Process and apparatus for processing hydrocarbons to produce light olefins

Abstract

Light olefins may be produced from hydrocarbons by a process that includes co-feeding a hydrocarbon feed stream with one or more of steam, a recycle stream, or an oxygenate into one or more feed inlets of a reactor. The reactor may include an upper reactor portion defining an upper reaction zone and a lower reactor portion defining a lower reaction zone. The catalyst may move in a generally downward direction through the upper reactor portion and the lower reactor portion, and the hydrocarbon feed stream may move in a generally upward direction through the lower reactor portion and the upper reactor portion such that the hydrocarbon feed stream and the catalyst move in a countercurrent orientation. Contacting the catalyst with the hydrocarbon feed stream may crack one or more components of the hydrocarbon feed stream and form a hydrocarbon product stream.

Description

Technical Field

[0001] Embodiments of the present disclosure generally relate to methods for processing hydrocarbons, and more particularly, to methods 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 issues in the art, the present disclosure aims to provide technical solutions for improved methods for producing light olefins. Summary of the Invention

[0004] A method for processing hydrocarbons to produce light olefins is provided. The light olefins can be produced from hydrocarbons by a method including feeding a hydrocarbon feed stream and one or more co-feeds of steam, recycle stream, or oxygenate into one or more feed inlets of a reactor. 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 method for processing hydrocarbons to produce light olefins includes feeding a main hydrocarbon feed stream and a co-feed of steam into a feed inlet of a reactor for contact with a catalyst, the co-feed being provided in an amount of about 1 to 150 mass % co-feed relative to the mass of the main hydrocarbon feed stream.

[0006] In certain embodiments, the method for processing hydrocarbons to produce light olefins includes feeding a main hydrocarbon feed stream and a co-feed of a recycle stream derived from the hydrocarbon product stream.

[0007] In certain embodiments, the method for processing hydrocarbons to produce light olefins includes feeding a main hydrocarbon feed stream and a co-feed of an oxygenate into a feed inlet of a reactor for contact with a catalyst, the co-feed being provided in an amount of about 1 to 50 mass % co-feed relative to the mass of the main hydrocarbon feed stream.

[0008] In certain embodiments, a method for processing hydrocarbons to produce light olefins includes feeding a main hydrocarbon feed stream and a co-feed into a feed inlet of a reactor to contact a catalyst, the co-feed comprising steam in an amount of about 1 to 150 mass % steam relative to the mass of the main hydrocarbon feed stream and recycle oil derived from a hydrocarbon product stream.

[0009] In certain embodiments, a method for processing hydrocarbons to produce light olefins includes feeding a main hydrocarbon feed stream and a co-feed into a feed inlet of a reactor to contact a catalyst, the co-feed comprising steam in an amount of about 1 to 150 mass % steam relative to the mass of the main hydrocarbon feed stream, and an oxygenate in an amount of about 1 to 50 mass % relative to the mass of the main hydrocarbon feed stream.

[0010] In certain embodiments, a method for processing hydrocarbons to produce light olefins includes feeding a main hydrocarbon feed stream and a co-feed into a feed inlet of a reactor to contact a catalyst, the co-feed comprising steam in an amount of about 1 to 150 mass % steam relative to the mass of the main hydrocarbon feed stream, recycle oil derived from a hydrocarbon product stream, and an oxygenate in an amount of about 1 to 50 mass % relative to the mass of the main hydrocarbon feed stream.

[0011] In certain embodiments, a method for processing hydrocarbons to produce light olefins includes feeding a first hydrocarbon feed stream into a first feed inlet of a reactor and feeding a second hydrocarbon feed stream into a second feed inlet of the reactor to contact a catalyst.

[0012] In certain embodiments where the recycle oil stream comprises all or a portion of the co-feed, the other reaction products comprise at least light cycle oil, and wherein the co-feed comprises all or a portion of the light cycle oil as all or a portion of the recycle stream, and wherein the recycle stream is provided in an amount of about 1 to 20 mass % co-feed relative to the main hydrocarbon feed stream. In certain embodiments where the recycle oil stream comprises all or a portion of the co-feed, the other reaction products comprise at least light naphtha, and wherein the co-feed comprises all or a portion of the light naphtha as all or a portion of the recycle stream, and wherein the recycle stream is provided in an amount of about 1 to 50 mass % co-feed relative to the main hydrocarbon feed stream.

[0013] In certain embodiments where the oxygenate comprises all or a portion of the co-feed, the oxygenate can comprise one or more alcohols, ketones or aldehydes. In certain embodiments where the oxygenate comprises all or a portion of the co-feed, methanol can be used.

[0014] In an embodiment of the present disclosure, the reactor comprises: an upper reactor portion defining an upper reaction zone, the upper reactor portion comprising a catalyst inlet for receiving a catalyst and a hydrocarbon product outlet, wherein the catalyst inlet and the hydrocarbon product outlet are located at or near the top of the upper reaction zone, and wherein the reaction zone refers to the region in the reactor where a specific reaction occurs; and a lower reactor portion defining a lower reaction zone, the lower reactor portion comprising 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 reaction zone, and wherein the lower reaction zone is in fluid communication with and adjacent to the upper reaction zone. The catalyst has a downward superficial velocity through the upper reaction zone and the lower reaction zone, and the hydrocarbon feed stream has an upward superficial velocity through the upper reaction zone and the lower reaction zone, such that the hydrocarbon feed stream and the catalyst move and contact in a countercurrent orientation. The upper reaction zone operates in a countercurrent plug flow manner. Wherein the mass ratio of the catalyst to the oil in the upper reaction zone is about 5 to 100, and the superficial velocity of the hydrocarbon feed stream in the upper reaction zone is 10 m / s or less. The lower reaction zone operates in a dense bed fluidization manner, wherein the weight hourly space velocity of the lower reaction zone is about 1 to 200 hr -1 . Contacting the catalyst with the hydrocarbon feed stream and a co-feed cracks one or more components of the hydrocarbon feed stream and forms a hydrocarbon product stream. The hydrocarbon product stream comprises light olefins and may also include other reaction products, the light olefins include one or more of ethylene, propylene or butene, and the other reaction products include one or more of light cycle oil and dry gas, LPG, aromatics, light naphtha, full-range naphtha, heavy naphtha or heavy cycle oil. The hydrocarbon product stream exits the upper reaction zone through the hydrocarbon product outlet.

[0015] In certain embodiments, the method further comprises: feeding the catalyst through the catalyst outlet into a catalyst regenerator, wherein the catalyst passing through the catalyst outlet is the spent catalyst; regenerating at least a portion of the spent catalyst to form a regenerated catalyst; and feeding the regenerated catalyst through the catalyst inlet into the upper reaction zone. The method may further comprise passing the catalyst through a steam stripping section of the reactor before the catalyst outlet. For example, in the steam stripping section, steam contacts the catalyst, and at least a portion of the hydrocarbons adsorbed on the catalyst are stripped out of the catalyst.

[0016] Any combination of the various embodiments and implementations disclosed herein may be used. These and other aspects and features can be understood from the following description of certain embodiments and the drawings and claims. Description of the Drawings

[0017] 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.

[0018] Figure 1Schematically depicts a reactor and a catalyst regenerator for producing light olefins in accordance with one or more embodiments disclosed herein.

[0019] Figure 2 Schematically depicts a reactor and a catalyst regenerator for producing light olefins in accordance with one or more other embodiments.

[0020] Figure 3 Schematically shows a lower reactor portion of a reactor for producing light olefins in accordance with one or more additional embodiments disclosed herein.

[0021] Figure 4 Schematically depicts a cross-sectional view of an upper reactor portion of a reactor for producing light olefins in accordance with one or more embodiments disclosed herein. Specific Embodiments

[0022] Embodiments of the present disclosure relate to systems and processes for processing hydrocarbons to produce light olefins. The present disclosure includes embodiments related to the methods and apparatuses described in co-owned U.S. Patent Application 16 / 940,668, filed Jul. 28, 2020, and titled “Methods and apparatuses for processing hydrocarbons to produce light olefins” and published as US20220033714A1, which is incorporated herein by reference in its entirety.

[0023] As used in the present disclosure, a “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, a “reaction zone” refers to a 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 that includes a region arranged as a dense bed fluidized reactor. In certain embodiments, the reactor includes one reaction zone and another reaction zone, where the one reaction zone is a region arranged as a countercurrent plug flow reactor and the other reaction zone is 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.

[0024] As used in this disclosure, "hydrocarbon reactant" refers to hydrocarbons from the hydrocarbon feed stream passing through the reactor and can 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 primary hydrocarbon feed stream or initial hydrocarbon feed stream passing through the reactor and can include one or more co-feeds, including steam and / or oxygenates. In certain embodiments, "hydrocarbon reactant" refers to hydrocarbons from the primary hydrocarbon feed stream passing through the reactor and can 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 primary hydrocarbon feed stream passing through the reactor and can 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, including steam and / or oxygenates, passing 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 recycle oil (light recycle oil, heavy recycle oil, or a combination thereof) from the reactor effluent, passing 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, where the recycle and co-feeds pass with the first and / or second hydrocarbon feed stream.

[0025] As used in this disclosure, "catalyst" refers to any substance that increases the rate of a specific chemical reaction. The catalysts described in this disclosure can be used to facilitate various reactions, such as, but not limited to, cracking. As used in this disclosure, "cracking" generally refers to a chemical reaction in which a molecule having a carbon-carbon bond 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.

[0026] As used in this 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 as well as 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 this 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.

[0027] As used in this 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 to the spent catalyst, the "regenerated catalyst" can have less coke, a higher temperature, or both, and can have higher catalytic activity compared to the spent catalyst. Compared to 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.

[0028] As used in this 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, that is, 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, for example, C1-C3 means a mixture comprising C1, C2, and C3.

[0029] 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 oil, Arabian light crude oil, Arabian super light crude oil, other Gulf crude oils, Brent crude oil, North Sea crude oil, North African and West African crude oils, Indonesian, Chinese crude oil, North American or South American crude oils, Russian and Central Asian crude oils, or mixtures thereof. The crude oil mixture can be a full-range crude oil or a topped crude oil. 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.

[0030] As used in the present disclosure, all boiling point ranges relative 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 a fraction 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.

[0031] As used in the present 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". The term "naphtha" as used herein 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. The term "light naphtha" as used herein 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. The term "heavy naphtha" as used herein 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 by distillation in an intermediate refining process. The term "kerosene" as used herein 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 within 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.

[0032] 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°.

[0033] The term "recycle oil" is used herein to refer to a mixture of light recycle oil and heavy recycle oil. The term "light recycle oil" and its acronym "LCO" as used herein refer to light recycle oil produced by a conventional FCC unit and also 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 recycle oil" and its acronym "HCO" as used herein refer to heavy recycle oil produced by a conventional FCC unit and also 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.

[0034] Conventional FCC processes operate in the reactor with a relatively low catalyst holdup by utilizing a lean bed or a circulating fluidized state (e.g., a dilute fluidized bed). Additionally, conventional catalytic cracking processes can utilize a co-current flow pattern, whereby the catalyst and the 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 a method for producing light olefins by catalytic cracking, wherein the catalyst and the hydrocarbon contact each other in a countercurrent manner, and wherein a portion of the reactor operates in a dense bed fluidized manner. 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 traditional 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 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 lower yield of light olefins in a traditional FCC riser reactor where the catalyst and the hydrocarbon flow co-currently through the reactor.

[0035] Now refer Figure 1 and 2, schematically depicts a reactor 100 for producing light olefins. The reactor includes 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.

[0036] In certain embodiments, as shown with respect to Figure 1 , a 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.

[0037] In certain embodiments, as shown with respect to Figure 2 , a 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, an optional embodiment as shown in Figure 2 also includes a co-feed 109 (shown in dashed lines), which is introduced together with the main hydrocarbon feed stream 108 and the recycle stream 102a through one or more feed inlets 101.

[0038] In certain embodiments, as shown with respect to Figure 3 , 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 reactors 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%.

[0039] 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).

[0040] The feed to one or more second inlets 291 includes 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 includes the second hydrocarbon feed stream 298. In certain embodiments, the feed to one or more second inlets 291 includes 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 includes the second hydrocarbon feed stream 298 and the recycle stream 202b. In certain embodiments, the feed to one or more second inlets 291 includes 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 includes the recycle stream 202b. In certain embodiments, the feed to one or more second inlets 291 includes the recycle stream 202b and a co-feed 299 (or co-feeds 299).

[0041] Continuing to refer Figure 1 and Figure 2 and also referring Figure 3 , the upper reactor section 110 defines an upper reaction zone 111. In operation, 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 an intermediate component or reactor section, 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, hydrocarbon reactants are fed directly from the lower reactor section 120 or 220 into the upper reactor section 110.

[0042] Referring 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, 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. 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, so 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 section 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 leaving the reactor 100.

[0043] As Figures 1 - 3 shown, the lower reactor section 120 or 220 can have a larger cross-sectional area than the upper reactor section 110. In certain embodiments, the lower section 120 or 220 and the lower reaction zone 121 or 221 are characterized by the shape of a cylindrical section. In one or more embodiments, the lower reactor section 120 or 220 can have a cross-sectional area substantially similar to that of the upper reactor section 110. In certain embodiments, the lower section 120 or 220 and the lower reaction zone 121 or 221 are characterized by the shape of a cylindrical section with a frustoconical section 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 height percentages related to the bottom height, middle height, and top height refer to the height along the cylindrical section of the lower reactor section 220.

[0044] In one or more embodiments, the upper reaction zone 111 can operate 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 operate in a countercurrent plug flow manner.

[0045] 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.

[0046] 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 directly fed 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 form a dense fluidized bed in the lower reaction zone 121 or 221. As described herein, "dense bed fluidization state" means a state in which the fluidized bed has a clearly defined upper limit or surface limited to the dense bed. For example, the 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 with an increase in the velocity of the gas flowing through the bed.

[0047] 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 contain 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 contain, consist of, or consist essentially of the following: 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 contain 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 contain 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 contain 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.

[0048] 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 contain, consist of, or consist essentially of the following: 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.

[0049] 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%.

[0050] 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 the oxygenate is provided as a co-feed, it is 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 oxygenate may contain one or more alcohols, ketones or aldehydes. In one or more embodiments, the oxygenate may contain methanol.

[0051] 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.

[0052] In certain embodiments, recycle stream 102a or 202a and / or 202b comprises non-aromatic light naphtha, which includes butene (along with 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.

[0053] 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.

[0054] Reference Figure 3 , the first inlet 281 and the second inlet 291 may 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

[0055] In certain embodiments, the initial feed stream is split 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.

[0056] 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.

[0057] 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.

[0058] In one or more embodiments, the weight hourly space velocity (WHSV) of the lower reaction zone 121 or 221 can be about 1 - 200 hr -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 hr -1 . The WHSV can be used to describe the amount of catalyst in the packed bed of the lower reaction zone 121 or 221. Without wishing to be bound by theory, it is believed that the packed bed allows a large amount of catalyst to be present in the lower reaction zone, which can increase the yield of light olefins.

[0059] As the hydrocarbon reactants and the catalyst move through reactor 100, the hydrocarbon reactants can have an upward superficial velocity through the horizontal cross-section of reactor 100, and the catalyst can 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 can 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.

[0060] 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 an 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 a 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.

[0061] 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 can occur in conventional riser reactors 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 the hydrocarbon feed to light olefins.

[0062] Without wishing to be bound by theory, it is also believed that countercurrent flow can also result in 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.

[0063] 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 of less than 10.0 m / s can result in increased contact between the catalyst and the hydrocarbon, which in turn can result in 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 a desired range.

[0064] 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.

[0065] 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 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.

[0066] 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 include 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.

[0067] 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 a 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 a high catalytic activity to react. When the hydrocarbon feed is fed from the lower reaction zone 121 or 221 to the upper reaction zone 111, the hydrocarbon feed will encounter a 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.

[0068] 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 to the steam stripping zone 131. In additional embodiments, the spent catalyst can be fed directly from the lower reaction zone 121 to 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 to 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 in stream 104 through the catalyst outlet. In embodiments using a co-feed and including steam, the co-feed together with the hydrocarbon feed stream is in addition to the steam introduced into the steam stripping zone 131 via stream 105.

[0069] In one or more embodiments, the spent catalyst can be fed into 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 directly fed 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.

[0070] 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 leave the regenerator vessel 170. Additionally, the regenerated catalyst can leave 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 directly fed 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.

[0071] Examples

[0072] 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.

[0073] Example 1: A Micro Activity Test (MAT) unit was used to determine the conversion and selectivity of a hydrocarbon stream at different catalyst-to-oil ratios to simulate changing the amount of catalyst (catalyst holdup) in a countercurrent reactor. The hydrocarbon stream was hexane, and cracking occurred at 650 °C. The catalyst was a ZSM-5 based solid acid catalyst. Catalyst-to-oil ratios of 4.69, 7.06, and 10.61 were examined, and the light olefin yields are shown in Table 1. As shown in Table 1, the yield of light olefins increased with increasing catalyst-to-oil ratio. Additionally, the yield of coke decreased with increasing catalyst-to-oil ratio. This may be due to a reduction in bimolecular reactions that lead to coke formation. Since an increase in the catalyst-to-oil ratio is associated with an increase in the amount of catalyst within the reactor, increasing the catalyst holdup in the reactor led to an increase in the conversion of hydrocarbons to light olefins. Additionally, when the amount of catalyst in the reactor was increased, the conversion of hydrocarbons to light olefins could be achieved in a reactor of reduced size.

[0074] The conversion of hydrocarbons to light olefins using a two-layer catalyst was carried out in a MAT unit. The hydrocarbon stream was hexane, and cracking occurred at 650 °C. The first catalyst layer was a partially deactivated catalyst. The catalyst was deactivated at 810 °C for 6 hours under 100% steam. The first catalyst layer accounted for 30% of the total catalyst in the MAT unit. The first catalyst layer represented the dense fluidized bed section of the reactor described in the present disclosure. The second catalyst layer was fresh catalyst and accounted for 70% of the catalyst in the MAT unit. The second catalyst layer represented the countercurrent plug flow section of the reactor described in the present disclosure. The light olefin yields from hexane cracked over the two-layer catalyst are shown in Table 2. Table 2 also shows the light olefin yields from a single-layer catalyst with a catalyst-to-oil ratio of 10.61 from Example 1. As shown in Table 2, cracking hexane in the presence of the two-layer catalyst led to a slightly lower conversion due to the presence of coke on the first catalyst layer. The mol% of C2 to C4 olefins was 45.9 mol% for the two-layer catalyst and 47 mol% for the single-layer catalyst. However, when considering the difference in conversion, the two-layer catalyst led to a higher selectivity for light olefins than the single-layer catalyst. Thus, the two-zone reactor disclosed in the specification can provide increased selectivity when used for the production of light olefins.

[0075] Example 2: Laboratory-scale results from a dense fluidized bed reactor unit (which was designed to simulate some aspects of the MZFBR claimed in this patent) were used to determine the conversion and selectivity of hydrocarbon streams at different temperatures. The catalyst was a formulated catalyst having 20 wt% ZSM-5, 20 wt% zeolite Y, and the balance being filler, binder, and silicon carbide. The estimated WHSV exceeded 1 h-1. The hydrocarbon feed stream was Arab Light (AL) crude oil, and the co-feed was steam, with an oil:steam volume ratio of 1:1 (equivalent to an oil:steam mass ratio of 1:1.16, or where steam accounted for 53.7% of the total feed, on a split basis). The product yields are presented in Table 3. As shown in Table 3, the light olefins in terms of ethylene, propylene, and butene produced by the MZFBR bench-scale reactor at 625 °C and 650 °C were 38.6 wt% and 37.5 wt%, respectively. The off-gas and coke yields increased with temperature. It should be mentioned that the amount of coke increased when crude oil was used without steam. Operating in the absence of steam increased the likelihood of plugging in the transfer lines, for example, at temperatures above about 500 °C. Steam was used as a diluent, which could prevent bimolecular reactions and reduce coke formation.

[0076] For purposes of the simplified schematic and description Figures 1 - 4 presented, many valves, temperature sensors, electronic controllers, etc. that could be employed and are known to those of ordinary skill in certain process operation areas are not included. Additionally, the attendant components typically included in a typical chemical process operation, such as air supply, catalyst hopper, flue gas treatment system, dryer, heater, heat exchanger, piping, 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 attendant 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 present embodiments disclosed. 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 may 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.

[0077] It should be understood that like numbers in the figures represent like elements in several figures, and that not all components and / or steps shown and described with reference to the figures are required in all embodiments or arrangements. Further, the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of 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 indicates 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 one 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).

[0078] 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 which is used to introduce a recitation of a series of features of a structure and should be interpreted in a manner similar to the more common open introductory term "comprising".

[0079] 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 limiting.

[0080] 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 is to be understood as specifically disclosing all ranges formed from 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.

[0081] 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 with respect to another claim element or the chronological order of acts of performing a method, but is merely 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 claim elements.

[0082] It is noted that the above figures and examples are not meant to limit the scope of the present disclosure to a single embodiment, since other embodiments are possible by interchanging some or all of the described or illustrated elements. Further, in cases where certain elements of the present disclosure can be implemented using known components, either partially or fully, only those portions of such known components that are 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 the present specification, unless otherwise expressly stated herein, an embodiment showing a single component is not necessarily limited to other embodiments including multiple identical components, and vice versa. Further, the applicant does not intend to ascribe any uncommon or special meaning to any term in the specification or claims, 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.

[0083] The foregoing description of the specific embodiments will so fully reveal the general nature of the present disclosure that others can, by applying knowledge within the skill in 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 range of equivalents of the disclosed embodiments. It should be understood that the language or terminology herein is for the purpose of description and not of limitation, such that the terminology or phraseology of the present 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 should be understood that the dimensions discussed or shown are based on the figures of one example, and other dimensions can be used without departing from the present disclosure.

[0084] 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 structures and functions or steps equivalent to those recitations.

[0085]

[0086]

[0087]

Claims

1. A method for processing hydrocarbons to produce light olefins, the method comprising: Feeding a main hydrocarbon feed stream and a co-feed of steam into an inlet of a reactor to contact a catalyst, the co-feed being provided in an amount of the co-feed of about 1 to 150 mass % relative to the mass of the main hydrocarbon feed stream, wherein the reactor comprises: An upper reactor portion defining an upper reaction zone, the upper reactor portion including a catalyst inlet for receiving the catalyst and a hydrocarbon product outlet, wherein the catalyst inlet and the hydrocarbon product outlet are located at or near the top of the upper reaction zone, and wherein the reaction zone refers to a region in the reactor where a specific reaction occurs; 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 reaction zone, and wherein the lower reaction zone is in fluid communication with and adjacent to the upper reaction zone; and Wherein: The catalyst has a downward superficial velocity through the upper reaction zone and the lower reaction zone, and the hydrocarbon feed stream has an upward superficial velocity through the upper reaction zone and the lower reaction zone, such that the hydrocarbon feed stream and the catalyst move and contact in a countercurrent orientation; The upper reaction zone operates in a countercurrent plug flow manner. Wherein the mass-based catalyst-to-oil ratio in the upper reaction zone is about 5 to 100, and the superficial velocity of the hydrocarbon feed stream in the upper reaction zone is about 10 m / s or less; The lower reaction zone is operated in a dense bed fluidization mode, wherein the weight hourly space velocity of the lower reaction zone is about 1 to 200 hr -1 ; and Contacting the catalyst with the hydrocarbon feed stream and the co-feed 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 Allowing the hydrocarbon product stream to leave the upper reaction zone through the hydrocarbon product outlet.

2. The method according to claim 1, wherein the co-feed further comprises a recycle stream derived from the hydrocarbon product stream.

3. The method according to claim 1, wherein the co-feed further comprises an oxygenate in an amount of about 1 to 50 mass % relative to the mass of the main hydrocarbon feed stream.

4. A method for processing hydrocarbons to produce light olefins, the method comprising: Feeding a main hydrocarbon feed stream and a co-feed of a recycle stream derived from the hydrocarbon product stream into an inlet of a reactor to contact a catalyst, wherein the reactor comprises: An upper reactor portion defining an upper reaction zone, the upper reactor portion including a catalyst inlet for receiving the catalyst and a hydrocarbon product outlet, wherein the catalyst inlet and the hydrocarbon product outlet are located at or near the top of the upper reaction zone, and wherein the reaction zone refers to a region in the reactor where a specific reaction occurs; 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 reaction zone, and wherein the lower reaction zone is in fluid communication with and adjacent to the upper reaction zone; and Wherein: The catalyst has a downward superficial velocity through the upper reaction zone and the lower reaction zone, and the hydrocarbon feed stream has an upward superficial velocity through the upper reaction zone and the lower reaction zone, such that the hydrocarbon feed stream and the catalyst move and contact in a countercurrent orientation; The upper reaction zone operates in a countercurrent plug flow mode. The mass-based catalyst-to-oil ratio in the upper reaction zone is about 5 to 100, and the superficial velocity of the hydrocarbon feed stream in the upper reaction zone is 10 m / s or less; The lower reaction zone is operated in a dense bed fluidization mode, where the weight hourly space velocity of the lower reaction zone is about 1 to 200 hr -1 ; and Contacting the catalyst with the hydrocarbon feed stream and a co-feed 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 include one or more of ethylene, propylene or butene, and the other reaction products include one or more of light cycle oil and dry gas, LPG, aromatics, light naphtha, full-range naphtha, heavy naphtha or heavy cycle oil; and Letting the hydrocarbon product stream leave the upper reaction zone through the hydrocarbon product outlet.

5. The method according to claim 4, wherein the co-feed further comprises steam in an amount of about 1 to 150 mass% steam relative to the mass of the main hydrocarbon feed stream.

6. The method according to claim 4 or 5, wherein the co-feed further comprises an oxygenate in an amount of about 1 to 50 mass% oxygenate relative to the mass of the main hydrocarbon feed stream.

7. A method for processing hydrocarbons to produce light olefins, the method comprising: Feeding a first hydrocarbon feed stream into a first feed inlet of a reactor and feeding a second hydrocarbon feed stream into a second feed inlet of the reactor to contact a catalyst, wherein the reactor comprises: An upper reactor portion defining an upper reaction zone, the upper reactor portion comprising a catalyst inlet for receiving the catalyst and a hydrocarbon product outlet, wherein the catalyst inlet and the hydrocarbon product outlet are located at or near the top of the upper reaction zone, and wherein the reaction zone refers to the region in the reactor where a specific reaction occurs; and A lower reactor portion defining a lower reaction zone, the lower reactor portion comprising a first feed inlet, a second feed inlet and a catalyst outlet, wherein the first feed inlet and the catalyst outlet are located at or near the bottom of the lower reaction zone, the second feed inlet is located at or near the middle height of the lower reaction zone or at or near the top of the lower reaction zone, and wherein the lower reaction zone is in fluid communication with and adjacent to the upper reaction zone; and Wherein: The catalyst has a downward superficial velocity through the upper reaction zone and the lower reaction zone, and the first hydrocarbon feed stream and the second hydrocarbon feed stream have an upward superficial velocity through the upper reaction zone and the lower reaction zone, such that the first hydrocarbon feed stream, the second hydrocarbon feed stream and the catalyst move and contact in a countercurrent orientation; The upper reaction zone operates in a countercurrent plug flow mode. The mass-based catalyst-to-oil ratio in the upper reaction zone is about 5 to 100, and the superficial velocity of the first hydrocarbon feed stream and the second hydrocarbon feed stream in the upper reaction zone is about 10 m / s or less; The lower reaction zone is operated in a dense bed fluidization mode, wherein the weight hourly space velocity of the lower reaction zone is about 1 to 200 hr -1 ; and Contacting a catalyst with a first hydrocarbon feed stream and a second hydrocarbon feed stream to crack one or more components of the first hydrocarbon feed stream and the second hydrocarbon feed stream and form a hydrocarbon product stream, wherein the hydrocarbon product stream comprises light olefins and other reaction products, the light olefins include one or more of ethylene, propylene or butene, and the other reaction products include 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 a hydrocarbon product outlet.

8. The method according to claim 7, further comprising introducing a co-feed together with the first hydrocarbon feed stream, the second hydrocarbon feed stream, or both the first hydrocarbon feed stream and the second hydrocarbon feed stream.

9. The method according to claim 8, wherein the co-feed comprises one or more of the following: Steam in an amount of about 1 to 150 mass% based on the mass of the main hydrocarbon feed stream; A recycle stream derived from the hydrocarbon product stream; or Oxygenates in an amount of about 1 to 50 mass% based on the mass of the main hydrocarbon feed stream.

10. The method according to claim 8 or 9, wherein the co-feed is introduced together with the first hydrocarbon feed stream.

11. A method for processing hydrocarbons to produce light olefins, the method comprising: Feeding a main hydrocarbon feed stream and a co-feed of oxygenates into a feed inlet of a reactor to contact a catalyst, the co-feed being provided in an amount of co-feed of about 1 to 50 mass% based on the mass of the main hydrocarbon feed stream, wherein the reactor comprises: An upper reactor section defining an upper reaction zone, the upper reactor section comprising a catalyst inlet for receiving the catalyst and a hydrocarbon product outlet, wherein the catalyst inlet and the hydrocarbon product outlet are located at or near the top of the upper reaction zone, and wherein the reaction zone refers to the area in the reactor where a specific reaction occurs; and A lower reactor section defining a lower reaction zone, the lower reactor section comprising 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 reaction zone, and wherein the lower reaction zone is in fluid communication with and adjacent to the upper reaction zone; and Wherein: The catalyst has a downward superficial velocity through the upper reaction zone and the lower reaction zone, and the hydrocarbon feed stream has an upward superficial velocity through the upper reaction zone and the lower reaction zone, such that the hydrocarbon feed stream and the catalyst move and contact in a countercurrent orientation; The upper reaction zone operates in a countercurrent plug flow manner. Wherein the catalyst-to-oil ratio in the upper reaction zone is about 5 to 100, and the superficial velocity of the hydrocarbon feed stream in the upper reaction zone is about 10 m / s or less; The lower reaction zone is operated in a dense bed fluidization mode, wherein the weight hourly space velocity of the lower reaction zone is about 1 to 200 hr -1 ; and Contacting the catalyst with the hydrocarbon feed stream and the co-feed 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 include one or more of ethylene, propylene or butene, and the other reaction products include 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 a hydrocarbon product outlet.

12. The method according to claim 11, wherein the co-feed further comprises one or both of the following: steam in an amount of about 1 to 150% by mass relative to the mass of the main hydrocarbon feed stream, or a recycle stream derived from the hydrocarbon product stream.

13. The method according to any one of claims 2, 4 or 9, 10 or 11, wherein the other reaction products comprise at least light cycle oil, and wherein the co-feed comprises all or part of the light cycle oil as all or part of the recycle stream, and wherein the recycle stream is provided in an amount of about 1 to 20% by mass of the co-feed relative to the main hydrocarbon feed stream.

14. The method according to any one of claims 2, 4 or 9, 10 or 11, wherein the other reaction products comprise at least light naphtha, and wherein the co-feed comprises all or part of the light naphtha as all or part of the recycle stream, and wherein the recycle stream is provided in an amount of about 1 to 50% by mass of the co-feed relative to the main hydrocarbon feed stream.

15. The method according to any one of claims 3, 6, 9, 10 or 11, wherein the oxygenate comprises one or more of an alcohol, a ketone or an aldehyde.

16. The method according to claim 15, wherein the oxygenate comprises methanol.

17. The method according to any one of claims 1-6 or 11-16, wherein the feed inlet comprises a first feed inlet and a second feed inlet, wherein the first feed inlet is located at or near the bottom of the lower reaction zone, wherein the second feed inlet is located at or near the middle of the lower reaction zone or at the top, wherein the main hydrocarbon feed stream is fed to the first feed inlet, and wherein the secondary hydrocarbon feed stream is fed to the second feed inlet.

18. The method according to any one of claims 7-10 or 17, wherein the first hydrocarbon feed stream is less reactive than the second hydrocarbon feed stream.

19. The method according to claim 18, wherein the first and second hydrocarbon feed streams are fractions of crude oil, which include one or more fractions having a nominal boiling point equal to or below about 350 °C, one or more fractions having a nominal boiling point equal to or above about 350 °C, hydrocarbons in the naphtha range or other crude oil fractions, wherein the first hydrocarbon feed stream has fewer reactive hydrocarbons including alkanes relative to the second hydrocarbon feed stream, and wherein the second hydrocarbon feed stream has more reactive hydrocarbons, such as olefins, relative to the first hydrocarbon feed stream.

20. The method according to claim 18 or 19, wherein the second hydrocarbon feed stream further comprises methanol.

21. The method according to any one of claims 1-6 or 11-16, wherein the main hydrocarbon feed stream comprises crude oil.

22. The method according to any one of claims 7-10 or 17, wherein the first hydrocarbon feed stream comprises crude oil.

23. The method according to any one of claims 1-6 or 11-16, wherein the main hydrocarbon feed stream has an initial boiling point of at least about 25 °C.

24. The method according to any one of claims 7-10 or 17, wherein the first hydrocarbon feed stream, the second hydrocarbon feed stream or both the first hydrocarbon feed stream and the first hydrocarbon feed stream have an initial boiling point of at least about 25 °C.

25. The method according to any one of claims 1-6 or 11-16, wherein the main hydrocarbon feed stream comprises one or more of a C4 component, 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 distillate, or kerosene.

26. The method according to any one of claims 7-10 or 17, wherein the first hydrocarbon feed stream, the second hydrocarbon feed stream, or both the first hydrocarbon feed stream and the first hydrocarbon feed stream comprise one or more of a C4 component, 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 distillate, or kerosene.

27. The method according to any one of claims 1-26, wherein the residence time of the hydrocarbon feed stream in the reactor is from 0.1 to 10 seconds.

28. The method according to any one of claims 1-27, wherein the temperature in the reactor is from 420 °C to 750 °C.

29. The method according to any one of claims 1 to 28 further comprises: feeding the catalyst through a catalyst outlet into a catalyst regenerator, wherein the catalyst passing through the catalyst outlet is spent catalyst; regenerating at least a portion of the spent catalyst to form regenerated catalyst; and feeding the regenerated catalyst through a catalyst inlet into the upper reaction zone.

30. The method according to any one of claims 1 to 29, further comprising passing the catalyst through a steam stripping section of the reactor before the catalyst outlet.

31. The method according to claim 30, wherein, In the steam stripping section, steam contacts the catalyst and at least a portion of the hydrocarbons adsorbed on the catalyst are stripped from the catalyst.

32. The method according to any one of claims 1-31, wherein the catalyst exhibits plug flow as it moves downward through the upper reaction zone.

33. The method according to any one of claims 1 to 31, wherein the cross-sectional area of the lower reactor section is equal to or greater than the cross-sectional area of the upper reactor section.

34. The method according to any one of claims 1 to 31, wherein: the catalyst exhibits plug flow as it moves downward through the upper reaction zone; the hydrocarbons exhibit plug flow as they move upward through the upper reaction zone; and the cross-sectional area of the lower reactor section is equal to or greater than the cross-sectional area of the upper reactor section.

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