Method for distributing catalyst in countercurrent reactor and method for processing hydrocarbons

Abstract

A method for distributing catalyst in a countercurrent reactor may include: passing catalyst from a catalyst hopper to a perforated plate distributor; distributing the catalyst into the reaction zone of the countercurrent reactor by passing the catalyst from the catalyst discharge zone through the pores of the perforated plate distributor into the reaction zone wherein the catalyst enters the pores of the perforated plate distributor at an apparent velocity of 0.01 m / s to 10 m / s and the apparent velocity is in a substantially downward direction; and passing the hydrocarbon feed stream into a reaction zone wherein the catalyst moves through the reaction zone in a substantially downward direction and the hydrocarbon feed stream moves through the reaction zone in a substantially upward direction, and wherein contacting the catalyst with the hydrocarbon feed stream cracks one or more components of the hydrocarbon feed stream and forms a hydrocarbon product stream.

Description

Cross-reference to related applications

[0001] This application claims priority to U.S. Patent Application Serial No. 18 / 474,954, filed September 26, 2023, entitled “Method for distributing a catalyst in a countercurrent reactor and method for processing hydrocarbons,” the entire contents of which are incorporated herein by reference. Technical Field

[0002] The embodiments of this disclosure generally relate to methods for distributing catalysts, and more specifically to methods for distributing catalysts in a countercurrent reactor. Background Technology

[0003] Light olefins, including ethylene, propylene, and butene, are fundamental intermediates used in most areas of the petrochemical industry. In particular, pure light olefin streams can be used in the production of a wide variety of polymers and chemicals. Light olefins can be produced via catalytic cracking processes. With the increasing demand for light olefins, there is a need for improved catalytic cracking methods, including improved catalyst distribution methods. Summary of the Invention

[0004] Uniform catalyst distribution within the reactor can improve the selectivity of catalytic cracking processes for desired products, such as light olefins. An embodiment of the method for distributing the catalyst described herein involves passing the catalyst through the pores of a perforated plate distributor and into the reaction zone of a countercurrent reactor. The catalyst can enter the pores of the perforated plate distributor at an apparent velocity of 0.01 m / s to 10 m / s. Passing the catalyst through the perforated plate distributor at such an apparent velocity results in a more uniform distribution of the catalyst within the reaction zone. This improves the control of the contact time between the catalyst and hydrocarbons within the reactor, thereby leading to increased yields of desired products (such as light olefins) and reduced occurrence of undesirable side reactions.

[0005] According to one or more embodiments, a method for distributing a catalyst in a countercurrent reactor includes: transferring the catalyst from a catalyst hopper to a perforated plate distributor, wherein the perforated plate distributor comprises a plate extending along a substantially horizontal cross-section of the countercurrent reactor, the plate comprising a plurality of holes, and wherein the catalyst comprises particulate solids; distributing the catalyst into the reaction zone of the countercurrent reactor by transferring the catalyst from a catalyst discharge zone through the holes of the perforated plate distributor into the reaction zone, wherein the catalyst enters the holes of the perforated plate distributor at an apparent velocity of 0.01 m / s to 10 m / s, and wherein the apparent velocity is substantially downward; and transferring a hydrocarbon feed stream into the reaction zone, wherein the catalyst moves through the reaction zone in a substantially downward direction, the hydrocarbon feed stream moves through the reaction zone in a substantially upward direction, and wherein the catalyst is contacted with the hydrocarbon feed stream to crack one or more components of the hydrocarbon feed stream and form a hydrocarbon product stream.

[0006] According to one or more embodiments, a method for processing hydrocarbons to produce light olefins includes: passing a hydrocarbon feed stream to the feed inlet of a countercurrent reactor, wherein the countercurrent reactor comprises: a catalyst hopper; an upper reactor portion comprising an upper reaction zone, the upper reactor portion including a perforated plate distributor and a hydrocarbon product outlet, wherein the perforated plate distributor and the hydrocarbon product outlet are located at or near the top of the upper reactor portion, and wherein the perforated plate distributor comprises a plate extending along a substantially horizontal cross-section of the upper reactor portion, the plate including a plurality of holes; 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 The lower reaction zone is in fluid communication with and adjacent to the upper reaction zone; wherein: the catalyst comprises particulate solids, and the catalyst moves in a generally downward direction through the upper reactor section and the lower reactor section, and the hydrocarbon feed stream moves in a generally upward direction through the upper reactor section and the lower reactor section, such that the hydrocarbon feed stream and the catalyst move in a countercurrent orientation; and the catalyst is brought into contact 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 one or more of ethylene, propylene, or butene; and the catalyst is distributed into the upper reaction zone of the countercurrent reactor by transferring the catalyst from the catalyst discharge zone through the holes of a perforated plate distributor into the upper reaction zone, wherein the catalyst enters the holes of the perforated plate distributor at an apparent velocity of 0.01 m / s to 10 m / s; and the hydrocarbon product stream is transferred out of the upper reaction zone through a hydrocarbon product outlet. Attached Figure Description

[0007] The following detailed description of specific embodiments of this disclosure can be best understood when read in conjunction with the accompanying drawings, wherein the same structures are indicated by the same reference numerals, and wherein: Figure 1 A countercurrent reactor according to one or more embodiments disclosed herein is schematically depicted; Figure 2A A catalyst hopper according to one or more embodiments disclosed herein is schematically depicted; Figure 2B A catalyst hopper according to one or more embodiments disclosed herein is schematically depicted; Figure 3A A catalyst hopper according to one or more embodiments disclosed herein is schematically depicted; Figure 3B A catalyst hopper according to one or more embodiments disclosed herein is schematically depicted; Figure 4A perforated plate distributor according to one or more embodiments disclosed herein is schematically depicted; Figure 5 A reactor and catalyst regenerator for producing light olefins are schematically depicted according to one or more embodiments disclosed herein; and Figure 6 A radial catalyst distribution model in a countercurrent reactor according to an embodiment of Example 1 is described.

[0008] In order to describe Figures 1 to 5 The simplified schematic diagrams and illustrations provided do not include numerous valves, temperature sensors, electronic controllers, etc., that are applicable in certain chemical processing operations and are well known to those skilled in the art. Furthermore, auxiliary components typically included in typical chemical processing operations, such as air supply units and flue gas treatment systems, are not depicted. Auxiliary components in the cracking unit, such as the bleed 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 embodiments described in this disclosure. It should be understood that the reactor diameter should not be inferred from the drawings, and the reactor diameter may be similar to or different from that depicted in the drawings. Furthermore, operating components, such as those described herein, may be added to the embodiments described in this disclosure.

[0009] It should also be noted that the arrows in the accompanying drawings refer to process flows. However, arrows can equivalently refer to transfer lines that can be used to transfer process flows between two or more system components. Furthermore, arrows connected to system components define an inlet or outlet in each given system component. The direction of the arrows generally aligns with the primary direction of material movement within the physical transfer line represented by the arrow. Additionally, arrows not connecting two or more system components indicate product flows leaving the depicted system or system inlet flows entering the depicted system. Product flows may be further processed in an auxiliary chemical processing system or may be commercialized as a final product. System inlet flows may be flows transferred from auxiliary chemical processing systems or may be unprocessed feedstream flows. Some arrows may represent recycle flows, i.e., effluent streams recycled from system components to the system. However, it should be understood that in some embodiments, any indicated recycle flow may be replaced by a system inlet flow of the same material, and a portion of the recycle flow may leave the system as a system product.

[0010] Furthermore, the arrows in the accompanying drawings can schematically depict process steps that transfer a flow from one system component to another. For example, an arrow pointing from one system component to another can indicate the "transfer" of the effluent from one system component to another, which may include the contents of the process flow "leaving" or being "removed" from one system component and the contents of that product flow being "introduced" into another system component.

[0011] Reference will now be made in more detail to various embodiments, some of which are illustrated in the accompanying drawings. Where possible, the same reference numerals will be used throughout the drawings to refer to the same or similar parts. Detailed Implementation

[0012] Embodiments of this disclosure relate to a method for distributing a catalyst. The catalyst can be distributed in a countercurrent reactor. According to one or more embodiments described herein, the method for distributing the catalyst may include passing the catalyst to a perforated plate distributor and distributing the catalyst into the reaction zone of the countercurrent reactor. The catalyst can pass through the pores of the perforated plate distributor, and the catalyst can enter the pores at an apparent velocity of 0.01 m / s to 10 m / s. Distributing the catalyst into the reaction zone of the countercurrent reactor at such an apparent velocity improves the uniformity of catalyst distribution in the reaction zone. Improved uniformity of catalyst flow allows for improved control of the reactor system to avoid undesirable side reactions and increase the yield of desired products.

[0013] It should be noted that the methods for distributing the catalyst can be used in a variety of countercurrent reactor systems and are not limited to any of the exemplary countercurrent reactor systems described herein.

[0014] As used herein, a "reactor" refers to a vessel in which one or more reactants can undergo one or more chemical reactions in the presence of one or more catalysts. As used herein, a "reaction zone" refers to a region within the reactor where a particular reaction occurs. One or more "reaction zones" may be provided within the reactor. For example, a "reactor section" may house a "reaction zone," such as an upper reactor section housing an upper reaction zone. In one or more embodiments described herein, the boundaries of the reaction zone may be at least partially defined by system components of the reactor. For example, in one or more embodiments described herein, the "reaction zone" may be located below a perforated plate distributor that distributes catalyst into the reaction zone.

[0015] As used in this disclosure, the term "countercurrent" can be used to describe a relationship between process flows flowing in substantially opposite directions, wherein the process flows pass over or through each other. For example, a first process flow flowing in a substantially downward direction may flow countercurrently with a second process flow flowing in a substantially upward direction. The flow direction of the flow may be the same as the direction of the apparent velocity of the flow. As used throughout this disclosure, the term "countercurrent reactor" can be used to describe a reactor in which catalyst and reactants and / or products flow through the reactor in a countercurrent orientation.

[0016] As described herein, "apparent velocity" refers to the velocity of a single phase flowing through a given cross-sectional area. The apparent velocity of a phase is determined using the bulk flow of that phase; therefore, individual particles or molecules within the phase can move in a direction different from or even opposite to the bulk flow of that phase without affecting the direction of the phase's apparent velocity. In one or more embodiments, the apparent velocity of the catalyst entering the pores of a porous plate distributor can be substantially downward.

[0017] As used in this disclosure, "catalyst" means any substance that increases the rate of a particular chemical reaction. The catalysts described in this disclosure can be used to promote a variety of reactions, such as, but not limited to, cracking reactions. As used in this disclosure, "cracking" generally refers to a chemical reaction in which molecules having carbon-carbon bonds break into more than one molecule by breaking one or more carbon-carbon bonds, or a chemical reaction from compounds including cyclic moieties, such as cycloalkanes, naphthalenes, aromatic compounds, etc., to compounds that do not have cyclic moieties or contain fewer cyclic moieties than before cracking.

[0018] As used in this disclosure, the term "used catalyst" refers to a catalyst that has been introduced into and passed through a reaction zone with cracked hydrocarbon feedstock, but has not been regenerated in a regenerator after being introduced into the reaction zone. "Used catalyst" may have coke deposited on it, and may include partially coked catalyst as well as fully coked catalyst. The amount of coke deposited on the "used catalyst" may be greater than the amount of coke remaining on the regenerated catalyst after regeneration.

[0019] As used in this disclosure, the term "regenerated catalyst" refers to a catalyst that has been introduced into the 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 on the catalyst to restore at least a portion of the catalyst's catalytic activity, or both. A "regenerated catalyst" may have less coke, a higher temperature, or both, compared to a spent catalyst, and may have higher catalytic activity. A "regenerated catalyst" may have more coke and lower catalytic activity compared to a fresh catalyst that has not passed through the cracking reaction zone and regenerator.

[0020] Now refer to Figure 1The countercurrent reactor 100 may include a catalyst hopper 110 housing a catalyst discharge zone 112, a reactor section 120 housing a reaction zone 122, and a perforated plate distributor 130. The perforated plate distributor 130 may be located between the catalyst discharge zone 112 and the reaction zone 122. As described herein, the catalyst discharge zone 112 may be located above the perforated plate distributor 130, and the reaction zone 122 may be located below the perforated plate distributor, such that catalyst can be transferred from the catalyst discharge zone 112, through the perforated plate distributor 130, and into the reaction zone 122. In one or more embodiments, the catalyst discharge zone 112 may be sized such that catalyst passing through the catalyst discharge zone 112 can reach the perforated plate distributor 130 at an apparent velocity of 0.01 m / s to 10 m / s, as described in more detail below.

[0021] In one or more embodiments, a method for distributing catalyst in a countercurrent reactor 100 may include transferring catalyst from a catalyst hopper 110 to a perforated plate distributor 130. The catalyst transferred from the catalyst hopper 110 to the perforated plate distributor 130 may comprise fresh catalyst, regenerated catalyst, or a combination of fresh and regenerated catalyst as further detailed herein. According to one or more embodiments, the catalyst may comprise particulate solids. The particulate solids may have any suitable size and shape. For example, the size and shape of the catalyst particulate solids may enable the particulate solids to be fluidized for transport between system components of the countercurrent reactor 100. Furthermore, the size and shape of the particulate solids may be designed to facilitate single or multiple reactions carried out in the countercurrent reactor 100.

[0022] Now refer to Figure 2A and Figure 2B In some embodiments described herein, catalyst hopper 110 may contain a fluidized bed 210 of catalyst. In one or more embodiments, the fluidized bed 210 of catalyst may have a dense bed fluidization regime. As used herein, a “dense bed fluidization regime” refers to a fluidization regime in which the fluidized bed has a clearly defined upper limit or surface of the dense bed layer. For example, dense bed fluidization regimes include steady fluidization, bubbling fluidization, throttling fluidization, and turbulent fluidization regimes. In one or more embodiments, a fluidizing gas 240 may be delivered to catalyst hopper 110 to fluidize the catalyst. In a dense bed fluidization, the particle entrainment may be low, but may increase with increasing gas velocity through the bed. Without being bound by theory, the flow rate of the fluidizing gas 240 may be used to control the flow rate of the catalyst from catalyst hopper 110 to perforated plate distributor 130. In one or more embodiments, the flow rate of the fluidizing gas may be less than or equal to 5 m / s.

[0023] In one or more embodiments, the catalyst may overflow from the fluidized bed 210 of the catalyst and fall through the catalyst discharge zone 112 to the perforated plate distributor 130. (Refer to...) Figure 2A The catalyst can overflow from the fluidized bed 210 into the conduit 220, and then be transferred from the fluidized bed 210 to the porous plate distributor 130 via the conduit 220. (Refer to...) Figure 2B The catalyst hopper 110 may include multiple conduits 220. Catalyst can overflow from the fluidized bed 210 of the catalyst into the multiple conduits 220 and be transferred from the fluidized bed 210 of the catalyst to the perforated plate distributor 130. The number of conduits 220 is not limited. The shape and distribution of the conduits 220 are not limited. In one or more embodiments, the conduits 220 may be symmetrical about a central vertical axis. In one or more embodiments, the catalyst hopper 110 may include 2 to 50 conduits. In some embodiments, the inner diameter of each conduit may be 5 mm to 30 mm.

[0024] Now refer to Figure 3A and Figure 3B In some embodiments described herein, catalyst hopper 110 may be configured to redirect the delivered catalyst bed to perforated plate distributor 130. For example, catalyst hopper 110 may include baffle 320 located within catalyst hopper 110 such that at least a portion of catalyst flow 310 can contact baffle 320 and be redirected through catalyst discharge zone 112 to perforated plate distributor 130. Catalyst flow 310 may be a delivered catalyst bed comprising catalyst and fluidizing gas. In one or more embodiments, fluidizing gas may comprise vapor, inert gas (e.g., nitrogen, helium, or argon), or dry gas (e.g., methane). In one or more embodiments, the apparent velocity of fluidizing gas may be from 1.5 m / s to 10 m / s. Unintentionally, the apparent velocity of fluidizing gas may be sufficient to maintain rapid fluidization of the delivered catalyst bed.

[0025] exist Figure 3A In the depicted embodiment, the catalyst stream 310 can enter the catalyst hopper 110 in a substantially horizontal direction and can be redirected by baffle 320 at approximately 90°, causing the catalyst to move in a substantially downward direction through the catalyst discharge zone 112 toward the perforated plate distributor 130. Although the angle between the baffle 320 and the perforated plate distributor 130 is... Figure 3AThe depicted embodiment is approximately 90°, but in some embodiments, the baffle 320 and the porous plate distributor 130 can be positioned at any suitable angle such that the catalyst is redirected to the porous plate distributor 130. For example, but not limited to, the angle between the baffle 320 and the porous plate distributor can be 90° to 160°, 110° to 160°, 130° to 160°, 150° to 160°, 90° to 140°, 90° to 120°, 90° to 100°, or any range or combination of these endpoints.

[0026] exist Figure 3B In the depicted embodiment, the catalyst flow 310 can enter the catalyst hopper 110 in a substantially vertical direction, and the shape and position of the baffle 320 can be configured to redirect the catalyst downwards through the catalyst discharge zone 112 to the perforated plate distributor 130. In some embodiments, for example Figure 3B The described implementation scheme allows supplemental fluidizing gas 350 to be delivered to the catalyst hopper 110 to control the flow of the delivered catalyst bed.

[0027] Now refer to Figure 4 The porous plate distributor 130 may comprise a plate 410 extending along a substantially horizontal cross-section of the countercurrent reactor 100. As used herein, a “substantially horizontal cross-section” may be within 15°, 10°, 5°, or even 1° in the horizontal direction. The plate 410 may have a first main surface 412 and a second main surface 414 opposite to the first main surface 412. The plate 410 may comprise a plurality of holes 420. Each hole may be an opening extending from the first main surface 412 of the plate 410 to the second main surface 414 of the plate 410. The holes 420 may be sized such that the catalyst used in the countercurrent reactor 100 can pass through the holes 420. The holes 420 may be positioned on the plate 410 in any suitable pattern or distribution such that the catalyst is uniformly distributed into the reaction zone 122 of the countercurrent reactor 100 as it passes through the porous plate distributor 130. The holes 420 may have any suitable cross-sectional shape. For example, but not limited to, the holes may have a circular, elliptical, or polygonal cross-sectional shape in a cross-section parallel to the first main surface 412 and the second main surface 414 of the plate 410. In one or more embodiments, the porous plate distributor 130 may extend along the entire substantially horizontal cross-section of the countercurrent reactor 100 such that substantially all of the catalyst entering the reaction zone 122 passes through the porous plate distributor 130.

[0028] In one or more embodiments, the thickness of plate 410 may be from 0.05 μm to 0.5 μm. The thickness of plate 410 refers to the distance between the first main surface 412 and the second main surface 414 of plate 410. For example, but not limited to, the thickness of plate 410 may be 0.05 m to 0.5 m, 0.1 m to 0.5 m, 0.15 m to 0.5 m, 0.2 m to 0.5 m, 0.25 m to 0.5 m, 0.3 m to 0.5 m, 0.35 m to 0.5 m, 0.4 m to 0.5 m, 0.45 m to 0.5 m, 0.05 m to 0.45 m, 0.05 m to 0.4 m, 0.05 m to 0.35 m, 0.05 m to 0.3 m, 0.05 m to 0.25 m, 0.05 m to 0.2 m, 0.05 m to 0.15 m, 0.05 m to 0.1 m, or any range or combination of ranges formed by these endpoints.

[0029] In one or more embodiments, the diameter of the hole 420 can be from 5 mm to 50 mm. In embodiments with non-circular holes, the diameter refers to the diameter of the smallest circle of the externally circumscribed hole 420. For example, the diameter of the hole 420 can be 5 mm to 50 mm, 15 mm to 50 mm, 25 mm to 50 mm, 35 mm to 50 mm, 45 mm to 50 mm, 5 mm to 40 mm, 5 mm to 30 mm, 5 mm to 20 mm, 5 mm to 10 mm, or any range or combination of these ranges formed by these endpoints. In some embodiments, the holes may each have substantially the same size. In some embodiments, the holes may have different sizes. In some embodiments, the holes may be arranged symmetrically on the plate 410. The distance between the holes 420 is not necessarily limited. In some embodiments, the distance between a hole 420 and the next nearest hole 420 may be less than or equal to half the diameter of the hole 420. The distance between the holes 420 may be the shortest distance from the edge of one hole 420 to the edge of another hole 420.

[0030] The method for distributing a catalyst described herein may include distributing the catalyst into the reaction zone 122 of a countercurrent reactor 100 by passing the catalyst through the orifices 420 of a porous plate distributor 130. In one or more embodiments, the catalyst may enter the orifices 420 of the porous plate distributor 130 at an apparent velocity of 0.01 m / s to 10 m / s. For example, the catalyst can enter the orifices 420 of the porous plate distributor 130 at the following apparent velocities: 0.01 m / s to 10 m / s, 0.1 m / s to 10 m / s, 0.5 m / s to 10 m / s, 1 m / s to 10 m / s, 2 m / s to 10 m / s, 3 m / s to 10 m / s, 4 m / s to 10 m / s, 5 m / s to 10 m / s, 6 m / s to 10 m / s, 7 m / s to 10 m / s, 8 m / s to 10 m / s, 9 m / s to 10 m / s, 0.01 m / s to 9 m / s, 0.01 m / s to 8 m / s, 0.01 m / s to 7 m / s, 0.01 m / s to 6 m / s, 0.01 m / s to 5 m / s, 0.01 m / s to 4 ... m / s, 0.01 m / s to 3 m / s, 0.01 m / s to 2 m / s, 0.01 m / s to 1 m / s, 0.01 m / s to 0.5 m / s, 0.01 m / s to 0.1 m / s, or any range or combination of ranges formed by these endpoints.

[0031] In one or more embodiments, the reaction zone may include an acceleration zone and a constant-rate zone. As used herein, an "acceleration zone" refers to the portion of the reaction zone in which the catalyst is introduced and the apparent rate of the catalyst is changing, while a "constant-rate zone" refers to the portion of the reaction zone in which the apparent rate of the catalyst is substantially constant. In an embodiment, the acceleration zone may be located between the perforated plate distributor and the constant-rate zone. Without being bound by theory, the height of the acceleration zone within the reaction zone 122 of the countercurrent reactor can be reduced when the catalyst passes through the perforated plate distributor 130 at an apparent rate of 0.01 m / s to 10 m / s. Reducing the height of the acceleration zone results in a more uniform distribution of catalyst within the reaction zone and a more uniform catalyst holdup within the reaction zone. In other words, reducing the acceleration zone results in the catalyst moving through the reaction zone in a more uniform manner. This improves the ability to control the reactor. For example, using the catalyst distribution method described herein allows for improved control of the contact time within the reactor, which can lead to increased yields of desired products and reduced occurrence of undesirable side reactions.

[0032] In one or more embodiments, the apparent rate of the catalyst entering the orifice 420 of the porous plate distributor 130 can be 10% to 100% of the steady-state rate reached by the catalyst in the constant-rate zone of the reaction zone 122 of the countercurrent reactor 100. The steady-state rate of the catalyst can be calculated according to Equation 1.

[0033] Equation 1 In equation 1, V s It is the average steady-state particle velocity (m / s); G s Catalyst flux (kg / m³) 2 s); ρ s Particle density (kg / m³) 3 );ε s This refers to the catalyst hold-up. In one or more embodiments, the apparent velocity of the catalyst entering the orifices 420 of the porous plate distributor 130 can be 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%, 10% to 90%, 10% to 80%, 10% to 70%, 10% to 60%, 10% to 50%, 10% to 40%, 10% to 30%, 10% to 20%, or any range or combination of these endpoints, of the apparent velocity of the catalyst entering the reaction zone. Without being bound by theory, the closer the apparent velocity of the catalyst entering the reaction zone is to the catalyst's stable velocity, the smaller the acceleration zone may be.

[0034] In one or more embodiments, the pressure differential across the perforated plate distributor can be from 0.5 barg to 5 barg. For example, the pressure differential across the perforated plate distributor can be 0.5 barg to 5 barg, 1 barg to 5 barg, 1.5 barg to 5 barg, 2 barg to 5 barg, 2.5 barg to 5 barg, 3 barg to 5 barg, 3.5 barg to 5 barg, 4 barg to 5 barg, 4.5 barg to 5 barg, 0.5 barg to 4.5 barg, 0.5 barg to 4 barg, 0.5 barg to 3.5 barg, 0.5 barg to 3 barg, 0.5 barg to 2.5 barg, 0.5 barg to 2 barg, 0.5 barg to 1.5 barg, 0.5 barg to 1 barg, or any range or combination of ranges formed by these endpoints. Unwilling to be bound by theory, adjusting the pressure difference across the porous plate distributor can be used to control the flow characteristics of the catalyst passing through the porous plate distributor, such as the apparent velocity.

[0035] In one or more embodiments, the catalyst flow rate may be less than the flooding point of the countercurrent reactor 100. The flooding point of the countercurrent reactor can be calculated using Equation 2.

[0036] Equation 2 In equation 2, U g It is the apparent gas velocity (m / s); g It is the acceleration due to gravity (m / s²) 2 ); D It is the diameter (m) of the countercurrent tower reactor; θ It is the internal friction angle of the particle (approximately 70° for spherical particles); ρ g Gas density (kg / m³) 3 ); ρ D It is the density of the dense phase (kg / m³) 3 ); G s,F This is a generalization. In one or more embodiments, the catalyst flow rate may be such that the catalyst-to-hydrocarbon feed ratio (catalyst-to-oil ratio) in the countercurrent reactor 100 is 5 to 100 based on the mass of the catalyst and hydrocarbons. For example, but not limited to, the catalyst-to-hydrocarbon ratio in the countercurrent reactor 100 may be 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, 5 to 30, 5 to 20, 5 to 10, or any range or combination of these endpoints, based on the mass of the catalyst and hydrocarbons.

[0037] Refer again Figure 1Hydrocarbon feed stream 144 may enter reactor section 120 through one or more hydrocarbon feed inlets located in reactor section 120. The one or more hydrocarbon feed inlets may be located at or near the bottom of reactor section 120. The reactor section may also include one or more catalyst outlets located at or near the bottom of reactor section 120, allowing catalyst stream 152 to exit reactor section 120. In one or more embodiments, catalyst stream 152 may contain spent catalyst. As described herein, the location at or near the bottom of reactor section 120 corresponds to a position within the range of the bottom 10%, bottom 5%, or even bottom 1% of the height of reactor section 120. Reactor section 120 may include a hydrocarbon product outlet, which may be located at or near the top of reactor section 120. As described herein, the location at or near the top of reactor section 120 corresponds to a position within the range of the top 10%, top 5%, or even top 1% of the height of reactor section 120. In one or more embodiments, the hydrocarbon product outlet may be located below the perforated plate distributor 130. In some embodiments, the hydrocarbon product outlet may be located above the perforated plate distributor. In one or more embodiments, the catalyst may move in a substantially downward direction through reaction zone 122. The hydrocarbon feed stream 144 can move in a generally upward direction through the reaction zone 122. The catalyst is brought into contact with the hydrocarbon feed stream 144 to crack one or more components of the hydrocarbon feed stream 144, forming the hydrocarbon product stream 142.

[0038] According to one or more embodiments, the method described above for distributing the catalyst in a countercurrent reactor 100 can be used in methods for processing hydrocarbons to produce light olefins. Embodiments of reactor systems and methods for producing light olefins are described below. It should be noted that the method described above for distributing the catalyst is not limited to use in reactor systems for producing light olefins, but can be used in reactor systems configured to carry out multiple chemical reactions.

[0039] Now refer to Figure 5The diagram schematically depicts a countercurrent reactor 500 for the production of light olefins. The countercurrent reactor 500 includes a catalyst hopper 110, an upper reactor section 510, and a lower reactor section 520. In some embodiments, the countercurrent reactor 500 includes a stripping section 530. The upper reactor section 510 may include an upper reaction zone 511. The lower reactor section 520 may define a lower reaction zone 521. A hydrocarbon feed stream 501 may enter the lower reaction zone 521 through one or more feed inlets located in the lower reactor section 520. These feed inlets may be located at or near the bottom of the lower reactor section 520. Furthermore, the lower reactor section 520 may include one or more catalyst outlets located at or near the bottom of the lower reactor section 520. As described herein, the location at or near the bottom of the lower reactor section 520 corresponds to a position within the range of 10%, 5%, or even 1% of the height of the lower reactor section 520.

[0040] The upper reactor section 510 defines an upper reaction zone 511. A hydrocarbon feed stream 501 is movable through a lower reaction zone 521 and into the upper reaction zone 511. The upper reactor section 510 and the lower reactor section 520 are in fluid communication with each other. In one or more embodiments, the upper reactor section 510 and the lower reactor section 520 may be adjacent to each other without any intermediate components or reactor sections in between. In one or more embodiments, the hydrocarbon feed stream 501 may be directly transferred from the lower reactor section 520 to the upper reactor section 510.

[0041] The upper reactor section 510 includes a hydrocarbon product outlet and a perforated plate distributor 130, which may be located at or near the top of the upper reactor section 510. As described herein, the location at or near the top of the upper reactor section 510 corresponds to a position within the range of the top 10%, top 5%, or even top 1% of the height of the upper reactor section 510. The perforated plate distributor 130 may comprise a plate 410 extending along a substantially horizontal cross-section of the upper reactor section 510, and the plate 410 may include a plurality of holes 420. The perforated plate distributor 130 may have the features described above and Figure 4 The structure is depicted in the diagram. The catalyst can be distributed into the upper reaction zone 511 of the countercurrent reactor 500 through the holes 420 of the porous plate distributor 130. In one or more embodiments, the catalyst can enter the holes 420 of the porous plate distributor 130 at an apparent velocity of 2 m / s to 20 m / s as previously described.

[0042] Hydrocarbon feed stream 144 may comprise one or more of the following: C4 component, light naphtha, heavy naphtha, full-range naphtha, vacuum gas oil, crude oil, FCC gasoline, olefin naphtha, atmospheric residue, vacuum residue, condensate, deasphalted crude oil, dewaxed crude oil, deasphalted-dewaxed crude oil, kerosene, or diesel oil. In one or more embodiments, hydrocarbon feed stream 144 may comprise crude oil, consist substantially of crude oil, or consist of crude oil. As used herein, “crude oil” refers to a naturally occurring mixture of petroleum liquids and gases. Typically, crude oil undergoes minimal processing before being used in the methods described herein. Crude oils considered herein include those with an API specific gravity of 25° to 40°, such as those with an API specific gravity of 25° to 30°, 30° to 35°, 35° to 40°, or any combination of these ranges.

[0043] In a further embodiment, the hydrocarbon feed stream 144 may contain a fraction of crude oil, or petrochemical products derived from crude oil, having an initial boiling point of at least 25°C. For example, in one or more embodiments, the hydrocarbon feed stream 144 may contain light naphtha and may have an initial boiling point of 25°C to 35°C and a final boiling point of 85°C to 95°C. In one or more embodiments, the hydrocarbon feed stream 144 may contain heavy naphtha and may have an initial boiling point of 80°C to 95°C and a final boiling point of 190°C to 210°C. In a further embodiment, the hydrocarbon feed stream 144 may contain full-range naphtha and have an initial boiling point of 25°C to 35°C and a final boiling point of 190°C to 210°C.

[0044] In one or more embodiments, the catalyst may comprise a zeolite catalyst, such as USY zeolite, ZSM-5 zeolite, or a combination of several suitable types of zeolite catalysts. Alternatively, the catalyst may comprise other suitable solid acid catalysts. In one or more embodiments, the catalyst may comprise a binder, promoter, inert material, and matrix to have acceptable physical and chemical properties, such as catalyst attrition index and catalyst density, making it suitable for use in the proposed reactor configuration.

[0045] like Figure 5 As shown, the lower reactor portion 520 may have a larger cross-sectional area than the upper reactor portion 510. In one or more embodiments, the lower reactor portion 520 may have a cross-sectional area substantially similar to that of the upper reactor portion 510.

[0046] In one or more embodiments, the upper reaction zone 511 can operate in a plug flow regime. In one or more embodiments, the hydrocarbon feed 144 can exhibit plug flow as it moves upward through the upper reaction zone 511. Similarly, the catalyst can exhibit plug flow as it moves downward through the upper reaction zone 511. Because the flow of the catalyst is opposite to the flow of the hydrocarbon feed, the flow is countercurrent, and the upper reaction zone 511 can operate in a plug flow regime.

[0047] In one or more embodiments, the catalyst-to-oil ratio in the upper reaction zone 511 can be from 5 to 100. For example, the catalyst-to-oil ratio in the upper reaction zone 511 can be 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, or even 90 to 100. In further embodiments, the catalyst-to-oil ratio in the upper reaction zone 511 can be 5 to 90, 5 to 80, 5 to 70, 5 to 60, 5 to 50, 5 to 40, 5 to 30, 5 to 20, or even 5 to 10. Not wishing to be bound by theory, it is believed that the catalyst-to-oil ratio suitable for the upper reaction zone 511 is less restricted because the catalyst can flow through the upper reaction zone 511 by gravity rather than being transported through the reactor by the flow of hydrocarbons. Furthermore, the high catalyst-to-oil ratio indicates the presence of a large amount of catalyst in the upper reaction zone 511, which is believed to lead to an increased conversion rate of hydrocarbon feedstock to light olefins.

[0048] The catalyst is mobile through the upper reaction zone 511 and into the lower reaction zone 521. In one or more embodiments, the catalyst can be transferred directly from the upper reaction zone 511 to the lower reaction zone 521. The lower reaction zone 521 can operate in a dense-phase fluidized state. In one or more embodiments, the catalyst can be transferred from the upper reaction zone 511 to the lower reaction zone 521, forming a dense-phase fluidized bed in the lower reaction zone 521. As described herein, a “dense-phase fluidized state” refers to a fluidized bed having a clearly defined upper limit or surface of the dense-phase bed. For example, dense-phase fluidized states include steady fluidization, bubbling fluidization, throttling fluidization, and turbulent fluidization. In a dense-phase fluidized bed, the particle entrainment may be low but can increase with increasing gas velocity through the bed.

[0049] In one or more embodiments, the weight hourly space velocity (WHSV) of the lower reaction zone 521 can be 1 hr. -1 Up to 200 hr -1 For example, the WHSV of the lower reaction zone 521 can be 1 hr. -1 Up to 200hr -11 hr -1 Up to 175 hr -1 1 hr -1 Up to 150 hr -1 1 hr -1 Up to 125 hr -1 1 hr -1 Up to 100 hr -1 1 hr -1 Up to 75 hours -1 1 hr -1 Up to 50 hr -1 or even 1 hour -1 Up to 25 hours -1 In a further embodiment, the WHSV of the lower reaction zone 521 can be 25 hr. -1 Up to 200 hr -1 50 hr -1 Up to 200 hr -1 75 hr -1 Up to 200 hr -1 100 hr -1 Up to 200 hr -1 125 hr -1 Up to 200 hr -1 150 hr -1 Up to 200 hr -1 or even 175 hours -1 Up to 200 hr -1 WHSV can be used to describe the amount of catalyst in the dense-phase bed of the lower reaction zone 521. Not wanting to be bound by theory, it is believed that a dense-phase bed allows for a large amount of catalyst in the lower reaction zone, which could increase the yield of light olefins.

[0050] As the hydrocarbon feed stream 144 and catalyst move through the countercurrent reactor 500, the hydrocarbon feed stream 144 may have an upward apparent velocity across the horizontal cross-section of the countercurrent reactor 500, while the catalyst may have a downward apparent velocity across the horizontal cross-section of the countercurrent reactor 500. For example, the hydrocarbon feed stream 144 may flow from the feed inlet in the lower reactor section 520 to the hydrocarbon product outlet in the upper reactor section 510. Thus, the main flow direction of the hydrocarbon feed stream 144 moving through the horizontal cross-section of the countercurrent reactor 500 is upward, resulting in an upward apparent velocity. Similarly, the catalyst flows from the perforated plate distributor 130 to the catalyst outlet in the stripping section 530 of the countercurrent reactor 500, and the main flow direction of the catalyst moving through the horizontal cross-section of the countercurrent reactor 500 is downward, resulting in a downward apparent velocity. In one or more embodiments, the upward apparent velocity of the hydrocarbon feed stream 144 and the downward apparent velocity of the catalyst result in a countercurrent flow pattern between the hydrocarbon feed stream 144 and the catalyst. Therefore, in one or more embodiments, the hydrocarbon feed stream 144 and the catalyst move in a countercurrent orientation.

[0051] To avoid being bound by theory, it is believed that countercurrent contact between the hydrocarbon feed stream 144 and the catalyst can prevent catalyst backmixing, which can occur in conventional riser reactors and promote undesirable side reactions that negatively impact the production of light olefins. Furthermore, countercurrent contact between the hydrocarbon feed stream 144 and the catalyst is believed to prevent core-annular flow through the reactor, where the catalyst concentration is high near the reactor walls and low at the reactor center where most of the hydrocarbon flow occurs. Typically, core-annular flow reduces the amount of catalyst-hydrocarbon contact, thus decreasing the conversion of the hydrocarbon feed to light olefins.

[0052] Unwilling to be bound by theory, it is also believed that countercurrent flow can increase olefin yield by allowing more reactive chemicals in the hydrocarbon feed to contact less reactive catalysts, and vice versa. Typically, the catalyst in the lower reaction zone 521 has already been contacted with hydrocarbons in the upper reaction zone 511. Therefore, the catalyst in the lower reaction zone 521 is usually partially deactivated and less active than the catalyst in the upper reaction zone 511. Contacting the hydrocarbon feed with a large amount of less active catalyst in the lower reaction zone 521 allows the more reactive chemicals in the hydrocarbon feed to crack when they come into contact with the less active catalyst in the lower reaction zone 521. This, in turn, allows the more active catalyst in the upper reaction zone 511 to crack the less reactive chemicals in the hydrocarbon feed, thereby increasing the yield of light olefins produced from the hydrocarbon feed.

[0053] In one or more embodiments, the apparent velocity of the hydrocarbon feed stream 144 moving through the upper reactor section 510 is 3.0 m / s or lower. For example, the apparent velocity of the hydrocarbon feed stream through the upper reactor section 510 can be 3.0 m / s or lower, 2.0 m / s or lower, 1.0 m / s or lower, 0.9 m / s or lower, 0.8 m / s or lower, 0.7 m / s or lower, 0.6 m / s or lower, 0.5 m / s or lower, or even 0.4 m / s or lower. It is not desirable to be bound by theory, but it is believed that an apparent velocity of the hydrocarbon feed stream below 3.0 m / s within the upper reactor section 510 can lead to increased contact between the catalyst and the hydrocarbons, which in turn can lead to an increased conversion of the hydrocarbon feed to light olefins. To maintain the apparent velocity of the hydrocarbon feed stream 144 within the desired range, the residence time of the hydrocarbons in the countercurrent reactor 500 can be controlled by adjusting the height of the upper reactor section 510 and the height of the lower reactor section 520.

[0054] In one or more embodiments, the residence time of the hydrocarbon feed stream 144 in the countercurrent reactor 500 is from 0.1 seconds to 10 seconds. For example, the residence time of the hydrocarbon feed stream 144 in the countercurrent reactor 500 can be 0.1 seconds to 10 seconds, 0.5 seconds to 10 seconds, 1 second to 10 seconds, 2 seconds to 10 seconds, 3 seconds to 10 seconds, 4 seconds to 10 seconds, 5 seconds to 10 seconds, 6 seconds to 10 seconds, 7 seconds to 10 seconds, 8 seconds to 10 seconds, or even 9 seconds to 10 seconds. In a further embodiment, the residence time of the hydrocarbon feed stream 144 in the countercurrent reactor 500 can be 0.1 seconds to 9 seconds, 0.1 seconds to 8 seconds, 0.1 seconds to 7 seconds, 0.1 seconds to 6 seconds, 0.1 seconds to 5 seconds, 0.1 seconds to 4 seconds, 0.1 seconds to 3 seconds, 0.1 seconds to 2 seconds, or even 0.1 seconds to 1 second.

[0055] When the hydrocarbon feed stream 144 contacts the catalyst, at least a portion of the hydrocarbon feed stream 144 can be cracked to form hydrocarbon product 142. In one or more embodiments, the temperature within the countercurrent reactor 500 can be from 420°C to 750°C to promote the cracking of the hydrocarbon feed stream 144. For example, the temperature within the countercurrent reactor 500 can be from 460°C to 750°C, 500°C to 750°C, 540°C to 750°C, 580°C to 750°C, 620°C to 750°C, 660°C to 750°C, or even 700°C to 750°C. In further embodiments, the temperature within the countercurrent reactor 500 can be from 420°C to 710°C, 420°C to 670°C, 420°C to 630°C, 420°C to 590°C, 420°C to 550°C, or even 420°C to 510°C. In a further embodiment, the temperature inside the countercurrent reactor 500 can be from 440°C to 720°C or from 480°C to 680°C.

[0056] In one or more embodiments, the hydrocarbon products may comprise light olefins and other reaction products. For example, among other reaction products, the hydrocarbon products may comprise ethylene, propylene, butene, or combinations thereof. In one or more embodiments, other reaction products may comprise dry gas, aromatics, naphtha, light cycle oil, heavy cycle oil, or even heavy oil. In one or more embodiments, the hydrocarbon product stream 142 containing light olefins may be discharged from the upper reaction zone 511 via a hydrocarbon product outlet in the upper reactor section 510. In one or more embodiments, the hydrocarbon product stream 142 may contain a portion of unreacted hydrocarbon feed. In one or more embodiments, the hydrocarbon product stream 142 may contain a catalyst entrained within the hydrocarbon product stream 142, which may be separated from the hydrocarbon product stream 142 in a separation device. Any suitable separation device, including a cyclone separator or series of cyclone separators, may be used to separate the entrained catalyst from the hydrocarbon product stream 142. In one or more embodiments, light olefins may be separated from the hydrocarbon product stream 142. The separation of light olefins from the hydrocarbon product stream 142 may be achieved by any suitable means, including, for example, distillation. In one or more embodiments, separating light olefins from hydrocarbon product stream 142 can produce a relatively pure ethylene stream, propylene stream, or butene stream.

[0057] In one or more embodiments, the cracked hydrocarbon feed stream 144 may generate spent catalyst. Spent catalyst may be generated in the upper reaction zone 511 and the lower reaction zone 521. In one or more embodiments, the spent catalyst may contain coke from the catalyst. Coke can reduce the activity of the catalyst, and the spent catalyst may have reduced activity compared to regenerated or fresh catalyst. In one or more embodiments, the non-circulating fluidized bed of the lower reaction zone 521 may contain spent catalyst. Not wishing to be bound by theory, the more reactive components in the hydrocarbon feed stream 144 may be cracked in the lower reaction zone 521 because the reaction of these components does not require high catalytic activity. As the hydrocarbon feed is transferred from the lower reaction zone 521 to the upper reaction zone 511, the hydrocarbon feed will encounter the more active fresh or regenerated catalyst, and the less reactive components in the hydrocarbon feed will be cracked. Therefore, the countercurrent flow of the catalyst and the hydrocarbon feed stream 144 can lead to an increased conversion of the hydrocarbon feed to light olefins.

[0058] In one or more embodiments, the countercurrent reactor 500 may include a stripping section 530 located below the lower reactor section 520. The stripping section 530 may define a stripping zone 531. The stripping section 530 may be in fluid communication with and adjacent to the lower reactor section 520. In one or more embodiments, spent catalyst may be transferred from the lower reaction zone 521 to the stripping zone 531. In a further embodiment, spent catalyst may be transferred directly from the lower reaction zone 521 to the stripping zone 531. Steam may be transferred to the stripping zone 531 via stream 505. In the stripping zone 531, the steam may contact the spent catalyst and strip at least a portion of the hydrocarbon feed or hydrocarbon product from the spent catalyst. After contact with steam in the stripping zone 531, the spent catalyst may be transferred out of the countercurrent reactor 500 via stream 504 through the catalyst outlet.

[0059] In one or more embodiments, spent catalyst may be passed to a catalyst regenerator 550, where it is regenerated to form a regenerated catalyst. The catalyst regenerator 550 may include a riser 560 and a separator 570. Spent catalyst may enter the riser 560 through a catalyst inlet. In one or more embodiments, the riser 560 is in fluid communication with the stripping zone 531 of the countercurrent reactor 500, and spent catalyst may be passed directly from the stripping zone 531 to the riser 560. In one or more embodiments, an airflow 551 is passed to the riser 560, and air and spent catalyst move upward along the riser 560. In one or more embodiments, the airflow 551 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.

[0060] Regenerated catalyst and air can be moved from riser 560 to separator 570. In one or more embodiments, riser 560 and separator 570 are adjacent to each other, and regenerated catalyst and air move directly from riser 560 to separator 570. Separator 570 can be any suitable separation system for separating catalyst from air, including a cyclone separator system. In one or more embodiments, air stream 552 can exit separator 570. Furthermore, regenerated catalyst can exit separator 570 through regenerated catalyst outlet. In one or more embodiments, regenerated catalyst can be included in the catalyst in stream 503. In one or more embodiments, separator 570 and catalyst hopper 110 are in fluid communication with each other, and regenerated catalyst can be directly transferred from separator 570 of regenerator 550 to catalyst hopper 110 of countercurrent reactor 500. Regenerated catalyst can be transferred from catalyst hopper 110 to perforated plate distributor 130 and distributed into upper reaction zone 511. In one or more embodiments, fresh catalyst can be added to catalyst in stream 503. In such implementations, the catalyst may comprise both a regenerated catalyst and a fresh catalyst.

[0061] Example The following examples illustrate one or more additional features of this disclosure.

[0062] Example 1: Radial catalyst distribution in a countercurrent reactor A model for the radial particle distribution of the catalyst in a countercurrent reactor was established. The catalyst was simulated to enter the top of the countercurrent reactor with a uniform radial distribution. The radial distribution of the catalyst in the countercurrent reactor system was simulated at two steam fractions: 40% and 50%. The radial distribution of the catalyst in each reactor was depicted as follows: Figure 6 The radial distribution of the catalyst in reactor 610 operating at a 40% steam fraction was depicted, and the radial distribution of the catalyst in reactor 620 operating at a 50% steam fraction was depicted. The oil flow rate and catalyst-to-oil ratio remained constant between the modeled reactors. The catalyst-to-oil ratio in each reactor was 60. The increase in steam fraction resulted in an increase in the apparent velocity of the gas flowing upward through the reactor and a decrease in the apparent velocity of the catalyst flowing downward through the reactor.

[0063] like Figure 6 As shown, in the model with a steam fraction of 40%, the radial distribution of the catalyst in reactor 610 is non-uniform in the acceleration zone 612. As the catalyst moves into the reaction zone 614, the catalyst holdup decreases while maintaining a relatively uniform radial distribution. In the model with a steam fraction of 50%, the radial distribution of the catalyst in reactor 620 is also non-uniform in the acceleration zone 622. Specifically, the catalyst holdup near the reactor edge is greater than that near the reactor center. As the catalyst moves into the reaction zone 624, the catalyst holdup decreases, and the radial distribution of the catalyst becomes more uniform. Observing the acceleration and reaction zones at the same oil flow rate and catalyst-to-oil ratio but different steam fractions, the radial catalyst distribution becomes more uniform with increasing apparent catalyst velocity.

[0064] Increasing the catalyst inlet rate into the reactor reduces the length of the acceleration zone. Conversely, reducing the acceleration zone length reduces the portion of the reactor with uneven solids holdup. Uneven catalyst holdup in the reactor reduces catalyst-reactant contact efficiency. The catalyst distribution methods described herein result in the catalyst entering the reactor at a rate sufficient to reduce or even eliminate the acceleration zone. This leads to a more uniform radial catalyst distribution within the reactor, allowing for improved reactor control and reduced unwanted side reactions.

[0065] In a first aspect of this disclosure, a method for distributing a catalyst in a countercurrent reactor includes: transferring the catalyst from a catalyst hopper to a perforated plate distributor, wherein the perforated plate distributor comprises a plate extending along a substantially horizontal cross-section of the countercurrent reactor, the plate comprising a plurality of holes, and wherein the catalyst comprises particulate solids; distributing the catalyst into the reaction zone of the countercurrent reactor by transferring the catalyst from a catalyst discharge zone through the holes of the perforated plate distributor into a reaction zone, wherein the catalyst enters the holes of the perforated plate distributor at an apparent velocity of 0.01 m / s to 10 m / s, and wherein the apparent velocity is substantially downward; and transferring a hydrocarbon feed stream into the reaction zone, wherein the catalyst moves through the reaction zone in a substantially downward direction, the hydrocarbon feed stream moves through the reaction zone in a substantially upward direction, and wherein the catalyst is contacted with the hydrocarbon feed stream to crack one or more components of the hydrocarbon feed stream and form a hydrocarbon product stream.

[0066] The second aspect of this disclosure may include the first aspect, wherein the pressure difference across the perforated plate distributor is 0.5 barg to 5 barg.

[0067] A third aspect of this disclosure may include the first or second aspect, wherein the ratio of catalyst to hydrocarbon feed is 5 to 100 based on the mass of the catalyst and the hydrocarbon feed.

[0068] The fourth aspect of this disclosure may include any one of the first to third aspects, wherein the plate of the perforated plate distributor includes a first main surface and a second main surface opposite to the first main surface, wherein each of the plurality of holes is an opening extending from the first main surface to the second main surface.

[0069] The fifth aspect of this disclosure may include any one of the first to fourth aspects, wherein the catalyst hopper contains a catalyst bed having a dense-phase fluidized state, the catalyst overflows from the catalyst bed, and the catalyst falls through a catalyst discharge zone to a porous plate distributor.

[0070] The sixth aspect of this disclosure may include any one of the first to fourth aspects, wherein transferring the catalyst from the catalyst hopper to the perforated plate distributor includes contacting at least a portion of the conveyed catalyst bed containing the catalyst and carrier gas with a baffle located within the catalyst hopper, such that the catalyst is redirected through the catalyst discharge zone to the perforated plate distributor.

[0071] The seventh aspect of this disclosure may include the sixth aspect, wherein the angle between the baffle and the perforated plate distributor is 90° to 160°.

[0072] The eighth aspect of this disclosure may include any one of the first to seventh aspects, wherein the apparent rate of the catalyst in the reaction zone is substantially opposite to the apparent rate of the hydrocarbon feed stream in the reaction zone.

[0073] In a ninth aspect of this disclosure, a method for processing hydrocarbons to produce light olefins includes: passing a hydrocarbon feed stream to a feed inlet of a countercurrent reactor, wherein the countercurrent reactor comprises: a catalyst hopper; an upper reactor portion including an upper reaction zone, the upper reactor portion including a perforated plate distributor and a hydrocarbon product outlet, wherein the perforated plate distributor and the hydrocarbon product outlet are located at or near the top of the upper reactor portion, and wherein the perforated plate distributor includes a plate extending along a substantially horizontal cross-section of the upper reactor portion, the plate including a plurality of holes; 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 The lower reaction zone is in fluid communication with and adjacent to the upper reaction zone; wherein: the catalyst comprises particulate solids, and the catalyst moves in a generally downward direction through the upper reactor section and the lower reactor section, and the hydrocarbon feed stream moves in a generally upward direction through the upper reactor section and the lower reactor section, such that the hydrocarbon feed stream and the catalyst move in a countercurrent orientation; and the catalyst is brought into contact 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 one or more of ethylene, propylene, or butene; and the catalyst is distributed into the upper reaction zone of the countercurrent reactor by transferring the catalyst from the catalyst discharge zone through the holes of a perforated plate distributor into the upper reaction zone, wherein the catalyst enters the holes of the perforated plate distributor at an apparent velocity of 0.01 m / s to 10 m / s; and the hydrocarbon product stream is transferred out of the upper reaction zone through a hydrocarbon product outlet.

[0074] The tenth aspect of this disclosure may include the ninth aspect, wherein the pressure difference across the perforated plate distributor is 0.5 barg to 5 barg.

[0075] The eleventh aspect of this disclosure may include the ninth or tenth aspect, wherein the upper reaction zone operates in a countercurrent plug flow state.

[0076] The twelfth aspect of this disclosure may include the eleventh aspect, wherein the catalyst-to-oil ratio in the upper reaction zone is 5 to 100.

[0077] The thirteenth aspect of this disclosure may include any one of the ninth to twelfth aspects, wherein the lower reaction zone operates in a dense-phase fluidized state.

[0078] The fourteenth aspect of this disclosure may include the thirteenth aspect, wherein the gravity hourly space velocity in the lower reaction zone is 1 hr. -1 Up to 200 hr -1 .

[0079] The fifteenth aspect of this disclosure may include any one of the ninth to fourteenth aspects, wherein the method further includes: passing a catalyst through a catalyst outlet to 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 passing the regenerated catalyst through a perforated plate distributor to an upper reaction zone.

[0080] The subject matter of this disclosure has been described in detail with reference to specific embodiments. It should be understood that any detailed description of a component or feature of an embodiment does not necessarily imply that such component or feature is essential for that particular embodiment or any other embodiment. Furthermore, it will be apparent to those skilled in the art that various modifications and variations can be made to the described embodiments without departing from the spirit and scope of the claimed subject matter.

[0081] In order to describe and define this disclosure, it should be noted that the terms "about" or "approximately" are used in this disclosure to indicate the degree of uncertainty that may be inherent in any quantitative comparison, numerical value, measurement, or other representation. In this disclosure, the terms "about" and / or "approximately" are also used to indicate the degree of deviation that may exist between a quantitative representation and the reference value, without altering the essential function of the subject matter.

[0082] It should be noted that one or more of the following claims use the term "wherein" as a transitional phrase. In defining this technology, it should be noted that this term is introduced in the claims as an open-ended transitional phrase to introduce a description of a series of structural features, and this term should be interpreted in a similar manner to the more commonly used open-ended preamble term "comprising".

[0083] It should be understood that when describing a first component as "comprising" a second component, it may be considered that in some embodiments, the first component is "composed of" or "substantially composed of" the second component. It should be further understood that when describing a first component as "comprising" a second component, it may be considered that in some embodiments, the first component contains at least 10%, at least 20%, at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, at least 95%, or even at least 99% of the second component (wherein the percentage may be weight percentage or molar percentage).

[0084] The transitional phrases “composed of” and “substantially composed of” can be interpreted as a subset of open-ended transitional phrases (such as “contains” and “includes”), such that any statement using an open-ended phrase to introduce a series of elements, components, materials, or steps should be interpreted as also disclosing a statement using the closed terms “composed of” and “substantially composed of” that series of elements, components, materials, or steps. For example, a statement that “contains” components A, B, and C should be interpreted as also disclosing a composition “composed of” components A, B, and C as well as a composition “substantially composed of” components A, B, and C.

[0085] It should be understood that any two quantitative values ​​assigned to an attribute can constitute a range for that attribute, and this disclosure considers all combinations of ranges formed by all said quantitative values ​​for a given attribute. It should be understood that in some embodiments, the compositional range of a chemical component in a stream or reactor should be understood as including a mixture of isomers of that component. For example, specifying a compositional range for butene may include a mixture of various isomers of butene. It should be understood that the embodiments provide compositional ranges for various streams, and the total amount of isomers of a particular chemical composition can constitute a range.

Claims

1. A method for distributing a catalyst in a countercurrent reactor, the method comprising: The catalyst is transferred from the catalyst hopper to a porous plate distributor, wherein the porous plate distributor comprises a plate extending along a substantially horizontal cross-section of the countercurrent reactor, the plate comprising a plurality of holes, and wherein the catalyst comprises particulate solids. The catalyst is distributed into the reaction zone of the countercurrent reactor by passing it from the catalyst discharge zone through the holes of the porous plate distributor into the reaction zone, wherein the catalyst enters the holes of the porous plate distributor at an apparent velocity of 0.01 m / s to 10 m / s, and wherein the apparent velocity is substantially downward. as well as A hydrocarbon feed stream is passed into the reaction zone, wherein the catalyst moves through the reaction zone in a substantially downward direction, the hydrocarbon feed stream moves through the reaction zone in a substantially upward direction, and wherein the catalyst is brought into contact with the hydrocarbon feed stream to crack one or more components of the hydrocarbon feed stream and form a hydrocarbon product stream.

2. The method according to claim 1, wherein the pressure difference across the porous plate distributor is 0.5 barg to 5 barg.

3. The method according to claim 1 or 2, wherein the ratio of the catalyst to the hydrocarbon feed is 5 to 100 based on the mass of the catalyst and the hydrocarbon feed.

4. The method according to any one of claims 1 to 3, wherein the plate of the perforated plate distributor comprises a first main surface and a second main surface opposite to the first main surface, wherein each of the plurality of holes is an opening extending from the first main surface to the second main surface.

5. The method according to any one of claims 1 to 4, wherein the catalyst hopper contains a catalyst bed having a dense-phase fluidized state, the catalyst overflows from the catalyst bed, and the catalyst falls through the catalyst discharge zone to the porous plate distributor.

6. The method according to any one of claims 1 to 4, wherein transferring the catalyst from the catalyst hopper to the perforated plate distributor comprises contacting at least a portion of the conveyed catalyst bed containing the catalyst and carrier gas with a baffle located within the catalyst hopper, such that the catalyst is redirected through the catalyst discharge zone to the perforated plate distributor.

7. The method of claim 6, wherein the angle between the baffle and the perforated plate distributor is 90° to 160°.

8. The method according to any one of claims 1 to 7, wherein the apparent rate of the catalyst in the reaction zone is substantially opposite to the apparent rate of the hydrocarbon feed stream in the reaction zone.

9. A method for processing hydrocarbons to produce light olefins, the method comprising: The hydrocarbon feed stream is passed to the feed inlet of a countercurrent reactor, wherein the countercurrent reactor comprises: Catalyst hopper; The upper reactor section includes an upper reaction zone, the upper reactor section includes a perforated plate distributor and a hydrocarbon product outlet, wherein the perforated plate distributor and the hydrocarbon product outlet are located at or near the top of the upper reactor section, and wherein the perforated plate distributor includes a plate extending along a substantially horizontal cross-section of the upper reactor section, the plate including a plurality of holes. as well as The lower reactor section defines a lower reaction zone, the lower reactor section includes 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 section, and wherein the lower reaction zone is in fluid communication with and adjacent to the upper reaction zone; in: The catalyst comprises particulate solids, and the catalyst moves in a generally downward direction through the upper reactor section and the lower reactor section, while the hydrocarbon feed stream moves in a generally upward direction through the upper reactor section and the lower reactor section, such that the hydrocarbon feed stream and the catalyst move in a countercurrent orientation; and The catalyst is 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 one or more of ethylene, propylene, or butene; and The catalyst is distributed into the upper reaction zone of the countercurrent reactor by transferring it from the catalyst discharge zone through the pores of the porous plate distributor into the upper reaction zone, wherein the catalyst enters the pores of the porous plate distributor at an apparent velocity of 0.01 m / s to 10 m / s; and The hydrocarbon product stream is transferred out of the upper reaction zone through the hydrocarbon product outlet.

10. The method of claim 9, wherein the pressure difference across the porous plate distributor is 0.5 barg to 5 barg.

11. The method according to claim 9 or claim 10, wherein the upper reaction zone operates in a countercurrent plug flow state.

12. The method according to claim 11, wherein the ratio of catalyst to oil in the upper reaction zone is 5 to 100.

13. The method according to any one of claims 9 to 12, wherein the lower reaction zone operates in a dense-phase fluidized state.

14. The method of claim 13, wherein the gravity hourly space velocity in the lower reaction zone is 1 hr. -1 Up to 200 hr -1 .

15. The method according to any one of claims 9 to 14, further comprising: The catalyst is transferred to the catalyst regenerator through the catalyst outlet, wherein the catalyst passing through the catalyst outlet is spent catalyst; Regenerate at least a portion of the spent catalyst to form a regenerated catalyst; as well as The regenerated catalyst is transferred to the upper reaction zone through the porous plate distributor.

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