unless otherwise specified, the term "stream" (and variants of this term, such as hydrocarbon stream, hydrocarbon feed stream, feed stream, product stream, etc.) can include one or more of various hydrocarbon compounds, such as straight-chain, branched-chain or cyclic alkanes, alkenes, dienes, alkynes, alkyl aromatics, alkenyl aromatics, condensed and non-condensed di-, tri- and tetra-aromatic compounds, and gases such as hydrogen and methane, C2+ hydrocarbons, and can also include various impurities. The term "C # hydrocarbon" or "C # " is used herein with its well-known meaning, i.e., where "#" is an integer value and means a hydrocarbon having that number of carbon atoms. The term "C # + hydrocarbon" or "C #"+" refers to a hydrocarbon having that value or more carbon atoms. The term "C # -hydrocarbon" or "C # -" refers to a hydrocarbon having that value or fewer carbon atoms. Similarly, ranges are also listed, such as C1-C3 meaning a mixture comprising C1, C2, and C3.

[0022] As used herein, the term "crude oil" refers to a naturally occurring mixture of petroleum liquids and gases that can be extracted from a geological formation and can be provided in its unrefined form. Crude oils suitable as source materials for the processes herein include Arabian heavy crude, Arabian light crude, Arabian super light crude, other Gulf crudes, Brent crude, North Sea crude, North African and West African crudes, Indonesian, Chinese crude, North or South American crude, Russian and Central Asian crude, or mixtures thereof. The crude oil mixture can be a full-range crude or a topped crude. As used herein, "crude oil" also refers to such a mixture that has undergone some pretreatment, such as water-oil separation; and / or gas-oil separation; and / or desalting; and / or stabilization. In certain embodiments, the crude oil refers to any such mixture having an API gravity (ASTM D287 standard) greater than or equal to about 25°, 30°, 32°, 34°, 36°, 38°, 40°, 42°, or 44°, including those having an API gravity of 25° to 40°, such as 25° to 30°, 30° to 35°, 35° to 40°, or any combination of these ranges.

[0023] As used in the present disclosure, all boiling point ranges with respect to hydrocarbon fractions derived from crude oil via atmospheric and / or vacuum distillation shall refer to the true boiling point values obtained from crude oil determination, or commercially acceptable equivalents. The modifying term "straight-run" is used herein and has its well-known meaning, i.e., describing fractions directly derived from an atmospheric distillation unit, optionally subjected to steam stripping, without other refining treatments such as hydrotreating, fluid catalytic cracking, or steam cracking.

[0024] As used in this disclosure, the acronym "LPG" as used herein is the well-known acronym for the term "liquefied petroleum gas" and is generally a mixture of C3-C4 hydrocarbons. In certain embodiments, these are also referred to as "light fractions". As used herein, the term "naphtha" refers to hydrocarbons having a nominal boiling range of about 20 - 210, 20 - 205, 20 - 190, 20 - 180, 20 - 170, 25 - 210, 25 - 205, 25 - 190, 25 - 180, 25 - 170, 32 - 210, 32 - 205, 32 - 190, 32 - 180, 32 - 170, 35 - 210, 35 - 205, 35 - 190, 35 - 180 or 35 - 170 °C. As used herein, the term "light naphtha" refers to hydrocarbons having a nominal boiling range of about 20 - 110, 20 - 100, 20 - 90, 20 - 85, 25 - 110, 25 - 100, 25 - 90, 25 - 85, 32 - 110, 32 - 100, 32 - 90, 32 - 85, 35 - 110, 35 - 100, 35 - 90 or 35 - 85 °C. As used herein, the term "heavy naphtha" refers to hydrocarbons having a nominal boiling range of about 85 - 210, 85 - 205, 85 - 190, 85 - 180, 85 - 170, 90 - 210, 90 - 205, 90 - 190, 90 - 180, 90 - 170, 95 - 210, 95 - 205, 95 - 190, 95 - 180, 95 - 170, 100 - 210, 100 - 205, 100 - 193, 100 - 190, 100 - 180, 100 - 170, 110 - 210, 110 - 205, 110 - 193, 110 - 190, 110 - 180 or 110 - 170 °C. In certain embodiments, naphtha, light naphtha and / or heavy naphtha refer to such petroleum fractions obtained by distillation of crude oil or intermediate refining processes. As used herein, the term "kerosene" refers to hydrocarbons having a nominal boiling range of about 160 - 280, 160 - 270, 160 - 260, 170 - 280, 170 - 270, 170 - 260, 180 - 280, 180 - 270, 180 - 260, 190 - 280, 190 - 270, 190 - 260, 193 - 280, 193 - 270 or 193 - 260 °C.In certain embodiments, the term "middle distillate" is used to refer to one or more fractions containing hydrocarbons having a nominal boiling range of about 160 - 400, 160 - 380, 160 - 370, 160 - 360, 160 - 340, 170 - 400, 170 - 380, 170 - 370, 170 - 360, 170 - 340, 180 - 400, 180 - 380, 180 - 370, 180 - 360, 180 - 340, 190 - 400, 190 - 380, 190 - 370, 190 - 360, 190 - 340, 193 - 400, 193 - 380, 193 - 370, 193 - 360 or 193 - 340 °C. In certain embodiments, the term "straight-run middle distillate" is used to refer to one or more straight-run fractions from an atmospheric distillation unit. In embodiments where other terms are used herein, the middle distillate fraction may also include all or a portion of the atmospheric gas oil range hydrocarbons and / or all or a portion of the kerosene. In additional embodiments, the term "middle distillate" is used to refer to fractions from one or more operations boiling in this range. As used herein, the term "atmospheric residue" refers to the bottom hydrocarbons having an initial boiling point corresponding to the end point of the hydrocarbons in the AGO range and having an end point characteristic of the crude oil feed. As used herein, the term "vacuum gas oil" refers to hydrocarbons having a nominal boiling range of about 370 - 565, 370 - 550, 370 - 540, 370 - 530, 370 - 510, 400 - 565, 400 - 550, 400 - 540, 400 - 530, 400 - 510, 420 - 565, 420 - 550, 420 - 540, 420 - 530 or 420 - 510 °C. As used herein, the term "vacuum residue" refers to the bottom hydrocarbons having an initial boiling point corresponding to the end point of the hydrocarbons in the vacuum gas oil range and having an end point characteristic of the crude oil feed.

[0025] The term "condensate" refers to hydrocarbons separated from a natural gas stream. As used herein, "condensate" also refers to such mixtures that have undergone some pretreatment, such as water - oil separation; and / or gas - oil separation; and / or desalting; and / or stabilization. In certain embodiments, condensate refers to any such mixture having an API gravity (ASTM D287 standard) greater than or equal to about 45°, 50°, 60° or 65°.

[0026] The term "recirculating oil" is used herein to refer to a mixture of light cycle oil and heavy cycle oil. The term "light cycle oil" and its acronym "LCO" as used herein refers to light cycle oil produced by a conventional FCC unit and also refers to the corresponding range of hydrocarbons from the countercurrent multi-zone fluidized bed reactor herein. The nominal boiling range of LCO is, for example, in the range of about 215 - 350, 216 - 350, 220 - 350, 215 - 343, 216 - 343, 220 - 343, 215 - 330, 216 - 330 or 220 - 330 °C. The term "heavy cycle oil" and its acronym "HCO" as used herein refers to heavy cycle oil produced by a conventional FCC unit and also refers to the corresponding range of hydrocarbons from the countercurrent multi-zone fluidized bed reactor. The nominal boiling range of HCO is, for example, in the range of about 330+, 343+ or 350+, e.g., 330 - 530, 330 - 510, 343 - 530, 343 - 510, 350 - 530 or 350 - 510 °C.

[0027] Conventional FCC processes operate in the reactor with a relatively low catalyst holdup by utilizing a lean bed or circulating fluidized state, such as a dilute fluidized bed. Additionally, conventional catalytic cracking processes can utilize a co-current flow pattern, whereby the catalyst and hydrocarbon flow through the reactor in the same direction, which can lead to undesirable flow patterns such as backmixing and core-annular flow. Embodiments of the present disclosure relate to methods for producing light olefins by catalytic cracking, wherein the catalyst and hydrocarbon contact each other in a countercurrent manner, and wherein a portion of the reactor operates in a dense bed fluidization mode. Dense bed fluidization can allow more catalyst to be present in the reactor, which in turn can result in higher hydrocarbon conversion and higher light olefin yields than those observed in conventional catalytic cracking processes. Countercurrent flow can be described as increasing the conversion of the feed. For example, during countercurrent flow, fresh catalyst can move from the top of the reactor to the bottom, while the hydrocarbon feed flows from the bottom of the reactor to the top. The spent catalyst at the bottom of the reactor and near the reactor outlet contacts the upward flowing feed and converts the reactive components in the feed, including the heavy fractions of the feed). As the feed travels upward, the less reactive components in the feed are converted, contacting the hot and fresh catalyst in the top section of the reactor. Additionally, the countercurrent contact between the hydrocarbon and the catalyst can prevent backmixing or core-annular flow, which typically results in a reduced yield of light olefins in conventional FCC riser reactors where the catalyst and hydrocarbon flow co-currently through the reactor.

[0028] Now refer to Figure 1 and 2, schematically depicts a reactor 100 for producing light olefins using a catalyst formulation or mixture disclosed herein. The reactor comprises an upper reactor section 110, a lower reactor section 120, and a steam stripping section 130. The upper reactor section 110 defines an upper reaction zone 111 and the lower reactor section 120 defines a lower reaction zone 121. In certain embodiments, operation of the reactor 100 includes a main hydrocarbon feed stream 108 that enters the lower reaction zone 121 through one or more feed inlets 101 located in the lower reactor section 120. The one or more feed inlets may be located at or near the bottom of the lower reactor section 120. Additionally, the lower reactor section 120 may include one or more catalyst outlets for discharging the spent catalyst stream 104, which are located at or near the bottom of the lower reactor section 120. As described herein, at or near the bottom of the lower reactor section 120 corresponds to a position at the bottom 10%, bottom 5%, or bottom 1% of the height of the lower reactor section 120.

[0029] In certain optional embodiments, as Figure 1 shown by the dashed line in, the co-feed 109 is introduced together with the main hydrocarbon feed stream 108 through one or more feed inlets 101 located in the lower reactor section 120. In certain embodiments, the co-feed 109 is fed into the reactor via the same feed inlet 101 as the hydrocarbon feed stream 108.

[0030] In certain embodiments, as with respect to Figure 2 shown, the recycle stream 102a is introduced together with the main hydrocarbon feed stream 108 through one or more feed inlets 101 located in the lower reactor section 120. In certain embodiments, the recycle stream 102a is fed into the reactor via the same feed inlet 101 as the hydrocarbon feed stream 108. Additionally, as Figure 2 shown in the optional embodiment, also includes a co-feed 109 (shown as a dashed line), which is introduced together with the main hydrocarbon feed stream 108 and the recycle stream 102a through one or more feed inlets 101.

[0031] In certain embodiments, as with respect to Figure 3 shown, another embodiment of the lower reactor section is provided, and the lower reactor section 220 may be associated with Figure 1 and Figure 2used in conjunction with other components of the reactor 100 or with the reactor described in US20220033714A1. The lower reactor section 220 defines a lower reaction zone 221 and includes one or more first inlets 281 and one or more second inlets 291. One or more first feed inlets 281 may be located at or near the bottom of the lower reactor section 220. One or more second feed inlets 291 may be located at an intermediate height of the lower reactor section 220 or at or near the top of the lower reactor section 220. In certain embodiments, one inlet is provided as the first feed inlet 281 and one inlet is provided as the second feed inlet 291. As used herein, at or near the bottom of the lower reactor section 220 corresponds to a position at the bottom 10%, bottom 5%, or bottom 1% of the height of the lower reactor section 220. As used herein, at or near the top of the lower reactor section 220 corresponds to a position at the top 10%, top 5%, or top 1% of the height of the lower reactor section 220. As used herein, located at an intermediate height of the lower reactor section 220 spans from a position at the bottom 15%, bottom 25%, or bottom 35% of the height of the lower reactor section 220 to a position at the top 15%, top 25%, or top 35% of the height of the lower reactor section 220; for example, an inlet located at an intermediate height of the lower reactor section 220 may be at a position between bottom 15% to top 15%, bottom 25% to top 25%, or bottom 35% to top 35%.

[0032] The feed to one or more first inlets 281 includes one or more of the following: a first hydrocarbon feed stream 288, a recycle stream 202a, or a co-feed 289 (or multiple co-feeds 289). In certain embodiments, the feed to one or more first inlets 281 includes the first hydrocarbon feed stream 288. In certain embodiments, the feed to one or more first inlets 281 includes the first hydrocarbon feed stream 288 and a co-feed 289 (or multiple co-feeds 289). In certain embodiments, the feed to one or more first inlets 281 includes the first hydrocarbon feed stream 288 and the recycle stream 202a. In certain embodiments, the feed to one or more first inlets 281 includes the first hydrocarbon feed stream 288, the recycle stream 202a, and a co-feed 289 (or multiple co-feeds 289). In certain embodiments, the feed to one or more first inlets 281 includes the recycle stream 202a. In certain embodiments, the feed to one or more first inlets 281 includes the recycle stream 202a and a co-feed 289 (or multiple co-feeds 289).

[0033] The feed to one or more second inlets 291 comprises one or more of the following: a second hydrocarbon feed stream 298, a recycle stream 202b, or a co-feed 299 (or co-feeds 299). In certain embodiments, the feed to one or more second inlets 291 comprises the second hydrocarbon feed stream 298. In certain embodiments, the feed to one or more second inlets 291 comprises the second hydrocarbon feed stream 298 and a co-feed 299 (or co-feeds 299). In certain embodiments, the feed to one or more second inlets 291 comprises the second hydrocarbon feed stream 298 and the recycle stream 202b. In certain embodiments, the feed to one or more second inlets 291 comprises the second hydrocarbon feed stream 298, the recycle stream 202b, and a co-feed 299 (or co-feeds 299). In certain embodiments, the feed to one or more second inlets 291 comprises the recycle stream 202b. In certain embodiments, the feed to one or more second inlets 291 comprises the recycle stream 202b and a co-feed 299 (or co-feeds 299).

[0034] Continuing reference Figure 1 and Figure 2 and also reference Figure 3 , the upper reactor section 110 defines an upper reaction zone 111. In operation, the hydrocarbon reactants move through the lower reaction zone 121 or 221 and reach the upper reaction zone 111. The upper reactor section 110 and the lower reactor section 120 or 220 are in fluid communication with each other. In one or more embodiments, the upper reactor section 110 and the lower reactor section 120 or 220 can be adjacent to each other without intermediate components or reactor sections, whereby the upper reactor section 110 and the lower reactor section 120 or 220 are in direct fluid communication with each other. In one or more embodiments, the hydrocarbon reactants are fed directly from the lower reactor section 120 or 220 into the upper reactor section 110.

[0035] Reference Figure 4 , a cross-sectional view of the upper reactor section 110 is shown. The upper reactor section 110 includes a reactor effluent outlet 112 and a catalyst inlet 113, which are located at or near the top of the upper reactor section 110. As described herein, being at or near the top of the upper reactor section 110 corresponds to a position at the top 10%, top 5%, or top 1% of the height of the upper reactor section 110. The catalyst can enter the upper reactor section 110 through the catalyst inlet 113. As Figure 4 shown, the catalyst inlet 113 can extend into the upper reactor section 110, such that the catalyst enters the upper reaction zone 111 below the hydrocarbon product outlet 112. Also as Figure 4As shown, the hydrocarbon product outlet 112 is defined by an opening in the upper reactor portion 110, and the hydrocarbon product outlet 112 does not extend into the upper reaction zone 111. Thus, the catalyst can enter the upper reaction zone below the hydrocarbon outlet 112. Without wishing to be bound by theory, it is believed that introducing the catalyst below the hydrocarbon product outlet 112 reduces the amount of catalyst entrained in the hydrocarbon product exiting the reactor 100.

[0036] As Figures 1 - 3 shown, the lower reactor portion 120 or 220 can have a larger cross-sectional area than the upper reactor portion 110. In certain embodiments, the lower portion 120 or 220 and the lower reaction zone 121 or 221 are characterized by the shape of a cylindrical portion. In one or more embodiments, the lower reactor portion 120 or 220 can have a cross-sectional area substantially similar to that of the upper reactor portion 110. In certain embodiments, the lower portion 120 or 220 and the lower reaction zone 121 or 221 are characterized by the shape of a cylindrical portion with a frustoconical portion at the top. In any embodiment, when referring to the position of one or more first feed inlets 281 and one or more second feed inlets 291, the percentage of height associated with the bottom height, middle height, and top height refers to the height along the cylindrical portion of the lower reactor portion 220.

[0037] In one or more embodiments, the upper reaction zone 111 can be operated in a countercurrent plug flow regime. In one or more embodiments, as the hydrocarbon reactants move upward through the upper reaction zone 111, the hydrocarbon reactants can exhibit plug flow. Similarly, as the catalyst moves downward through the upper reaction zone 111, the catalyst can exhibit plug flow. Since the flow of the catalyst is opposite to the flow of the hydrocarbon feed, the flow is countercurrent, and the upper reaction zone 111 can be operated in a countercurrent plug flow manner (regime).

[0038] In one or more embodiments, the catalyst-to-oil ratio in the upper reaction zone 111 can be from about 5 to 100. For example, the catalyst-to-oil ratio in the upper reaction zone 111 can be from about 5 to 100, 10 to 100, 20 to 100, 30 to 100, 40 to 100, 50 to 100, 60 to 100, 70 to 100, 80 to 100, 90 to 100, 5 to 90, 5 to 80, 5 to 70, 5 to 60, 5 to 50, 5 to 40, 50 to 30, 5 to 20, or 5 to 10. Without wishing to be bound by theory, it is believed that there are fewer constraints on the catalyst-to-oil ratio applicable to the upper reaction zone 111 because the catalyst can flow through the upper reaction zone 111 by gravity rather than being transported through the reactor by the flow of the hydrocarbon. Additionally, a high catalyst-to-oil ratio indicates a large amount of catalyst within the upper reaction zone 111, which is believed to result in an increased conversion of the hydrocarbon feed to light olefins.

[0039] The catalyst can move through the upper reaction zone 111 and enter the lower reaction zone 121 or 221. In one or more embodiments, the catalyst can be fed directly from the upper reaction zone 111 into the lower reaction zone 121 or 221. The lower reaction zone 121 or 221 can operate in a dense bed fluidization mode. In one or more embodiments, the catalyst can be fed from the upper reaction zone 111 into the lower reaction zone 121 or 221 and a dense fluidized bed can be formed in the lower reaction zone 121 or 221. As used herein, "dense bed fluidization mode" means a fluidized bed having a well-defined upper limit or surface limited to a dense bed. For example, dense bed fluidization modes include smooth fluidization, bubbling fluidization, slug fluidization, and turbulent fluidization modes. In a dense fluidized bed, the particle entrainment rate can be low but can increase as the velocity of the gas flowing through the bed increases.

[0040] In one or more embodiments, the initial hydrocarbon feed stream 108 or the first hydrocarbon feed stream 288 and / or the second hydrocarbon feed stream 298 can comprise crude oil, consist of crude oil, or consist essentially of crude oil. In additional embodiments, the initial hydrocarbon feed stream 108 or the first hydrocarbon feed stream 288 and / or the second hydrocarbon feed stream 298 can comprise, consist of, or consist essentially of: a crude oil fraction having an initial boiling point of at least 25 °C or a petrochemical product formed from crude oil. For example, in one or more embodiments, the initial hydrocarbon feed stream 108 or the first hydrocarbon feed stream 298 and / or the second hydrocarbon feed stream 298 can comprise light naphtha, consist of light naphtha, or consist essentially of light naphtha and can have an initial boiling point of about 20 °C to about 35 °C and a final boiling point of about 85 °C to about 110 °C. In one or more embodiments, the initial hydrocarbon feed stream 108 or the first hydrocarbon feed stream 288 and / or the second hydrocarbon feed stream 298 can comprise heavy naphtha, consist of heavy naphtha, or consist essentially of heavy naphtha and can have an initial boiling point of about 85 °C to about 110 °C and a final boiling point of about 170 °C to about 210 °C. In further embodiments, the initial hydrocarbon feed stream 108 or the first hydrocarbon feed stream 288 and / or the second hydrocarbon feed stream 298 can comprise full-range naphtha, consist of full-range naphtha, or consist essentially of full-range naphtha and have an initial boiling point of about 20 °C to 35 °C and a final boiling point of about 170 °C to about 210 °C.

[0041] In one or more embodiments, the initial hydrocarbon feed stream 108 or the first hydrocarbon feed stream 288 and / or the second hydrocarbon feed stream 298 can comprise, consist of, or consist essentially of: C4 components, light naphtha, heavy naphtha, full-range naphtha, vacuum gas oil, crude oil, FCC gasoline, olefinic naphtha, atmospheric residue, vacuum residue, condensate, deasphalted crude oil, dewaxed crude oil, deasphalted-dewaxed crude oil, middle distillates, or kerosene.

[0042] In one or more embodiments, the co-feed 109 as in the embodiment of Figure 1 , the optional co-feed 109 as in the embodiment of Figure 2 , the optional co-feed 209 as in the embodiment of Figure 3 and / or the optional co-feed 289 as in the embodiment of Figure 3 contain steam. In embodiments where steam is provided as a co-feed, it is provided in an amount of about 1 to 150 mass% co-feed, relative to the mass of the initial hydrocarbon feed. For example, in an amount of about 1 wt%, 5 wt%, 10 wt%, 20 wt%, 30 wt%, 40 wt%, 50 wt%, 60 wt%, 70 wt%, 80 wt%, 90 wt%, 100 wt%, 110 wt%, 120 wt%, 130 wt%, 140 wt% or any amount between about 1 to 150, 10 to 150, 20 to 150, 10 to 100, 10 to 70 or 10 to 40 wt%.

[0043] In one or more embodiments, the co-feed 109 as in the embodiment of Figure 1 , the optional co-feed 109 as in the embodiment of Figure 2 , the optional co-feed 209 as in the embodiment of Figure 3 and / or the optional co-feed 289 as in the embodiment of Figure 3 contain one or more oxygenates. In embodiments where oxygenates are provided as a co-feed, they are provided in an amount of about 1 to 50 wt% relative to the mass of the initial hydrocarbon feed. For example, in an amount of about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, 25 wt%, 30 wt%, 35 wt%, 40 wt%, 45 wt%, 50 wt% or any amount between about 1 to 50 wt%. In one or more embodiments, the oxygenates may contain one or more alcohols, ketones or aldehydes. In one or more embodiments, the oxygenates may contain methanol.

[0044] In one or more embodiments, recycle stream 102a or recycle stream 202a and / or recycle stream 202b comprises at least a portion of other reaction products derived from hydrocarbon product stream 102. In one or more embodiments, hydrocarbon product stream 102 is fractionated into light naphtha, non-aromatic naphtha, middle naphtha, heavy naphtha, light cycle oil, heavy cycle oil, or heavy oil, one or more fractions of an olefin-rich butene-containing fraction, and any one or more of the fractions comprises recycle stream 102a or 202a and / or 202b. In certain embodiments, recycle stream 102a or 202a and / or 202b comprises light cycle oil, consists of light cycle oil, or consists essentially of light cycle oil. In certain embodiments, recycle stream 102a or 202a and / or 202b is provided in an amount of about 1 to 20 weight percent, based on the mass of the initial hydrocarbon feed, such as about 1 weight percent, 2 weight percent, 5 weight percent, 10 weight percent, 15 weight percent, 20 weight percent, or any amount between about 1 to 20, 5 to 20, or 10 to 20 weight percent.

[0045] In certain embodiments, recycle stream 102a or 202a and / or 202b comprises non-aromatic light naphtha, which includes butene (and some butane and isobutane). In certain embodiments, recycle stream 102a or 202a and / or 202b is provided in an amount of about 1 to 50 weight percent, based on the mass of the initial hydrocarbon feed, such as about 1 weight percent, 2 weight percent, 5 weight percent, 10 weight percent, 15 weight percent, 20 weight percent, 25 weight percent, 30 weight percent, 35 weight percent, or any amount between about 1 to 50, 5 to 50, 10 to 50, or 20 to 50 weight percent.

[0046] Reference Figure 2 , recycle stream 102a is introduced together with feed stream 108 and optionally one or more co-feeds 109. In certain embodiments, recycle stream 102a is combined with initial feed stream 108. In certain embodiments, recycle stream 102a is combined with initial feed stream 108 and co-feed(s) 109. In certain embodiments, recycle stream 102a is combined with initial feed stream 108 and a co-feed 109 of steam. In certain embodiments, recycle stream 102a is combined with initial feed stream 108 and a co-feed 109 of one or more oxygenates. In certain embodiments, recycle stream 102a is combined with initial feed stream 108 and a co-feed 109 of steam and one or more oxygenates.

[0047] Reference Figure 3 , the first inlet 281 and the second inlet 291 can receive the same or different feeds. As described herein, the more active catalyst is towards the top of the lower reaction zone ( Figure 3 zone 221 in the example of

[0048] In certain embodiments, the initial feed stream is separated by volume or mass, with a first portion fed as a first hydrocarbon feed stream 288 to a first inlet 281 and a second portion fed as a second hydrocarbon feed stream 298 to a second inlet 291.

[0049] In certain embodiments, the initial feed stream is fractionated based on nominal boiling point, where a first portion having one or more first boiling ranges is fed as a first hydrocarbon feed stream 288 to a first inlet 281 and where a second portion having one or more second boiling ranges is fed as a second hydrocarbon feed stream 298 to a second inlet 291. For example, in some embodiments, the initial stream can be fractionated into a light portion and a heavy portion, whereby the first hydrocarbon feed stream 288 comprises the light portion and the second hydrocarbon feed stream 298 comprises the heavy portion. In certain embodiments, the fractionation point between the light portion and the heavy portion is in the range of about 200 - 375 °C, such as about 200, 225, 250, 275, 300, 325, 350, or 375. In some embodiments, the light portion can comprise naphtha-range hydrocarbons, such as olefin-rich C4 - C6 hydrocarbons, and the heavy portion can comprise the initial feed stream, such as crude oil or another initial hydrocarbon feed stream, such as the initial hydrocarbon feed stream 108 described above.

[0050] In one or more embodiments, the catalyst can comprise a zeolite catalyst, such as USY zeolite, ZSM-5 zeolite, or a combination of suitable zeolite catalysts of various types. Alternatively, the catalyst can comprise other suitable solid acid catalysts. In one or more embodiments, the catalyst can comprise fresh catalyst, regenerated catalyst, or a combination of fresh catalyst and regenerated catalyst, as described in further detail herein. In one or more embodiments, the catalyst can comprise binders, promoters, inert materials, and matrices to have acceptable physical and chemical properties, such as catalyst attrition index and catalyst density, such that it can be used in the proposed reactor configuration.

[0051] In certain embodiments, the catalyst particles in the systems and methods for processing hydrocarbons to produce light olefins disclosed herein comprise a mixture that is a physical blend of separate catalyst particles as at least a first composite particle and a second composite particle. The first composite particle comprises from about 5-70, 5-50, 5-45, 10-70, 10-50, 10-45, 20-50, or 20-45 weight % of a 10-membered ring zeolite component; from about 5-70, 5-50, 10-50, 5-30, or 5-25 weight % of a first binder component, from about 10-60, 10-50, or 10-40 weight % of a first filler component; and from 0-40, 5-40, 5-30, 5-25, 15-40, 15-30, or 15-25 weight % of an optional first additive component (wherein a lower limit of 0 weight % indicates the absence of the additive component). The 10-membered ring zeolite component of the first composite particle is optionally modified with phosphorus. The second composite particle comprises: from about 5-70, 5-50, 5-45, 10-70, 10-50, 10-45, 20-50, or 20-45 weight % of a 12-membered ring zeolite component, from about 5-70, 5-50, 10-50, 5-30, or 5-25 weight % of a second binder component, from about 10-60, 10-50, or 10-40 weight % of a second filler component; and from about 0-40, 5-40, 5-30, 5-25, 15-40, 15-30, or 15-25 weight % of an optional second additive component (wherein a lower limit of 0 weight % indicates the absence of the additive component). In such embodiments: the type and amount of the first binder component and the second binder component in each of the different first composite particles and second composite particles can be the same or different; the type and amount of the first filler component and the second filler component in each of the different first composite particles and second composite particles can be the same or different; and the type and amount (including the absence of the additive component) of the first optional additive component and the second optional additive component in each of the different first composite particles and second composite particles can be the same or different.

[0052] In certain embodiments, the catalyst particles in the systems and methods for processing hydrocarbons to produce light olefins disclosed herein comprise multi-zeolite composite particles. The multi-zeolite composite particles comprise: about 5-75, 5-40, 5-30, 5-25, 10-40, 10-30, 10-25, 15-40, 15-30 or 15-25 wt% of a 10-membered ring zeolite component modified with phosphorus, about 5-75, 5-40, 5-30, 5-25, 10-40, 10-30, 15-40, 15-30 or 20-40 wt% of a 12-membered ring zeolite component, about 5-70, 5-50, 10-50, 5-30 or 5-25 wt% of a binder component, about 10-60, 10-50, 10-40 wt% of an optional filler component; and about 0-40, 5-40, 5-30, 5-25, 15-40, 15-30 or 15-25 wt% of an additive component (where a lower limit of 0 wt% indicates the absence of the additive component).

[0053] Embodiments of the individual catalyst particles or multi-zeolite composite particles of at least a first composite particle and a second composite particle include a binder component. The binder component can be an amorphous component selected from alumina (including γ-alumina), silica, alumina-silicate, silica-aluminate, alumina phosphate, and combinations comprising two or more of the amorphous binder components.

[0054] Embodiments of the individual catalyst particles or multi-zeolite composite particles of at least a first composite particle and a second composite particle include a filler component. The filler component can be a clay selected from kaolin, sepiolite, talc, palygorskite, montmorillonite, and mixtures of two or more of the clay filler components. In certain embodiments, a phosphorus stabilizer (such as diammonium hydrogen phosphate or sodium hexametaphosphate) is combined with the clay component. In certain embodiments, the clay filler component has a surface area in the range of about 20-30 m 2 / g (kaolin), 200-300 m 2 / g (sepiolite), 2-40 m 2 / g (talc), 250-300 (palygorskite) or 250-400 m 2 / g (montmorillonite).

[0055] Embodiments of the at least first and second composite particles or multi-zeolite composite particles of individual catalyst particles include optional additive components. The optional additive components are selected from metal carbides (including silicon carbide), rare earth metals (including cerium and lanthanum), alkali metals (including sodium), alkaline earth metals, and metal oxides (including iron oxide and copper oxide). In certain embodiments, silicon carbide is used as the additive component, which can provide a given diameter in the range of about 1 - 1000, 100 - 1000, 200 - 1000, 500 - 1000, 1 - 900, 100 - 900, 200 - 900, or 500 - 900 nanometers. For example, in certain non-limiting examples herein, the given diameter of the silicon carbide particles is about 800 nanometers. Using silicon carbide as the additive component results in an increase in density and / or an improvement in the thermal conductivity across the catalyst body compared to the particles formed in the absence of the silicon carbide additive component.

[0056] In the above embodiments of the first and second composite particles or multi-zeolite composite particles, the 10-membered ring zeolite component (also known as mesoporous zeolite) is characterized in that the micropores have a pore diameter in the range of about 0.45 - 0.6 nanometers. In certain embodiments, the 10-membered ring zeolite comprises ferrierite (FER) or pentasil (MFI) framework. In certain embodiments, a zeolite with a pentasil (MFI) framework is used and comprises Zeolite Socony Mobil-5 (ZSM-5) or modified ZSM-5 modified by mesoporation.

[0057] In embodiments where the 10-membered ring zeolite is modified with phosphorus, an amount of the 10-membered ring zeolite is contacted with a modification precursor such as phosphoric acid to form a dispersion that is dried and calcined. For example, the contact conditions and characteristics of the modification precursor are such that the P / Al molar ratio of the calcined phosphorus-modified catalyst is in the range of about 0.1 - 1, 0.1 - 0.8, 0.1 - 0.5, 0.2 - 1, 0.2 - 0.8, or 0.2 - 0.5. In certain embodiments, the phosphorus-modified 10-membered ring zeolite comprises phosphorus-modified ZSM-5. In some embodiments, NH4 - ZSM-5 is used as the 10-membered ring zeolite component. In some embodiments, the phosphorus-modified NH4 - ZSM-5 is used as the 10-membered ring zeolite component.

[0058] In the above embodiments of the second composite particle and the second composite particle or the zeolite composite particle, the 12-ring zeolite component (also known as the macroporous zeolite) is characterized by a micropore diameter in the range of about 0.6 - 0.8 nanometers. In certain embodiments, the 12-ring zeolite component comprises a zeolite having a faujasite (FAU), mordenite (MOR), or β (*BEA) framework. In certain embodiments, a zeolite having a faujasite (FAU) framework is used, and the zeolite is selected from ultrastable Y (USY) zeolite, zeolite Y, and zeolite X. In some embodiments, H + USY zeolite is used as the 12-ring zeolite component.

[0059] The molar ratio of silica to alumina (SiO2 / AlO2, "SAR") of the zeolite component of the catalyst particles herein can vary. For example, suitable SAR values on a molar basis can generally be in the range of about 5 - 1000, 5 - 800, 5 - 500, 5 - 250, 5 - 100, 5 - 50, 10 - 1000, 10 - 800, 10 - 500, 10 - 250, 10 - 100, or 10 - 50. In certain embodiments where the zeolite is of the MFI type, such as ZSM-5, the SAR can be in the range of about 10 - 50. In certain embodiments where the zeolite is a FAU zeolite such as zeolite Y, the SAR can be in the range of about 2 - 30.

[0060] The zeolite component can be modified, treated, or processed using methods known in the art to increase hydrothermal stability, increase accessibility (mesoporation), modify acidity, and / or add metal functionality to manipulate the yield profile in favor of a particular product. For example, one or more zeolite components can be mesoporated to produce mesoporous zeolites that retain the crystalline framework of the zeolite micropores to allow larger molecules (e.g., greater than the size of a 10-ring) to diffuse into the catalyst for reaction. Mesoporation can include dealumination, desilication, steaming, or any other known method to produce mesopores. Additional components can also be added to the composite material used to manufacture the catalyst particles, including but not limited to metal scavengers and / or sulfur sorbents.

[0061] The catalyst particles disclosed herein can be formed by any known method to produce such catalyst particles: having a reasonable structure, mechanical integrity, including acceptable strength and attrition index; having a tapped density in the range of about 0.55 - 1.3, 0.55 - 0.93, 0.8 - 1.3, or 0.8 - 0.93 grams per milliliter; having high heat resistance without loss of mechanical integrity; having acceptable thermal conductivity; and having low thermal expansion (e.g., below about 850 °C).

[0062] For example, in some embodiments, an effective amount of a clay filler component, a zeolite component, a binder component, and an optional additive component are mixed into a liquid slurry and ultimately into a homogeneous liquid. In some embodiments, a stepwise procedure can be used to add the components. For example: in some embodiments, the clay filler component is formed into a homogeneous liquid and then the remaining components are added; in some embodiments, the clay filler component is formed into a homogeneous liquid, then the zeolite component is added, and then the binder component is added (where the optional additive component can be added with the zeolite component and / or the binder component). In certain embodiments, the binder component can be separately formed by dissolving a solid binder component in water and adding the mixture to the mixture of the clay filler component and the other components.

[0063] In certain embodiments, the mixture is homogenized, for example, by ball milling, by grinding the mixture with beads (such as zirconia beads) of a suitable diameter (e.g., 1 - 3 or 2 mm) for a suitable period of time, and homogenizing by separating the beads by filtration.

[0064] In certain embodiments, the homogenized slurry formulation is spray dried to obtain catalyst particles. Spray drying can be carried out using a suitable device that injects the mixture together with an atomizing gas and a drying gas into a cyclone separator, where the formed catalyst particles are dried. The dried catalyst particles are collected. For example, spray drying can be carried out at an inlet temperature of about 200 - 250 °C.

[0065] The formed catalyst particles can be calcined at a suitable temperature, heating rate, and for a suitable period of time to obtain the final catalyst particles, for example, at a temperature in the range of about 600 - 800 °C.

[0066] In one or more embodiments, the weight hourly space velocity (WHSV) of the lower reaction zone 121 or 221 can be about 1 - 200 h⁻¹ -1 . For example, the WHSV of the lower reaction zone 121 or 221 can be about 1 - 200, 1 - 175, 1 - 150, 1 - 125, 1 - 100, 1 - 75, 1 - 50, 1 - 25, 25 - 200, 50 - 200, 75 - 200, 100 - 200, 125 - 200, 150 - 200, or 175 - 200 h⁻¹ -1 . The WHSV can be used to describe the amount of catalyst in the dense bed of the lower reaction zone 121 or 221. Without wishing to be bound by theory, it is believed that the dense bed allows a large amount of catalyst to be present in the lower reaction zone, which can increase the yield of light olefins.

[0067] As the hydrocarbon reactants and the catalyst move through reactor 100, the hydrocarbon reactants may have an upward superficial velocity through the horizontal cross-section of reactor 100, and the catalyst may have a downward superficial velocity through the horizontal cross-section of reactor 100. As used herein, "superficial velocity" refers to the velocity at which a single phase flows through a given cross-sectional area. The overall flow of the phase is used to determine the superficial velocity of the phase; thus, individual particles or molecules within the phase may move in a direction different from or even opposite to the overall flow of the phase without affecting the direction of the superficial velocity of the phase.

[0068] For example, the hydrocarbon reactants flow from a feed inlet in the lower reactor section 120 or 220 to a hydrocarbon product outlet 112 in the upper reactor section 110. Thus, the overall flow of the hydrocarbon reactants through the horizontal cross-section of reactor 100 is in the upward direction, resulting in an upward superficial velocity. Similarly, the catalyst flows from a catalyst inlet 113 in the steam stripping section 130 of reactor 100 to a catalyst outlet, and the overall flow of the catalyst through the horizontal cross-section of reactor 100 is in the downward direction, resulting in a downward superficial velocity. In one or more embodiments, the upward superficial velocity of the hydrocarbon reactants and the downward superficial velocity of the catalyst result in a countercurrent flow pattern between the hydrocarbon reactants and the catalyst. Thus, in one or more embodiments, the hydrocarbon reactants and the catalyst move in a countercurrent orientation.

[0069] Without wishing to be bound by theory, it is believed that contacting the hydrocarbon reactants and the catalyst in a countercurrent manner can prevent backmixing of the catalyst that may occur in a conventional riser reactor and can promote undesirable side reactions that adversely affect the production of light olefins. Additionally, it is believed that contacting the hydrocarbon reactants and the catalyst in a countercurrent manner can prevent core-annular flow through the reactor, where the catalyst has a high concentration near the reactor wall and a low concentration toward the center of the reactor, where most of the hydrocarbon flow occurs. Generally, core-annular flow reduces the amount of contact between the catalyst and the hydrocarbon and can thus reduce the conversion of hydrocarbon feed to light olefins.

[0070] Without wishing to be bound by theory, it is also believed that countercurrent flow can also lead to an increase in the yield of olefins by allowing the more reactive chemicals in the hydrocarbon feed to contact the less active catalyst and allowing the less active catalyst to contact the more reactive chemicals in the hydrocarbon feed. Generally, the catalyst in the lower reaction zone 121 or 221 has already contacted the hydrocarbon in the upper reaction zone 111. Therefore, the catalyst in the lower reaction zone 121 or 221 is generally partially depleted and has a lower activity than the catalyst in the upper reaction zone 111. Contacting the hydrocarbon feed with a large amount of less active catalyst in the lower reaction zone 121 or 221 can allow the more reactive chemicals in the hydrocarbon feed to crack in the lower reaction zone 121 or 221 while contacting the less active catalyst. This in turn allows the more active catalyst in the upper reaction zone 111 to crack the less reactive chemicals in the hydrocarbon feed, increasing the yield of light olefins produced from the hydrocarbon feed.

[0071] In one or more embodiments, the superficial velocity of the hydrocarbon feed stream 101 flowing through the upper reactor section 111 is 10 m / s or less. For example, the superficial velocity of the hydrocarbon feed stream through the upper reactor section 111 can be less than or equal to 10.0 m / s, 9.0 m / s, 8.0 m / s, 7.0 m / s, 6.0 m / s, 5.0 m / s, 4.0 m / s, 3.0 m / s, 2.0 m / s, 1.0 m / s, 0.9 m / s, 0.8 m / s, 0.7 m / s, 0.6 m / s, 0.5 m / s or 0.4 m / s. Without wishing to be bound by theory, it is believed that a superficial velocity of the hydrocarbon feed stream within the upper reactor section 111 below 10.0 m / s can result in increased contact between the catalyst and the hydrocarbon, which in turn can lead to an increase in the conversion of the hydrocarbon feed to light olefins and a reduction in the mass transfer limitations between the hydrocarbon feed and the catalyst. Based on the design parameters of the reactor 100 including the height and diameter of the upper reactor section 110 and the lower reactor section 120 or 220, the superficial velocity of the hydrocarbon feed stream 101 can be obtained within the desired range.

[0072] In one or more embodiments, the residence time of the hydrocarbon feed stream 101 within the reactor 100 is about 0.1 - 10 seconds. For example, the residence time of the hydrocarbon feed stream 101 within the reactor 100 can be about 0.1 - 10 seconds, 0.5 - 10 seconds, 1 - 10 seconds, 2 - 10 seconds, 3 - 10 seconds, 4 - 10 seconds, 5 - 10 seconds, 6 - 10 seconds, 7 - 10 seconds, 8 - 10 seconds, 9 - 10 seconds, 0.1 - 9 seconds, 0.1 - 8 seconds, 0.1 - 7 seconds, 0.1 - 6 seconds, 0.1 - 5 seconds, 0.1 - 4 seconds, 0.1 - 3 seconds, 0.1 - 2 seconds or 0.1 - 1 second.

[0073] When the hydrocarbon feed stream 101 contacts the catalyst, at least a portion of the hydrocarbon feed stream 101 can be cracked to form hydrocarbon products. In one or more embodiments, the temperature within the reactor 100 can be from about 420 - 750 °C to facilitate the cracking of the hydrocarbon feed stream 101. For example, the temperature (in °C) within the reactor 100 can be about 420 - 750, 460 - 750, 500 - 750, 540 - 750, 580 - 750, 620 - 750, 660 - 750, 700 - 750, 420 - 670, 420 - 630, 420 - 590, 420 - 550, 420 - 510, 440 - 720, or 480 - 680.

[0074] In one or more embodiments, the hydrocarbon products can include light olefins and other reaction products. For example, in addition to other reaction products, the hydrocarbon products can also include ethylene, propylene, butene, or a combination thereof. In one or more embodiments, the other reaction products can include one or more of dry gas, aromatics, LPG, naphtha (including full-range naphtha, or separate light naphtha fraction and heavy naphtha fraction), light cycle oil, heavy cycle oil, and / or heavy oil. In one or more embodiments, the hydrocarbon product stream 102 containing light olefins can exit from the upper reaction zone 111 through the hydrocarbon product outlet 112 in the upper reactor section 110. In one or more embodiments, the hydrocarbon product stream 102 can contain catalyst entrained within the hydrocarbon product stream 102, which can be separated from the hydrocarbon product stream 102 in a separation device. Any suitable separation device, including a cyclone or a series of cyclones, can be used to separate the entrained catalyst from the hydrocarbon product stream 102. In one or more embodiments, the light olefins can be separated from the hydrocarbon product stream 102. The separation of the light olefins from the hydrocarbon product stream can be achieved by any suitable means, including, for example, distillation. In one or more embodiments, the separation of the light olefins from the hydrocarbon product stream can produce a stream of relatively pure ethylene, propylene, or butene.

[0075] In one or more embodiments, the cracking of the hydrocarbon feed stream 101 can produce spent catalyst. The spent catalyst can be produced in both the upper reaction zone 111 and the lower reaction zone 121 or 221. In one or more embodiments, the spent catalyst can contain coke on the catalyst. The coke can reduce the activity of the catalyst, and the spent catalyst can have reduced activity when compared to regenerated or fresh catalyst. In one or more embodiments, the dense fluidized bed of the lower reaction zone 121 or 221 can contain the spent catalyst. Without wishing to be bound by theory, the more reactive components of the hydrocarbon feed stream may crack in the lower reaction zone because those components do not require high catalytic activity to react. When the hydrocarbon feed is fed from the lower reaction zone 121 or 221 into the upper reaction zone 111, the hydrocarbon feed will encounter more active fresh or regenerated catalyst, and the less reactive components of the hydrocarbon feed will crack. Thus, the countercurrent flow of the catalyst and the hydrocarbon feed stream 101 can result in an increased conversion of the hydrocarbon feed to light olefins.

[0076] In one or more embodiments, the reactor 100 can include a steam stripping section 130 below the lower reactor section 120 or 220. The steam stripping section 130 can define a steam stripping zone 131. The steam stripping section 130 can be in fluid communication with and adjacent to the lower reactor section 120 or 220. In one or more embodiments, the spent catalyst can be fed from the lower reaction zone 121 or 221 into the steam stripping zone 131. In additional embodiments, the spent catalyst can be fed directly from the lower reaction zone 121 into the steam stripping zone 131, whereby the lower reaction zone 121 or 221 and the steam stripping zone 131 are in direct fluid communication with each other. Steam can be fed into the steam stripping zone 131 via stream 105. In the steam stripping zone 131, the steam can contact the spent catalyst and strip at least a portion of the hydrocarbons from the spent catalyst. After contacting the steam in the steam stripping zone 131, the spent catalyst can exit the reactor 100 via stream 104 through a catalyst outlet. In embodiments using a co-feed and including steam, the co-feed along with the hydrocarbon feed stream is in addition to the steam introduced into the steam stripping zone 131 via stream 105.

[0077] In one or more embodiments, the spent catalyst can be fed to a catalyst regenerator 150, where the spent catalyst is regenerated to form a regenerated catalyst. The catalyst regenerator 150 can include a riser 160 and a regenerator vessel 170. The spent catalyst can enter the riser 160 through a catalyst inlet. In one or more embodiments, the riser 160 is in fluid communication with the steam stripping zone 131 of the reactor 100, and the spent catalyst can be fed directly from the steam stripping zone 131 into the riser 160. In one or more embodiments, an air stream 151 is fed into the riser 160, and the air and the spent catalyst travel upward along the riser 160. In one or more embodiments, the air stream 151 is used to oxidize at least a portion of the coke on the spent catalyst, restoring the activity of the spent catalyst and forming a regenerated catalyst.

[0078] The regenerated catalyst and air can move from the riser 160 to the regenerator vessel 170. In one or more embodiments, the riser 160 and the regenerator vessel 170 are adjacent to each other, and the regenerated catalyst and air move directly from the riser 160 to the regenerator vessel 170, where the riser 160 and the regenerator vessel 170 are in direct fluid communication. In one or more embodiments, an air stream 152 can exit the regenerator vessel 170. Additionally, the regenerated catalyst can exit the regenerator vessel 170 through a regenerated catalyst outlet. In one or more embodiments, the regenerated catalyst can be included in the catalyst of the stream 103. In one or more embodiments, the regenerator vessel 170 and the upper reactor section 110 can be in fluid communication with each other, and the regenerated catalyst can be fed directly from the regenerator vessel 170 of the regenerator 150 into the upper reaction zone 111 of the reactor 100 through a catalyst inlet 113, where the regenerator vessel 170 and the upper reaction zone 111 are in direct fluid communication. In one or more embodiments, fresh catalyst can be added to the catalyst in the stream 103. In such an embodiment, the catalyst can include both the regenerated catalyst and the fresh catalyst.

[0079] Examples

[0080] The following examples illustrate one or more additional features of the present disclosure. In the following examples, a hydrocarbon feed stream is cracked into light olefins in the presence of a catalyst sample containing a mixture of spent catalyst and fresh catalyst to simulate a reactor having a lower fluidized bed and an upper countercurrent plug flow reaction zone as in the present disclosure.

[0081] Catalyst Preparation (Preparation of Phosphorus-Modified ZSM-5 Zeolite): Dissolve the modification precursor (phosphoric acid, H3PO4) in deionized water to match a P:Al molar ratio of 0.4. Stir the resulting solution at 60 °C for 10 minutes, then add ZSM-5 (SAR 23) to the solution and maintain the stirring at 60 °C for another 5 hours. After that, dry the dispersion in an oven at 100 °C for 12 hours and then calcine it at 650 °C for 3 hours.

[0082] Catalyst Preparation (Preparation of Formulated Catalysts): Add the zeolite component to a homogeneous liquid slurry of kaolin clay and distilled water and mechanically mix until homogeneous. Table 1 shows the specific formulations of the different catalyst particles formed, where all amounts are in weight percentages relative to the weight of the catalyst particles formed. The zeolite used is NH4 - ZSM-5, which has an SAR of 23 in moles; P-modified ZSM-5 with a P / Al molar ratio of 0.4; and / or H with an SAR of 30 in moles + USY. After the mixture of the clay and zeolite components, add the binder component, Al2Cl(OH)5 solution, to the slurry and stir. Perform a ball milling procedure with zirconia beads at 300 rpm. In the embodiments of catalysts S-7, S-8, S-9, and S-10, before ball milling, combine powdered SiC (given diameter 800 nm) with the slurry containing all components. Spray dry the slurry formulation at an inlet temperature of 220 °C. Calcine the final catalyst at 700 °C for 7 hours and then characterize and test it in a catalytic reaction. The formulated catalysts are as listed in Table 1.

[0083] Catalyst Application - Example 1: Mix catalyst particles S-8 and S-10 in S-8:S-10 mass ratios of 0.7:0.3 and 0.6:0.4. Test the mixed catalysts in a laboratory-scale dense fluidized bed reactor unit, which is designed to simulate some aspects of the MZFBR disclosed herein, where 4 g of catalyst loading is used for the reaction of hydrocarbon feed of Arab light crude oil. The reaction temperature varies at 625, 650, and 675 °C to determine the effect of temperature. The flow rates are: water, 0.1 mL / min; hydrocarbon feed, 0.1 mL / min; N2, 100 mL / min. The run time (TOS) is 80 minutes. Before the catalytic test, hydrothermally treat all catalysts in 90% steam at 810 °C for 5 hours. Figure 5A 、 5B and 5C plot the different physical mixtures of S-8:S-10 catalyst particles: 0.5:0.5 (left vertical bar), 0.6 and 0.4 (center vertical bar), 0.7 and 0.3 (right vertical bar), at different temperatures ( Figure 5A , 625 °C, Figure 5B, 650 °C and Figure 5C , the C1-C4 yields of the overall activity and product distribution in the catalytic cracking of Arab light crude oil at 675 °C).

[0084] Catalyst application - Example 2: Catalyst particles S-5 were tested in a laboratory-scale dense fluidized bed reactor unit that was designed to simulate some aspects of the MZFBR for the reaction of the hydrocarbon feed of Arab light crude oil disclosed herein. The reaction temperature was 570 °C. The flow rates were: water, 0.1 mL / min; hydrocarbon feed, 0.1 mL / min; N2, 100 mL / min. Before the catalytic test, the catalyst was hydrothermally treated at 810 °C in 90% steam for 5 hours. Figure 6 The yields were plotted as a function of run time.

[0085] For the purpose of describing the simplified schematic diagrams and descriptions of the drawings, many valves, temperature sensors, electronic controllers, etc. that can be employed and are known to those of ordinary skill in certain fields of processing operations are not included. In addition, the accompanying components typically included in a typical chemical processing operation, such as air supply, catalyst hopper, flue gas treatment system, dryer, heater, heat exchanger, pipes, pumps, compressors, and controllers, are not depicted. Further, although not shown, as is known, light gases (such as C1 and C2 gases) from one or more zones can be used as fuel for one or more heaters within the system. The accompanying components in the cracking unit, such as the effluent stream, spent catalyst discharge subsystem, and catalyst replacement subsystem, are also not shown. It should be understood that these components are within the spirit and scope of the disclosed embodiments herein. It should be understood that the reactor diameter and length or the relative diameter and length with respect to the zones should not be inferred from the drawings, and the diameter of the reactor can be similar or different from that depicted in the drawings. Additionally, operating components such as those described in the present disclosure can be added to the embodiments described in the present disclosure.

[0086] It should be understood that like numbers in the figures represent like elements in several figures, and not all components and / or steps shown and described in reference to the figures are required for all embodiments or arrangements. Additionally, the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the invention. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly dictates otherwise. It will be further understood that when used in this specification, the terms "comprises", "comprising", "has", "having", "includes", "including", "relates to", "relating to" and variations thereof specify the presence of the stated features, integers, steps, operations, elements and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and / or combinations thereof. For example, condition A or B is satisfied by any of the following: A is true (or present) and B is false (or absent), A is false (or absent) and B is true (or present), and both A and B are true (or present).

[0087] It should be noted that one or more of the following claims use the term "wherein" as a transitional phrase. For purposes of defining the invention, it should be noted that this term is introduced in the claims as an open transitional phrase that is used to introduce a recitation of a series of features of a structure and should be interpreted in a manner similar to that of the more common open introductory term "comprising".

[0088] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. In case of conflict, the present specification, including definitions, will control. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present invention, suitable methods and materials are described below. In addition, the materials, methods and examples are illustrative only and not restrictive.

[0089] When an equivalent, concentration or other value or parameter is given as a list of ranges, preferred ranges or upper preferred values and / or lower preferred values, this should be understood to specifically disclose all ranges formed by any pair of any range upper limit or preferred value and any range lower limit or preferred value, regardless of whether the ranges are separately disclosed. Where numerical ranges are recited herein, unless otherwise stated, the range is intended to include its endpoints, as well as all integers and fractions within the range.

[0090] It should be noted that the use of ordinal terms such as "first", "second", "third", etc. in the claims to modify the claim elements themselves does not imply any priority, precedence or order of one claim element over another or the chronological order of acts of a method of performing, but is only used as a label to distinguish one claim element having a particular name from another element having the same name (but using an ordinal term) to distinguish the claim elements.

[0091] It is noted that the above figures and examples are not meant to limit the scope of the present disclosure to a single embodiment, as other embodiments are possible by interchanging some or all of the described or illustrated elements. Further, in cases where some of the elements of the present disclosure can be implemented, in part or in whole, with known components, only those portions of such known components necessary for an understanding of the present disclosure are described, and detailed descriptions of other portions of such known components are omitted so as not to obscure the present disclosure. In this specification, unless otherwise expressly stated herein, an embodiment showing a single component is not necessarily limited to other embodiments including a plurality of the same components, and vice versa. Further, the applicant does not intend any term in the specification or claims to have an uncommon or special meaning unless expressly set forth as such. Further, the present disclosure covers current and future known equivalents of known components mentioned herein by way of illustration.

[0092] The foregoing description of the specific embodiments will so fully disclose the general nature of the present disclosure that others can, by applying knowledge within the skill of the relevant art, readily modify and / or adapt such specific embodiments for various applications without undue experimentation, without departing from the general concept of the present disclosure. Accordingly, such adaptations and modifications are intended to fall within the meaning and scope of the equivalents of the disclosed embodiments. It is to be understood that the language or terminology herein is for the purpose of description and not of limitation, such that the terminology or wording of this specification will be interpreted by those skilled in the art in light of the teachings and guidance presented herein in conjunction with the knowledge of those skilled in the relevant art. It is to be understood that the dimensions discussed or shown are in accordance with the figures of one example, and other dimensions can be used without departing from the present disclosure.

[0093] The above subject matter is provided by way of illustration only and should not be construed as limiting. Various modifications and changes can be made to the subject matter described herein without following the example embodiments and applications shown and described, and without departing from the true spirit and scope of the invention covered by the present disclosure, which is defined by a set of recitations in the appended claims and equivalents of such recitations in structure and function or steps.

[0094] Table 1

[0095]

Claims

1. A method for processing hydrocarbons to produce light olefins, the method comprising: Feeding a hydrocarbon feed stream into a feed inlet of a reactor to contact catalyst particles, wherein the reactor comprises: An upper reactor portion defining an upper reaction zone, the upper reactor portion including a catalyst inlet and a hydrocarbon product outlet, wherein the catalyst inlet and the hydrocarbon product outlet are located at or near the top of the upper reactor portion; and A lower reactor portion defining a lower reaction zone, the lower reactor portion including a feed inlet and a catalyst outlet, wherein the feed inlet and the catalyst outlet are located at or near the bottom of the lower reactor portion, and wherein the lower reaction zone is in fluid communication with and adjacent to the upper reaction zone; and Wherein the catalyst particles have a downward superficial velocity through the upper reactor portion and the lower reactor portion, and the hydrocarbon feed stream has an upward superficial velocity through the upper reactor portion and the lower reactor portion, such that the hydrocarbon feed stream and the catalyst particles move in a countercurrent orientation; Wherein the upper reaction zone operates in a countercurrent plug flow manner; Wherein the lower reaction zone operates in a dense bed fluidization manner; Wherein the catalyst particles are contacted with the hydrocarbon feed stream to crack one or more components of the hydrocarbon feed stream and form a hydrocarbon product stream; Wherein the hydrocarbon product stream comprises light olefins and other reaction products, the light olefins including one or more of ethylene, propylene or butene, and the other reaction products including one or more of dry gas, LPG, aromatics, light naphtha, full-range naphtha, heavy naphtha, light cycle oil or heavy cycle oil; And Causing the hydrocarbon product stream to leave the upper reaction zone through the hydrocarbon product outlet; Wherein the catalyst particles comprise: (a) A mixture which is a combination of a physical mixture of individual particles of at least a first composite particle and a second composite particle, The first composite particle comprises about 5-70 wt% of a 10-membered ring zeolite component optionally modified with phosphorus, about 5-70 wt% of a first binder component, about 10-60 wt% of a first filler component; and 0-40 wt% of an optional first additive component, and The second composite particle comprises about 5 wt% of a 12-membered ring zeolite component, about 5-70 wt% of a second binder component, about 10-60 wt% of a second filler component; and about 0-40 wt% of an optional second additive component; Wherein The first and second binder components are the same or different amorphous components selected from alumina (including γ-alumina), silica, alumina-silicate, silica-aluminate, alumina phosphate and combinations comprising two or more of said amorphous binder components, The first and second filler components are the same or different components selected from kaolin, sepiolite, talc, palygorskite, montmorillonite and two or more of said filler components; and The first and second additive components are the same or different components selected from metal carbides (including silicon carbide), rare earth metals (including cerium and lanthanum), alkali metals (including sodium), alkaline earth metals and metal oxides (including iron oxide and copper oxide); Or (b) A multi-zeolite composite particle comprising about 5-75 wt% of a 10-membered ring zeolite component modified with phosphorus, about 5-75 wt% of a 12-membered ring zeolite component, about 5-70 wt% of a binder component, about 10-60 wt% of a filler component; and about 0-40 wt% of an optional additive component; wherein the binder component is an amorphous component selected from alumina (including γ-alumina), silica, alumina-silicate, silica-aluminate, alumina phosphate, and a combination comprising two or more of said amorphous binder components; the filler component is selected from kaolin, sepiolite, talc, palygorskite, montmorillonite, and two or more of said filler components; and the additive component is selected from metal carbides (including silicon carbide), rare earth metals (including cerium and lanthanum), alkali metals (including sodium), alkaline earth metals, and metal oxides (including iron oxide and copper oxide).

2. The method according to claim 1, wherein the 10-membered ring zeolite component is characterized by a micropore diameter in the range of about 0.45 - 0.6 nanometers.

3. The method according to claim 2, wherein the 10-membered ring zeolite comprises a pentasil (MFI) framework.

4. The method according to claim 3, wherein the zeolite having a pentasil (MFI) framework includes Zeolite SoconyMobil-5 (ZSM-5) or ZSM-5 modified by mesoporation.

5. The method according to claim 4, wherein the zeolite having a pentasil (MFI) framework includes ZSM-5 modified by mesoporation, wherein the mesoporation is selected from dealumination, desilication, and steaming.

6. The method according to any one of claims 3-5, wherein the zeolite having a pentasil (MFI) framework comprises a phosphorus-modified pentasil (MFI) framework zeolite, wherein the phosphorus is in a P / Al molar ratio in the range of about 0.1 - 1.

7. The method according to claim 2, wherein the 10-membered ring zeolite includes ferrierite (FER) zeolite.

8. The method according to any one of claims 1 to 7, wherein the 12-membered ring zeolite component is characterized by a micropore diameter in the range of about 0.6 nanometers to 0.8 nanometers.

9. The method according to claim 8, wherein the 12-membered ring zeolite comprises a faujasite (FAU) framework.

10. The method according to claim 9, wherein the zeolite having a faujasite (FAU) framework is selected from ultrastable Y (USY) zeolite, zeolite Y, and zeolite X.

11. The method according to claim 8, wherein the 12-membered ring zeolite comprises a mordenite (MOR) framework.

12. The method according to claim 8, wherein the 12-membered ring zeolite comprises a β (*BEA) framework.

13. The method according to claim 1, wherein the 10-membered ring zeolite includes phosphorus-modified Zeolite Socony Mobil-5 (ZSM-5) with a P / Al molar ratio in the range of about 0.1 - 1, and wherein the 12-membered ring zeolite includes ultrastable Y (USY) zeolite.

14. The method according to claim 13, wherein the catalyst particles comprise a mixture of at least a first composite particle and a second composite particle, wherein the first composite particle accounts for about 20 wt% to 75 wt% or 30 wt% to 75 wt% of the total mass of the catalyst particles, and wherein the second composite particle accounts for about 20 wt% to 75 wt% or 25 wt% to 50 wt% of the total mass of the catalyst particles.

15. The method according to claim 13, wherein the catalyst particles comprise multi-zeolite catalyst particles, which comprise about 15 - 75 wt% of 10-membered ring zeolite and about 20 - 75 wt% of 12-membered ring zeolite.

16. The method according to claim 1, wherein about 5 wt% to 40 wt% of an additive component is provided.

17. The method according to claim 16, wherein the additive component comprises silicon carbide particles having a given diameter in the range of 1 - 1000 nanometers and in an amount of (a) about 15 - 25 wt% of the first composite particle and the second composite particle or (b) about 15 - 25 wt% of the multi-zeolite composite particle, and wherein the silicon carbide enables for (a) the first composite particle and the second composite particle, an increase in density, and for (a) the first composite particle and the second composite particle or (b) the multi-zeolite composite particle, an improvement in the thermal conductivity across the catalyst body as compared to the composite without the additive component.

18. The method according to any one of claims 1 - 17, wherein the catalyst particles have a tapped density in the range of about 0.55 - 1.3 g / ml.

19. The method according to any one of claims 1 to 18, further comprising: feeding the catalyst through a catalyst outlet into a catalyst regenerator, wherein the catalyst passing through the catalyst outlet is a spent catalyst; regenerating at least a portion of the spent catalyst to form a regenerated catalyst; and feeding the regenerated catalyst through a catalyst inlet into an upper reaction zone.

20. The method according to any one of claims 1 to 19, further comprising passing the catalyst through a steam stripping section of the reactor before the catalyst outlet.

21. The method according to claim 20, wherein, In the steam stripping section, steam contacts the catalyst, and at least a portion of the hydrocarbons adsorbed on the catalyst is stripped out of the catalyst.

22. The method according to any one of claims 1 - 21, further comprising introducing a co-feed together with the hydrocarbon feed stream, wherein the co-feed comprises steam, recycle oil derived from the hydrocarbon product stream, an oxygenate, or a combination of two or more of steam, recycle oil derived from the hydrocarbon product stream, and an oxygenate.

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