Fluidized catalytic conversion systems and their applications.

Abstract

A fluid catalytic conversion system is disclosed, which includes a reaction unit, a catalyst separation unit, and a catalyst regeneration unit. The reaction unit includes a first fluidized-bed reactor and a second fluidized-bed reactor connected in series, or a composite fluidized-bed reactor having a first reaction zone and a second reaction zone connected in series. The catalyst separation unit includes a separation device and a catalyst separator located inside or outside the separation device. The catalyst regeneration unit includes a first catalyst regenerator and a second catalyst regenerator, or a composite catalyst regenerator with a first regeneration zone and a second regeneration zone. The fluid catalytic conversion system allows reactants to undergo different reactions under more suitable catalyst and reaction conditions in different reactors or reaction zones, thereby improving the yield of the target product.

Description

Detailed Description of the Invention

[0001] [Technical field] This application relates to the field of petrochemical engineering, and more particularly to fluid catalytic conversion systems and their applications.

[0002] [Background technology] In petrochemical manufacturing processes, multiple reactors or multiple reaction zones can be used to create different reaction environments, while catalysts can be separated to use catalysts suitable for different reactions, or different regeneration zones can be used to regenerate catalysts, thereby improving the yield of target products.

[0003] CN110317628A discloses a catalytic cracking method and apparatus in which catalysts are installed in series. The apparatus includes a main reactor, a side reactor, a regenerator, and catalyst A and catalyst B storage tanks, with catalyst A and catalyst B main cyclone separators arranged above them. The regenerator is connected to catalyst A main cyclone separator, which is connected to catalyst B main cyclone separator. The catalyst B main cyclone separator is connected to the regenerator. The bottom of catalyst A storage tank is connected to the main reactor, and the bottom of catalyst B storage tank is connected to the side reactor.

[0004] CN104560149A discloses a catalytic conversion method for producing butylene. This method has a total of four reactors. In addition to adopting a dual riser and fluidized bed reactor configuration, a fluidized bed reactor is located outside the separator to crack the intermediate gasoline cut, and the reaction product flows into the riser reactor to continue the cracking reaction. After the reaction, the catalyst is carbonized and regenerated and returned to the reactor for reuse. This method uses a mixture containing Y zeolite and beta zeolite as a catalyst, which can improve the yield of propylene and butylene.

[0005] CN107828443A discloses a fluidized catalytic cracking process and apparatus for maximizing light olefin yields and other applications. In this process, hydrocarbons, a first catalyst, and a second catalyst are fed into a reactor. The first catalyst has a smaller average particle size and a lower density than the second catalyst. A first portion of the second catalyst is recovered as a bottom product from the reactor. The cracked hydrocarbon effluent, a second portion of the second catalyst, and the first catalyst are recovered as an upper product from the reactor. The upper product is separated in a separation system to obtain a first stream containing the first catalyst and the hydrocarbon liquid effluent, and a second stream containing the second catalyst. The second catalyst separated from the second stream is returned to the reactor.

[0006] CN1031834A discloses a catalytic conversion method for producing light olefins. This method uses petroleum fractions, residual oil, or crude oil with different boiling ranges as raw materials. The catalyst used is a mixture containing Y zeolite and a five-membered ring high-silicon zeolite. The reactor used is a fluidized bed or a moving bed. The reaction conditions are a temperature of 500-650°C, a pressure of 0.15-0.30 MPa, and a weight hourly space velocity of 0.2-20 h. -1 The catalyst-oil ratio is 2 to 12, and the catalyst after the reaction is carbonized and regenerated, and then returned to the reactor for reuse.

[0007] However, when heavy crude oil is catalytically cracked to produce ethylene and propylene using existing catalytic cracking conversion systems and processes, there is room for further improvement in the yields of ethylene and propylene obtained.

[0008] [Summary of the Invention] The objective of this application is to provide a fluidized catalytic conversion system and its application, which employs multiple fluidized bed reactors connected in series or multiple reaction zones connected in series, thereby enabling reactants to carry out different reactions under more suitable catalysts and reaction conditions in different reactors or reaction zones, thereby improving the yield of target products.

[0009] On the other hand, in order to achieve the above object, the present application provides a fluidized catalytic conversion system, which includes the following components: A reaction unit in which a reaction feedstock contacts and reacts with a catalyst to produce an oil-catalyst mixture, the reaction unit comprising a first fluidized-bed reactor and a second fluidized-bed reactor connected in series, or a composite fluidized-bed reactor having a first reaction zone and a second reaction zone connected in series, the first fluidized-bed reactor or the first reaction zone of the composite fluidized-bed reactor having a first feedstock inlet, a first catalyst inlet, and a first oil-catalyst mixture outlet, the second fluidized-bed reactor or the second reaction zone of the composite fluidized-bed reactor having an oil-catalyst mixture inlet, a second catalyst inlet, a second oil-catalyst mixture outlet, and an optional second feedstock inlet, wherein the first oil-catalyst mixture outlet of the first fluidized-bed reactor or the first oil-catalyst mixture outlet of the first reaction zone of the composite fluidized-bed reactor is connected to the oil-catalyst mixture inlet of the second fluidized-bed reactor or the oil-catalyst mixture inlet of the second reaction zone of the composite fluidized-bed reactor; A catalyst separation unit for separating the oil-catalyst mixture from the reaction unit to obtain oil-and-gas products and spent catalyst includes a disengager and a catalyst separator disposed inside or outside the disengager, the disengager having a gas-solid separator, at least one settling zone, and at least one stripping section connected to the bottom of the settling zone, and having an oil-catalyst mixture inlet, an oil-and-gas product outlet, and at least one catalyst outlet disposed at the bottom of the stripping section, the catalyst separator having a material inlet, a first material outlet, and a second material outlet, wherein the oil-catalyst mixture inlet of the separator is connected to the second oil-catalyst mixture outlet of the second fluidized bed reactor or the second reaction zone of the combined fluidized bed reactor; A catalyst regeneration unit regenerates the spent catalyst from the catalyst separation unit and recycles it to the reaction unit. The catalyst regeneration unit includes a first catalyst regenerator and a second catalyst regenerator, or a composite catalyst regenerator with a first regeneration zone and a second regeneration zone. The first catalyst regenerator or the first regeneration zone of the composite catalyst regenerator has a first spent catalyst inlet and a first regenerated catalyst outlet. The second catalyst regenerator or the second regeneration zone of the composite catalyst regenerator has a second spent catalyst inlet and a second regenerated catalyst outlet, where the first spent catalyst inlet and the second spent catalyst inlet are connected to the catalyst outlet of the separation device or the first and second material outlets of the catalyst separator, respectively. The first regenerated catalyst outlet is connected to the first catalyst inlet of the first reaction zone of the first fluidized bed reactor or the composite fluidized bed reactor. The second regenerated catalyst outlet is connected to the second catalyst inlet of the second fluidized bed reactor or the second reaction zone of the composite fluidized bed reactor.

[0010] Meanwhile, there is provided the use of the fluid catalytic conversion system of the present application for the catalytic conversion of hydrocarbon oils, in particular for the catalytic conversion of heavy feedstocks to produce light olefins.

[0011] In another aspect, there is provided a method for catalytically converting hydrocarbon oils, particularly heavy feedstocks, using the fluid catalytic conversion system of the present application, the method comprising the steps of: 1) in a first fluidized bed reactor or a first reaction zone of a composite fluidized bed reactor of a reaction unit of the fluidized catalytic conversion system, contacting a hydrocarbon oil feedstock with a first catalyst to carry out a first catalytic conversion reaction and obtain a first oil-catalyst mixture; 2) contacting the first oil-catalyst mixture with a second catalyst in a second fluidized bed reactor or a second reaction zone of a combined fluidized bed reactor of the reaction unit of the fluidized catalytic conversion system to carry out a second catalytic conversion reaction to obtain a second oil-catalyst mixture; 3) separating the second oil-catalyst mixture in a catalyst separation unit of the fluid catalytic conversion system to obtain an oil and gas product, a first spent catalyst, and a second spent catalyst; 4) regenerating the first spent catalyst in a first catalyst regenerator or a first regeneration zone of a combined catalyst regenerator of a catalyst regeneration unit of the fluid catalytic conversion system, and returning the resulting first regenerated catalyst to step 1) as the first catalyst; and 5) regenerating the second spent catalyst in a second catalyst regenerator or a second regeneration zone of a combined catalyst regenerator of a catalyst regeneration unit of the fluid catalytic conversion system, and returning the resulting second regenerated catalyst to step 2) as the second catalyst.

[0012] The fluidized catalytic conversion system of the present invention employs multiple fluidized-bed reactors / reaction zones arranged in series, creating different reaction environments within them. It also combines multi-stage catalyst separation with multiple catalyst regenerators / regeneration zones to separately regenerate multiple catalysts. As a result, different reactions can be achieved in different reactors / reaction zones under more suitable catalysts and reaction conditions, thereby improving the yield of target products. In particular, when used in the production of light olefins by catalytic cracking of heavy feedstocks, the fluidized catalytic conversion system of the present invention can further improve the yield of ethylene and propylene.

[0013] The catalytic conversion method of the present application first contacts a hydrocarbon oil feedstock with a first catalyst to carry out a first catalytic conversion reaction (e.g., a primary cracking reaction or an alkane dehydrogenation reaction), and then contacts the reaction product with a second catalyst to carry out a first catalytic conversion reaction (e.g., a secondary cracking reaction or an olefin cracking reaction). This realizes a relay of two catalytic conversion reactions of the hydrocarbon oil feedstock, and as a result, the active species generated in the first stage reaction can be completely retained in the feedstock for the second stage reaction, thereby accelerating the second catalytic conversion reaction, suppressing the occurrence of side reactions, and improving the yield of target products (e.g., light olefins such as ethylene and propylene).

[0014] Other features and advantages of the present application are explained in detail in the detailed description that follows.

[0015] [Brief description of the drawing] The accompanying drawings are included to provide a further understanding of the present application and constitute a part of this specification, and together with the following specific embodiments illustrate, but do not limit, the present application. In the accompanying drawings: FIG. 1 is a schematic structural diagram showing a preferred embodiment of the reaction unit of the system of the present application.

[0016] FIG. 2 is a schematic structural diagram showing another preferred embodiment of the reaction unit of the system of the present application.

[0017] FIG. 3 is a schematic structural diagram showing another preferred embodiment of the reaction unit of the system of the present application.

[0018] FIG. 4 is a schematic structural diagram showing a preferred embodiment of the catalyst separator of the present system.

[0019] FIG. 5 is a schematic structural diagram showing another preferred embodiment of the catalyst separator of the present system.

[0020] FIG. 6 is a schematic structural diagram showing another preferred embodiment of the catalyst separator of the present system.

[0021] FIG. 7 is a schematic structural diagram showing another preferred embodiment of the catalyst separator of the present system.

[0022] FIG. 8 is a schematic structural diagram of a catalytic conversion system according to one embodiment of the present application.

[0023] FIG. 9 is a schematic structural diagram showing one embodiment of the catalyst separation unit of the present application.

[0024] FIG. 10 is a schematic structural diagram showing one embodiment of the regenerator in the present application.

[0025] FIG. 11 is a schematic structural diagram of a catalytic conversion system according to one embodiment of the present application.

[0026] FIG. 12 is a schematic structural diagram showing one embodiment of the catalyst separation unit of the present invention.

[0027] FIG. 13 is a schematic structural diagram showing one embodiment of the regenerator of the present invention.

[0028] FIG. 14 is a schematic structural diagram of a catalytic conversion system according to one embodiment of the present application.

[0029] FIG. 15 is a schematic structural diagram of a catalytic conversion system according to one embodiment of the present application.

[0030] [Reference number explanation] In Figure 1-15: 1-1 first reaction zone, 1-2 second reaction zone, 2 separation device, 2-1 (first) settling zone, 2-2 (first) stripping section, 2-21 stripping baffle, 2-3 second settling zone, 2-4 second stripping section, 2-41 stripping baffle, 2-50 catalyst separator, 2-51 first stage catalyst separator, 2-52 second stage catalyst separator, 2-6 settling zone baffle, 2-7 cyclone separator, 2-8 gas collection chamber, 3-1 first regeneration zone, 3-2 second regeneration zone, 3-3 regenerator partition, 3-41 cyclone separator, 3-42 cyclone separator, 3-5 gas collection chamber; 101 First feedstock oil, 102 Prelifting gas, 103 Second feedstock oil, 104 Second oil-catalyst mixture, 200 Spent catalyst supply pipe, 201 Stripping gas, 202 First spent catalyst supply pipe, 203 Stripping product, 204 Second catalyst supply pipe, 205 Stripping gas, 206 Second spent catalyst supply pipe, 207 Stripping product, 208 Reacted oil and gas, 301A Main air, 301B Main air, 302 First regenerated catalyst supply pipe, 303 Second regenerated catalyst supply pipe, 304A Regenerated exhaust gas, 304B Regenerated exhaust gas.

[0031] [Detailed explanation] Specific examples of the present application are described in detail below. It should be understood that the specific examples described herein are used only to explain and illustrate the present application, and are not intended to limit the present application.

[0032] Specific examples of the present application are described in detail below. It should be understood that the specific examples described herein are used only to explain and illustrate the present application, and are not intended to limit the present application.

[0033] Specific numerical values ​​disclosed herein (including the endpoints of a range) should be understood not to be limited to that exact value, but to include values ​​near that exact value (e.g., all possible values ​​within ±5% of the exact value). Furthermore, within the disclosed ranges, the ranges between the endpoints, the ranges between the endpoints and a particular point, and the ranges between a particular point can be combined in any way to create one or more new numerical ranges, and these new numerical ranges are also considered to be specifically disclosed herein.

[0034] Unless otherwise specified, terms used herein have the meanings that are commonly understood by those skilled in the art. If a term is defined herein and that definition differs from the meaning that is commonly understood by those skilled in the art, the definition herein shall prevail.

[0035] As used herein, the term "upflow bed" refers to a fluidized bed in which reactants and catalyst move from bottom to top, and the term "downflow bed" refers to a fluidized bed in which reactants and catalyst move from top to bottom.

[0036] In this application, except for the contents explicitly described, for the matters or items not described, matters known to those skilled in the art shall be applied without modification. Furthermore, any embodiment described in this specification can be freely combined with one or more of the other embodiments described in this specification, and the technical solutions or technical ideas formed thereby shall be deemed to be part of the original disclosure or original record of this application, unless a person skilled in the art determines that the combination is obviously unreasonable, and shall not be deemed to be new content not disclosed or anticipated in this specification.

[0037] All patent and non-patent literature (including, but not limited to, textbooks and journal articles) referred to herein is hereby incorporated by reference in its entirety.

[0038] As noted above, in a first aspect, the present application provides a fluidized catalytic conversion system, the system comprising: A reaction unit in which a reaction feedstock contacts and reacts with a catalyst to produce an oil-catalyst mixture, the reaction unit comprising a first fluidized-bed reactor and a second fluidized-bed reactor connected in series, or a composite fluidized-bed reactor having a first reaction zone and a second reaction zone connected in series, the first fluidized-bed reactor or the first reaction zone of the composite fluidized-bed reactor having a first feedstock inlet, a first catalyst inlet, and a first oil-catalyst mixture outlet, the second fluidized-bed reactor or the second reaction zone of the composite fluidized-bed reactor having an oil-catalyst mixture inlet, a second catalyst inlet, a second oil-catalyst mixture outlet, and an optional second feedstock inlet, wherein the first oil-catalyst mixture outlet of the first fluidized-bed reactor or the first oil-catalyst mixture outlet of the first reaction zone of the composite fluidized-bed reactor is connected to the oil-catalyst mixture inlet of the second fluidized-bed reactor or the oil-catalyst mixture inlet of the second reaction zone of the composite fluidized-bed reactor; A catalyst separation unit in which the oil-catalyst mixture from the reaction unit is separated into oil, gas products, and spent catalyst, the catalyst separation unit comprising a separation device and a catalyst separator disposed inside or outside the separation device, the separation device including a gas-solid separator, at least one settling zone, and at least one stripping section connected to the bottom of the settling zone, and having an oil-catalyst mixture inlet, an oil and gas product outlet, and at least one catalyst outlet disposed at the bottom of the stripping section, the catalyst separator having a material inlet, a first material outlet, and a second material outlet, wherein the oil-catalyst mixture inlet of the separation device is connected to the second oil-catalyst mixture outlet of the second fluidized bed reactor or the second reaction zone of the combined fluidized bed reactor; A catalyst regeneration unit regenerates the spent catalyst from the catalyst separation unit and recycles it to the reaction unit. The catalyst regeneration unit includes a first catalyst regenerator and a second catalyst regenerator, or a composite catalyst regenerator with a first regeneration zone and a second regeneration zone. The first catalyst regenerator or the first regeneration zone of the composite catalyst regenerator has a first spent catalyst inlet and a first regenerated catalyst outlet. The second catalyst regenerator or the second regeneration zone of the composite catalyst regenerator has a second spent catalyst inlet and a second regenerated catalyst outlet, where the first spent catalyst inlet and the second spent catalyst inlet are connected to the catalyst outlet of the separation device or the first and second material outlets of the catalyst separator, respectively. The first regenerated catalyst outlet is connected to the first catalyst inlet of the first reaction zone of the first fluidized bed reactor or the composite fluidized bed reactor. The second regenerated catalyst outlet is connected to the second catalyst inlet of the second fluidized bed reactor or the second reaction zone of the composite fluidized bed reactor.

[0039] In a particularly preferred embodiment, in the catalyst separation unit, a catalyst separator is disposed outside the separation device, a catalyst outlet of the separation device is connected to a material inlet of the catalyst separator, a first material outlet of the catalyst separator is connected to a first spent catalyst inlet of a first catalyst regenerator or a first spent catalyst inlet of a first regeneration zone of a combined catalyst regenerator, and a second material outlet is connected to a second spent catalyst inlet of a second catalyst regenerator or a second regeneration zone of a combined catalyst regenerator.

[0040] In another preferred embodiment, in the catalyst separation unit, the catalyst separator is disposed inside a separation device. The separation device has a first settling zone, a first stripping section connected to the bottom of the first settling zone, a first catalyst outlet disposed at the bottom of the first stripping section, a second settling zone, a second stripping section connected to the bottom of the second settling zone, and a second catalyst outlet disposed at the bottom of the second stripping section. The second oil-catalyst mixture outlet of the second reaction zone of the second fluidized-bed reactor or the combined fluidized-bed reactor is connected to the material inlet of the catalyst separator via the oil-catalyst mixture inlet of the separation device. The first and second material outlets of the catalyst separator are connected to the first and second settling zones of the separation device, respectively. The first catalyst outlet of the separation device is connected to the first spent catalyst inlet of the first regeneration zone of the first catalyst regenerator or the combined catalyst regenerator. The second catalyst outlet of the separation device is connected to the second spent catalyst inlet of the second regeneration zone of the second catalyst regenerator or the combined catalyst regenerator.

[0041] In a preferred embodiment, the fluidized catalytic conversion system further comprises a first catalyst injected into the first fluidized bed reactor or into a first reaction zone of the composite fluidized bed reactor through the first catalyst inlet, and a second catalyst injected into the second fluidized bed reactor or into a second reaction zone of the composite fluidized bed reactor through the second catalyst inlet, wherein the particle size and density of the first catalyst are greater than the particle size and density of the second catalyst, respectively.

[0042] In a preferred embodiment, the first and second fluidized bed reactors, or the first and second reaction zones of a compound fluidized bed reactor, are independently in the form of an upflow bed or a downflow bed, more preferably both in the form of an upflow bed.

[0043] In a more preferred embodiment, the upflow bed is one or a combination of types selected from a bubbling bed, a turbulent bed, a fast bed, and a dilute transport bed, and preferably a type selected from a riser reactor, a fast bed reactor, or a dense phase bed reactor.

[0044] In certain further preferred embodiments, the second fluidized bed reactor or the second reaction zone of the combined fluidized bed reactor is of the upflow type and is partially or completely located within at least one settling zone of the separation device.

[0045] In a particularly preferred embodiment, the first and second fluidized bed reactors, or the first and second reaction zones of the combined fluidized bed reactor, are independently of each other of the upflow bed type selected from a riser reactor, a fast bed reactor, or a dense phase bed reactor.

[0046] The first reaction zone of the first fluidized bed reactor or the combined fluidized bed reactor has a first feedstock oil inlet, a first catalyst inlet, and a fluidizing medium inlet at the bottom, and a first oil-catalyst mixture outlet at the top; and The second reaction zone of the second fluidized bed reactor or composite fluidized bed reactor has an oil-catalyst mixture inlet, a second catalyst inlet, and an optional second feedstock oil inlet at the bottom, and a second oil-catalyst mixture outlet at the top.

[0047] As shown in FIG. 1, in certain particularly preferred embodiments, the first reaction zone 1-1 and the second reaction zone 1-2 of the composite fluidized bed reactor are both constant diameter riser reactor types.

[0048] As shown in FIG. 2, in another particularly preferred embodiment, the first reaction zone 1-1 of the combined fluidized bed reactor is of the constant diameter riser reactor type, and the second reaction zone 1-2 is of the fast bed reactor type.

[0049] In another particularly preferred embodiment, FIG. 3, the first reaction zone 1-1 of the combined fluidized bed reactor is of the type of riser reactor having a constant diameter, and the second reaction zone 1-2 is of the type of dense phase bed reactor.

[0050] In the embodiment shown in Figure 1-3, the first regenerated catalyst from the first catalyst regenerator or the first regenerated catalyst from the first regeneration zone of the combined catalyst regenerator is introduced into the bottom of the first reaction zone 1-1 through the first regenerated catalyst supply pipe 302, and after being lifted by the prelifting gas 102, comes into contact with and reacts with the injected first feedstock 101. The produced first oil-catalyst mixture enters the bottom of the second reaction zone 1-2, and the second regenerated catalyst from the second catalyst regenerator or the second regenerated catalyst from the second regeneration zone of the combined catalyst regenerator is introduced into the bottom of the second reaction zone 1-2 through the second regenerated catalyst supply pipe 303, comes into contact with and reacts with the first oil-catalyst mixture from the first reaction zone and the optionally injected second feedstock 103 to obtain the second oil-catalyst mixture 104.

[0051] In certain preferred embodiments, the catalyst separator is one or more combinations selected from a cyclone-type fast separator, a tri-lobe fast separator, a ballistic fast separator, a U-tube separator, and a wall-cutting fast separator, and is preferably a cyclone-type fast separator.

[0052] In another preferred embodiment, the catalyst separator is configured in the form of a plurality of separators in parallel, or a multi-stage separator in series, or a combination thereof, wherein each separator or each stage of the multi-stage separator is independently a cyclonic high-speed separator, a trilobe high-speed separator, a ballistic high-speed separator, a U-tube separator, or a wall-cutting high-speed separator, preferably a cyclonic high-speed separator.

[0053] As shown in FIG. 4, in certain particularly preferred embodiments, the material inlet of the catalyst separator is located on the side of the catalyst separator, one material outlet is located at the bottom of the catalyst separator, and another material outlet is located at the top of the catalyst separator.

[0054] As shown in FIG. 5, in another particularly preferred embodiment, the material inlet of the catalyst separator is located at the bottom of the catalyst separator, one material outlet is located at the side of the catalyst separator, and another material outlet is located at the top of the catalyst separator.

[0055] In another particularly preferred embodiment, the catalyst separator has a material inlet located at the top of the catalyst separator, one material outlet located at the bottom of the catalyst separator, and another material outlet located on the side of the catalyst separator, as shown in Figures 6 and 7. As shown in Figure 7, the side material outlets may be in the form of movable louvers, the number and angle of which can be adjusted to control the flow rate.

[0056] According to the present application, when the catalyst separator is arranged outside the separation device, in a particularly preferred embodiment, the catalyst separator is in the form of a two-stage separator connected in series, with the inlet of the first stage separator being connected to the catalyst outlet of the separation device. The first material outlet is arranged at the bottom of the first stage separator, and the light material outlet is arranged at the top thereof. The inlet of the second stage separator is connected to the light material outlet of the first stage separator. The second material outlet is arranged at the bottom of the second stage separator, and the residual reaction oil and gas outlet is arranged at the top thereof. More preferably, the residual reaction oil and gas outlet of the second stage separator is connected to the top of the separation device via a pipeline.

[0057] According to the present application, when the catalyst separator is disposed inside the separation device, in a further preferred embodiment, a settling zone partition is provided in the separation device to separate a first settling zone from a second settling zone. The first settling zone is located below the settling zone partition, and the second settling zone is located above the settling zone partition. The catalyst separator is fixed on the settling zone partition of the separation device so that its first material outlet is located in the first settling zone and its second material outlet is located in the second settling zone.

[0058] In a preferred embodiment, the hybrid catalyst regenerator includes a regenerator divider separating the first and second regeneration zones.

[0059] In a more preferred embodiment, the regenerator partition is vertically disposed, and the first and second regeneration zones are disposed on the left and right sides of the regenerator partition. Preferably, the tops of the first and second regeneration zones are connected, and a gas-solid separator is disposed within each of them. The top of the regenerator partition is located higher than the solids outlet of each gas-solid separator.

[0060] In a further preferred embodiment, the regenerator partition is horizontally disposed, and the first and second regeneration zones are disposed above and below the regenerator partition. Preferably, the first regeneration zone is disposed below the second regeneration zone, and a first regeneration exhaust gas outlet is disposed in the regenerator partition to allow the regeneration exhaust gas from the first regeneration zone to flow into the second regeneration zone.

[0061] Particular embodiments of the fluid catalytic conversion system of the first aspect of the present application are described in further detail below.

[0062] Embodiment 1 As shown in FIG. 8, the fluidized catalytic conversion system of the first embodiment includes a composite fluidized-bed reactor having an upstream-bed first reaction zone 1-1 and an upstream-bed second reaction zone 1-2, a separator 2, a catalyst separator 2-50, and a regenerator. The first reaction zone 1-1 has a first feedstock oil inlet, a first catalyst inlet, and a first oil-catalyst mixture outlet. The second reaction zone 1-2 has an oil-catalyst mixture inlet, a second catalyst inlet, a second oil-catalyst mixture outlet, and an optional second feedstock oil inlet. The first oil-catalyst mixture outlet of the first reaction zone 1-1 is connected to the oil-catalyst mixture inlet at the bottom of the second reaction zone 1-2. The separator 2 has an oil-catalyst mixture inlet, an oil and gas mixture outlet, and a catalyst outlet. The oil-catalyst mixture inlet is connected to the second oil-catalyst mixture outlet of the second reaction zone 1-2. The catalyst separator 2-50 is located outside the separator 2 and has a material inlet, a first material outlet, and a second material outlet. The material inlet is connected to the catalyst outlet of the separator 2. The regenerator is provided with a regenerator partition for dividing the regenerator into a first regeneration zone 3-1 and a second regeneration zone 3-2 arranged vertically. The first material outlet of the catalyst separator is connected to the first regeneration zone 3-1 to transport the first spent catalyst. The second material outlet of the catalyst separator is connected to the second regeneration zone 3-2 to transport the second spent catalyst. The first regeneration zone 3-1 is connected to the first reaction zone 1-1 to transport the first regenerated catalyst. The second regeneration zone 3-2 is connected to the second reaction zone 1-2 to transport the second regenerated catalyst.

[0063] In this embodiment, the first oil-catalyst mixture outlet of the first reaction zone is connected to the oil-catalyst mixture inlet at the bottom of the second reaction zone. That is, the first reaction zone and the second reaction zone are connected in series. This allows the materials undergoing the first catalytic conversion in the first reaction zone (including the first catalyst, reaction oil and gas, and fluidization medium) to enter the second reaction zone without separation and contact the second catalyst to undergo the second catalytic conversion reaction. That is, the first catalytic conversion reaction and the second catalytic conversion reaction can be carried out in a relay manner. The separator performs gas-solid separation and stripping on the materials undergoing the second catalytic conversion in the second reaction zone (including the first catalyst, second catalyst, reaction oil and gas, and fluidization medium), thereby obtaining oil and gas products and the mixed catalyst to be regenerated. The catalyst separator separates the mixed catalyst to be regenerated, so that the first spent catalyst and the second spent catalyst, which have larger particle sizes and densities, basically flow into the first regeneration zone, and the second spent catalyst, which have smaller particle sizes and densities, flow into the second regeneration zone. The two portions of the catalyst to be regenerated are then regenerated in the first and second regeneration zones, respectively, thereby achieving relatively independent regeneration of the first and second catalysts, which are then returned to the first and second reaction zones, respectively, to participate in the reaction again.

[0064] During operation, the first reaction zone contains an upflow first catalyst. The second reaction zone contains an upflow second catalyst and an upflow first catalyst. The particle size and density of the first catalyst are greater than those of the second catalyst. The catalyst separator separates the first catalyst from the second catalyst based on the difference between the particle size and density of the first catalyst and the particle size and density of the second catalyst. In the catalyst separator, a first material outlet for the first spent catalyst is located below a second material outlet for the second spent catalyst.

[0065] Optionally, part or all of the second reaction zone is located within the settling zone of the separator 2. For example, a pipe lateral to the second reaction zone for transporting the second oil-catalyst mixture 104 can be located within the settling zone of the separator 2.

[0066] In a particular preferred embodiment, as shown in Figure 9, the separation device is externally connected to a two-stage catalyst separator, where the lower part of the first-stage catalyst separator 2-51 has a first material outlet and the upper part of the first-stage catalyst separator has a light material outlet. The light material outlet is connected to the material inlet of the second-stage catalyst separator 2-52. The upper part of the second-stage catalyst separator is provided with a residual reaction oil and gas outlet, and the lower part of the second-stage catalyst separator is provided with a second material outlet.

[0067] In this preferred embodiment, as shown in FIG. 9, the separator includes a settling zone 2-1 and a stripping section 2-2 connected to the bottom of the settling zone 2-1. An oil and gas product outlet is provided at the top of the separator. A gas-solid separator is also provided within the separator. The second oil-catalyst mixture 104 from the second reaction zone 1-2 is introduced into the high-speed separator 2-7 of the separator. The resulting reaction oil and gas 208 is introduced into a subsequent product separation unit (not shown) via a gas collection chamber 2-8. The resulting mixed spent catalyst is introduced into the stripping section 2-2 for stripping. After stripping, the mixed spent catalyst is introduced into a first-stage catalyst separator 2-51 and a second-stage catalyst separator 2-52. Depending on the particle size distribution and particle density of the catalyst, the mixed spent catalyst is divided into a first spent catalyst with a large particle size and particle density and a second spent catalyst with a small particle size and particle density. The first spent catalyst is introduced into the first regeneration zone 3-1 through the first spent catalyst supply pipe 202 and regenerated. The second spent catalyst is introduced into the second regeneration zone 3-2 through the second spent catalyst supply pipe 206 and regenerated. The residual reaction oil and gas 207 in the catalyst separator is returned to the top of the separator through a pipeline and discharged out of the system together with the reaction oil and gas 208.

[0068] In a preferred embodiment, as shown in FIG. 10, the first regeneration zone 3-1 and the second regeneration zone 3-2 are arranged in series. The first regeneration zone 3-1 is located below the second regeneration zone 3-2. They are separated by a regenerator partition 3-3, which is provided with a first regeneration exhaust gas outlet. The first spent catalyst from the catalyst separator is introduced into the first regeneration zone 3-1 through the first spent catalyst supply pipe 202 and reacts with the main air from the bottom of the first regeneration zone 3-1 to produce a first regenerated catalyst and a first regeneration exhaust gas through a first regeneration reaction. The produced first regenerated catalyst is introduced into the first reaction zone 1-1 through the first regenerated catalyst supply pipe 302 and recycled. The first regeneration exhaust gas is introduced into the second regeneration zone 3-2 through the first regeneration exhaust gas outlet provided in the regenerator partition 3-3. The second spent catalyst from the catalyst separator is introduced into the second regeneration zone 3-2 via the second spent catalyst supply pipe 206, where it comes into contact with and reacts with the first regeneration exhaust gas from the first regeneration zone 3-1, producing a second regenerated catalyst and a second regeneration exhaust gas through a second regeneration reaction. The produced second regenerated catalyst is introduced into the second reaction zone 1-2 via the second regenerated catalyst supply pipe 303 and reused. The second regeneration exhaust gas 304A is discharged from the regenerator through the gas collection chamber 3-5. The first regeneration employs incomplete regeneration, while the second regeneration employs complete regeneration. That is, the first regeneration gas obtained in the first regeneration zone 3-1 is introduced into the second regeneration zone 3-2 and undergoes a regeneration reaction with the second regenerated catalyst.

[0069] In a particularly preferred embodiment, the fluidized catalytic conversion system is operated as follows: first feedstock 101 is preheated to 180-340°C and then injected through a nozzle into the bottom of a riser-type first reaction zone 1-1, where it contacts and reacts with a first catalyst introduced into the bottom of the first reaction zone 1-1 through a first regenerated catalyst supply pipe 302. The reaction temperature is 520-620°C, preferably 540-600°C, the catalyst-to-oil ratio is 2-25, preferably 3-20, and the reaction time is 1-15 seconds, preferably 2-10 seconds. The resulting first oil-catalyst mixture is introduced into a riser-type second reaction zone 1-2. The second feedstock oil 103 is preheated to 100-150°C and then injected through a nozzle into the bottom of the second reaction zone 1-2. The second feedstock oil is then contacted with the second catalyst introduced into the bottom of the second reaction zone 1-2 through the second regenerated catalyst supply pipe 303 and the first oil-catalyst mixture from the first reaction zone 1-1 to react with the second catalyst. The reaction temperature is 540-640°C, preferably 560-620°C, the catalyst-to-oil ratio is 3-30, preferably 5-25, and the reaction time is 1-10 seconds, preferably 2-8 seconds. The resulting oil-catalyst mixture is introduced into the high-speed separator 2-7 of the separation device. The resulting reaction oil and gas 208 are discharged from the device through the gas collection chamber 2-8. The resulting mixed spent catalyst is introduced into the stripping section 2-2 for stripping. After stripping, the mixed spent catalyst is introduced into the first-stage catalyst separator 2-51 and the second-stage catalyst separator 2-52. The first spent catalyst is introduced into the first regeneration zone 3-1 via the first spent catalyst supply pipe 202 and regenerated. The second spent catalyst is introduced into the second regeneration zone 3-2 via the second spent catalyst supply pipe 206 and regenerated. The regenerated first and second regenerated catalysts are returned to the bottom of the first reaction zone 1-1 and the bottom of the second reaction zone 1-2 via the first regenerated catalyst supply pipe 302 and the second regenerated catalyst supply pipe 303, respectively, and are reused.

[0070] Embodiment 2 As shown in Figure 11, the second embodiment of the fluidized catalytic conversion system includes a composite fluidized-bed reactor having an upstream-bed first reaction zone 1-1 and an upstream-bed second reaction zone 1-2, a separator, and a regenerator. The first reaction zone 1-1 has a first feedstock inlet, a first catalyst inlet, and a first oil-catalyst mixture outlet. The second reaction zone 1-2 has an oil-catalyst mixture inlet, a second catalyst inlet, a second oil-catalyst mixture outlet, and an optional second feedstock inlet. The first oil-catalyst mixture outlet of the first reaction zone 1-1 is connected to the oil-catalyst mixture inlet at the bottom of the second reaction zone 1-2. The separator is equipped with a settling zone partition 2-6 and a catalyst separator 2-50. The settling zone partition 2-6 separates the settling zone of the separator into a first settling zone 2-1 and a second settling zone 2-3. The first settling zone 2-1 is located below the settling zone partition 2-6, and the second settling zone 2-3 is located above the settling zone partition 2-6. The catalyst separator 2-50 has a material inlet connected to the second oil-catalyst mixture outlet of the second reaction zone 1-2, a first material outlet opening in the first settling zone 2-1, and a second material outlet opening in the second settling zone 2-3. The regenerator is provided with a regenerator partition that divides the regenerator into a first regeneration zone 3-1 and a second regeneration zone 3-2 arranged side by side. The first spent catalyst is transported between and connected to the first settling zone 2-1 and the first regeneration zone 3-1. The second spent catalyst is transported between and connected to the second settling zone 2-3 and the second regeneration zone 3-2. The first regenerated catalyst is transported between and connected to the first regeneration zone 3-1 and the first reaction zone 1-1. The second regenerated catalyst is transported and connected between the second regeneration zone 3-2 and the second reaction zone 1-2.

[0071] In this embodiment, the first oil-catalyst mixture outlet of the first reaction zone is connected to the oil-catalyst mixture inlet at the bottom of the second reaction zone. That is, the first reaction zone and the second reaction zone are connected in series. This allows the materials that have undergone the first catalytic conversion in the first reaction zone (including the first catalyst, reaction oil and gas, and fluidization medium) to enter the second reaction zone without separation and contact the second catalyst to carry out the second catalytic conversion reaction. That is, the first catalytic conversion reaction and the second catalytic conversion reaction can be carried out in a relay manner. The catalyst separator separates the materials that have undergone the second catalytic conversion in the second reaction zone (including the first catalyst, the second catalyst, reaction oil and gas, and fluidization medium). As a result, of the first spent catalyst and the second spent catalyst, those with larger particle sizes and densities flow primarily into the first settling zone, while those with smaller particle sizes and densities flow primarily into the second settling zone together with the reaction oil and gas and the fluidization medium. The spent catalyst in the first settling zone is then regenerated in a first regeneration zone, and the spent catalyst in the second settling zone is regenerated in a second regeneration zone, thereby achieving relatively independent regeneration of the first and second catalysts. The regenerated first and second catalysts are returned to the first and second reaction zones, respectively, to participate in the reaction again.

[0072] During operation, the first reaction zone contains an upflow first catalyst. The second reaction zone contains an upflow second catalyst and an upflow first catalyst. The particle size and density of the first catalyst are greater than those of the second catalyst. The catalyst separator separates the first catalyst from the second catalyst based on the difference between the particle size and density of the first catalyst and the particle size and density of the second catalyst.

[0073] Optionally, part or all of the second reaction zone is located within the first or second settling zone of the separator. For example, a lateral pipe of the second reaction zone for transporting the second oil-catalyst mixture 104 can be located within the second settling zone of the separator.

[0074] Preferably, a first stripping section and a second stripping section are provided, which are connected to the bottom of the first settling zone and the bottom of the second settling zone, respectively, and can be located inside or outside the separation device, for extracting oil and gas products adhering to the catalyst.

[0075] In a particularly preferred embodiment, as shown in Figure 12, the catalyst separator 2-50 is fixed on a settling zone partition 2-6. The bottom of the first settling zone 2-1 is connected to its first stripping section 2-2. The top of the first settling zone 2-1 is provided with a first stripping material outlet. The first stripping material outlet is connected to a pipeline 203. The bottom of the second settling zone 2-3 is connected to a second stripping section 2-4 located outside the separation apparatus. The top of the second stripping section 2-4 is provided with a second stripping material outlet. The second stripping material outlet is connected to a pipeline 207.

[0076] In this preferred embodiment, as shown in FIG. 12, the second oil-catalyst mixture 104 from the second reaction zone is introduced into a catalyst separator 2-50. Based on the catalyst particle size distribution and particle density, the second oil-catalyst mixture 104 is divided into a first catalyst portion having a large particle size and particle density and a second catalyst portion having a small particle size and particle density. The first catalyst portion is introduced into a first stripping section 2-2 via a first settling zone 2-1 and stripped to obtain a first spent catalyst. The first spent catalyst is introduced into a first regeneration zone 3-1 via a first spent catalyst supply pipe 202 for regeneration. The second catalyst portion is introduced into a second stripping section 2-4 via a second settling zone 2-3 and stripped to obtain a second spent catalyst. The second spent catalyst is introduced into a second regeneration zone 3-2 via a second spent catalyst supply pipe 206 for regeneration. The first stripping material obtained in the first stripping section 2-2 and the second stripping material obtained in the second stripping section 2-4 are both introduced into the top of the separation device and discharged out of the system together with the reaction oil and gas 208.

[0077] In a preferred embodiment, as shown in Figure 13, the first regeneration zone 3-1 and the second regeneration zone 3-2 are arranged side by side. Optionally, the first regeneration zone 3-1 and the second regeneration zone 3-2 are connected at their tops. The first regeneration zone 3-1 and the second regeneration zone 3-2 are provided with gas-solid separators 3-41 and 3-42, respectively. The upper end of the regenerator partition 3-3 is located higher than the solid outlets of the gas-solid separators 3-41 and 3-42.

[0078] In this preferred embodiment, as shown in FIG. 13, the first spent catalyst from the first stripping section 2-2 is introduced into the first regeneration zone 3-1 through the first spent catalyst supply pipe 202, where it reacts with the main air from the bottom of the first regeneration zone 3-1 to undergo a regeneration reaction. The resulting first regenerated catalyst is introduced into the first reaction zone 1-1 through the first regenerated catalyst supply pipe 302 and reused. The regenerated exhaust gas 304A is discharged from the regenerator through the gas collection chamber 3-5. The second spent catalyst from the second stripping section 2-4 is introduced into the second regeneration zone 3-2 through the second spent catalyst supply pipe 206, where it reacts with the main air from the bottom of the second regeneration zone 3-2 to undergo a regeneration reaction. The resulting second regenerated catalyst is introduced into the second reaction zone 1-2 through the second regenerated catalyst supply pipe 303 and reused. The regenerated exhaust gas 304A is discharged from the regenerator through the gas collection chamber 3-5.

[0079] In a second aspect, there is provided the use of the fluid catalytic conversion system of the present application for the catalytic conversion of hydrocarbon oils, particularly for the catalytic conversion of heavy feedstocks to produce light olefins.

[0080] In a third aspect, there is provided a method for catalytically converting hydrocarbon oils, particularly heavy feedstocks, using the fluid catalytic conversion system of the present application, the method comprising the steps of: 1) in a first fluidized bed reactor of a reaction unit of a fluidized catalytic conversion system or in a first reaction zone of a composite fluidized bed reactor, contacting a hydrocarbon oil feedstock with a first catalyst to carry out a first catalytic conversion reaction and obtain a first oil-catalyst mixture; 2) in a second fluidized bed reactor of the reaction unit of the fluidized catalytic conversion system or in a second reaction zone of the combined fluidized bed reactor, contacting the first oil-catalyst mixture with a second catalyst to carry out a second catalytic conversion reaction to obtain a second oil-catalyst mixture; 3) separating the second oil-catalyst mixture in a catalyst separation unit of the fluid catalytic conversion system to obtain an oil and gas product, a first spent catalyst, and a second spent catalyst; 4) regenerating the first spent catalyst in a first catalyst regenerator or a first regeneration zone of a combined catalyst regenerator of a catalyst regeneration unit of a fluid catalytic conversion system, and returning the resulting first regenerated catalyst to step 1) as the first catalyst; and 5) regenerating the second spent catalyst in a second catalyst regenerator or a second regeneration zone of a combined catalyst regenerator of a catalyst regeneration unit of the fluid catalytic conversion system, and returning the resulting second regenerated catalyst to step 2) as the second catalyst.

[0081] In a preferred embodiment, the particle size and density of the first catalyst are greater than the particle size and density of the second catalyst, respectively.

[0082] In a preferred embodiment, the first catalyst contains 60 to 100 mass%, preferably 80 to 100 mass%, of a heavy oil catalyst and 0 to 40 mass%, preferably 0 to 20 mass%, of a light oil catalyst, and the second catalyst contains 0 to 40 mass%, preferably 0 to 20 mass%, of a heavy oil catalyst and 60 to 100 mass%, preferably 80 to 100 mass%, of a light oil catalyst.

[0083] In a further preferred embodiment, based on the total weight of the heavy oil catalyst, the heavy oil catalyst comprises: 10-80%, preferably 30-60%, of modified or unmodified Y-type molecular sieve; 0-40%, preferably 0-20%, of modified or unmodified β molecular sieve; 0-40%, preferably 0-20%, of modified or unmodified ZSM-5 molecular sieve; 10-80%, preferably 15-60% clay; 10 to 30%, preferably 10 to 20%, of a binder; and 0-40%, preferably 0-20%, of a heat transfer agent, wherein the heat transfer agent is selected from SiO2, MgO, CaO, BaO, and MnO2, or any mixture thereof.

[0084] In a more preferred embodiment, the modified or unmodified Y molecular sieve in the heavy oil catalyst is one or more selected from HY, USY, REUSY, REY, REHY, DASY, and REDASY, or a Y-type molecular sieve obtained by treatment with various metal oxides. Methods for modifying the Y molecular sieve may include impregnation, ion exchange, sol-gel processing, and other methods well known to those skilled in the art. The modified or unmodified ZSM-5 molecular sieve may be one or more selected from ZRP zeolite, phosphorus-containing ZRP zeolite, rare earth-containing ZRP zeolite, phosphorus- and rare earth-containing ZRP zeolite, phosphorus- and alkaline earth metal-containing ZRP zeolite, and phosphorus- and transition metal-containing ZRP zeolite, preferably phosphorus- and rare earth-containing ZRP zeolite. Methods for modifying the ZSM-5 molecular sieve may include impregnation, ion exchange, sol-gel processing, and other methods well known to those skilled in the art. The modified β molecular sieve may be a β molecular sieve modified with phosphorus and a transition metal M, where M may be one or more selected from Fe, Co, Ni, Cu, Mn, Zn, and Sn. The β molecular sieve modified with phosphorus and a transition metal M may be prepared by various methods, such as by introducing phosphorus and a transition metal M during the synthesis of the β molecular sieve, or by introducing phosphorus and a transition metal M after the synthesis of the β molecular sieve through a process including ammonium exchange, phosphorus modification, transition metal M modification, and calcination treatment. The clay may be selected from various clays usable as catalyst components (e.g., kaolin, montmorillonite, bentonite). The binder may be one selected from silica sol, aluminum sol, and pseudoboehmite, or a mixture of two or three selected from silica sol, aluminum sol, and pseudoboehmite. A preferred binder is a dialuminum binder of alumina sol and pseudoboehmite.

[0085] In a preferred embodiment, based on the total weight of the gas oil catalyst, the gas oil catalyst comprises: 10-60%, preferably 20-50%, of modified or unmodified ZSM-5 molecular sieve; 0-40%, preferably 0-20%, of modified or unmodified Y molecular sieve; 0-40%, preferably 0-20%, of modified or unmodified β-structure molecular sieves; 10-80%, preferably 20-70% clay; 10 to 30%, preferably 10 to 20%, of a binder; and 0-40%, preferably 0-20%, of a heat transfer agent, wherein the heat transfer agent is selected from SiO2, MgO, CaO, BaO, and MnO2, or any mixture thereof.

[0086] In a more preferred embodiment, the modified or unmodified ZSM-5 molecular sieve in the diesel catalyst may be one or more selected from ZRP zeolites, phosphorus-containing ZRP zeolites, rare earth-containing ZRP zeolites, phosphorus- and rare earth-containing ZRP zeolites, phosphorus- and alkaline earth metal-containing ZRP zeolites, and phosphorus- and transition metal-containing ZRP zeolites, preferably phosphorus- and rare earth-containing ZRP zeolites. Modification methods for ZSM-5 molecular sieves include impregnation, ion exchange, sol-gel, and other methods known to those skilled in the art. The modified or unmodified Y molecular sieve may be one or more selected from HY, USY, REUSY, REY, REHY, DASY, REDASY, and Y-type molecular sieves obtained by treatment with various metal oxides. Modification methods for Y molecular sieves include impregnation, ion exchange, sol-gel, and other methods known to those skilled in the art. The modified β molecular sieve may be a β molecular sieve modified with phosphorus and a transition metal M, where M is one or more selected from Fe, Co, Ni, Cu, Mn, Zn, and Sn. The β molecular sieve modified with phosphorus and a transition metal M can be produced by various methods, such as by introducing phosphorus and a transition metal M during the synthesis of the β molecular sieve, or by introducing phosphorus and a transition metal M after the synthesis of the β molecular sieve through a process including ammonium exchange, phosphorus modification, transition metal M modification, and calcination treatment. The clay may be selected from various clays usable as catalyst components (e.g., kaolin, montmorillonite, bentonite). The binder may be one or a mixture of two or three selected from silica sol, alumina sol, and pseudoboehmite. A preferred binder is a dialuminum binder of alumina sol and pseudoboehmite.

[0087] In a further preferred embodiment, for heavy oil catalyst, the particle size range is 60-250 μm, preferably 80-200 μm, and the particle density is 1200-1600 kg / m 3 , preferably 1300 to 1500 kg / m 3 and for diesel catalyst, the particle size range is 10-100 μm, preferably 30-80 μm, and the particle density is 800-1200 kg / m 3, preferably 900 to 1100 kg / m 3 is.

[0088] In certain preferred embodiments, the first fluidized bed reactor or the first reaction zone of the combined fluidized bed reactor is of the riser reactor type, and the reaction conditions include a reaction temperature of 520-620°C, preferably 540-600°C, a catalyst-to-oil ratio of 2-25, preferably 3-20, and a reaction time of 1-15 seconds, preferably 2-10 seconds; and / or the second fluidized bed reactor or the second reaction zone of the combined fluidized bed reactor is of the dense phase bed reactor type, and the reaction conditions include a reaction temperature of 540-640°C, preferably 560-620°C, a catalyst-to-oil ratio of 20-300 kg / m 3 , preferably 100 to 200 kg / m 3 Catalyst distribution density, 2~15h -1 , preferably 5 to 10 hours -1 space velocity of 0.2 to 8 seconds, preferably 1 to 4 seconds, including oil and gas residence times.

[0089] In another preferred embodiment, the first fluidized bed reactor or the first reaction zone of the combined fluidized bed reactor is a type of fast bed reactor, and the reaction conditions include a reaction temperature of 520-620°C, preferably 540-600°C, a reagent-to-oil ratio of 2-25, preferably 3-20, and a reaction time of 1-15 seconds, preferably 2-10 seconds; and / or the second fluidized bed reactor or the second reaction zone of the combined fluidized bed reactor is a type of fast bed reactor, and the reaction conditions include a reaction temperature of 540-640°C, preferably 560-620°C, a reagent-to-oil ratio of 3-30, preferably 5-25, and a reaction time of 1-10 seconds, preferably 2-8 seconds.

[0090] In a preferred embodiment, the first catalyst regenerator or the first regeneration zone of the composite catalyst regenerator employs partial regeneration, and the second catalyst regenerator or the second regeneration zone of the composite catalyst regenerator employs complete regeneration. The partially regenerated exhaust gas produced in the first catalyst regenerator or the first regeneration zone of the composite catalyst regenerator is introduced into the second catalyst regenerator or the second regeneration zone of the composite catalyst regenerator to continue the regeneration reaction.

[0091] In a preferred embodiment, the regeneration conditions in the first catalyst regenerator or the first regeneration zone of the composite catalyst regenerator are a regeneration temperature of 640 to 700°C, preferably 660 to 680°C, a feed rate of 50 to 400 kg / m 3 , preferably 100 to 300 kg / m 3 and a main air residence time of 0.5 to 20 seconds, preferably 2 to 10 seconds.

[0092] In a preferred embodiment, the regeneration conditions in the second catalyst regenerator or the second regeneration zone of the composite catalyst regenerator are a regeneration temperature of 670-730°C, preferably 690-710°C, a feed rate of 30-350 kg / m 3 , preferably 80 to 250 kg / m 3 and a main air residence time of 0.5 to 15 seconds, preferably 2 to 10 seconds.

[0093] In a preferred embodiment, the heavy feedstock is selected from vacuum gas oil, atmospheric residue, vacuum residue, coker gas oil, deasphalted oil, furfural refinery raffinate oil, coal liquid oil, asphalt, shale oil, Fischer-Tropsch synthetic distillate oil, animal oil, vegetable oil, crude oil, biomass oil, or mixtures thereof.

[0094] A more detailed description of certain embodiments of the catalytic conversion process according to the third aspect of the present application is provided below.

[0095] First Type of Embodiment In a first particular embodiment, the catalytic conversion method comprises the steps of: 1) contacting a heavy feedstock with a first catalyst in a first reactor / reaction zone of the riser reactor type to carry out a first catalytic conversion reaction to obtain a first oil-catalyst mixture; 2) introducing the first oil-catalyst mixture into a second reactor / reaction zone of the dense phase bed reactor type and contacting it with a second catalyst to undergo a second catalytic conversion reaction to obtain a second oil-catalyst mixture; 3) subjecting the second oil-catalyst mixture to gas-solid separation and steam stripping in a separation device to obtain an oil-gas product and a mixed spent catalyst; 4) introducing the mixed spent catalyst into a catalyst separator outside the separation device and separating the mixed spent catalyst into a first spent catalyst and a second spent catalyst, wherein the catalyst separator comprises a first stage catalyst separator and a second stage catalyst separator; 5) performing a first regeneration on the first spent catalyst, returning it to step 1) as the first catalyst and participating in the first catalytic conversion reaction; and performing a second regeneration on the second spent catalyst, returning it to step 2) as the second catalyst and participating in the second catalytic conversion reaction.

[0096] In this type of embodiment, all of the materials that have undergone the first catalytic conversion in the first reactor / reaction zone (including the first catalyst, reaction oil and gas, and fluidization medium) enter the second reactor / reaction zone and undergo the second catalytic conversion reaction without being separated or contacting the second catalyst, i.e., the first catalytic conversion reaction and the second catalytic conversion reaction may be carried out in a relay manner.

[0097] In certain preferred embodiments, the reaction conditions in the first reactor / reaction zone include a reaction temperature of 520-620°C, preferably 540-600°C; a catalyst-to-oil ratio of 2-25, preferably 3-20; and a reaction time of 1-15 seconds, preferably 2-10 seconds. Optionally, the heavy feedstock can be preheated to 180-340°C and then injected into the first reactor / reaction zone through a nozzle.

[0098] In certain preferred embodiments, the reaction conditions in the second reactor / reaction zone are a reaction temperature of 540-640°C, preferably 560-620°C, a flow rate of 20-300 kg / m 3 , preferably 100 to 200 kg / m 3 Catalyst distribution density, 2~15h -1 , preferably 5 to 10 hours -1 space velocity; oil and gas residence time of 0.2 to 8 seconds, preferably 1 to 4 seconds.

[0099] Optionally, the catalytic conversion process further comprises the step of introducing a prelifting gas into the bottom of the first reactor / reaction zone, the prelifting gas may be selected from one or more of steam, nitrogen, and dry gas, preferably steam.

[0100] In a preferred embodiment, as shown in Figure 14, the fluidized catalytic conversion system includes a composite fluidized-bed reactor having a first reaction zone 1-1 in the form of a riser reactor and a second reaction zone 1-2 in the form of a dense-phase bed reactor; a separation device having a settling zone 2-1, a stripping section 2-2, and a cyclone separator 2-7; and a composite catalyst regenerator having a first regeneration zone 3-1 and a second regeneration zone 3-2. The outlet of the first reaction zone 1-1 is connected to the inlet of the second reaction zone 1-2. The second reaction zone 1-2 is disposed within the settling zone 2-1 of the separation device and is located below the settling zone. The bottom of the second reaction zone 1-2 is connected to the stripping section 2-2. The inlet of the cyclone separator 2-7 is located at the top of the separation device. The catalyst outlet of the cyclone separator 2-7 allows the catalyst therein to flow into the stripping section 2-2. The oil and gas outlets of the cyclone separator 2-7 are connected to the oil-gas separation system. The catalytic conversion system also includes a first-stage catalyst separator 2-51 and a second-stage catalyst separator 2-52. The inlet of the first-stage catalyst separator 2-51 is connected to the stripping section 2-2 via a spent catalyst supply pipe 200. The first material outlet of the first-stage catalyst separator 2-51 is connected to the first regeneration zone 3-1 via a first spent catalyst supply pipe 202. The light material outlet of the first-stage catalyst separator 2-51 is connected to the inlet of the second-stage catalyst separator 2-52 via a light material supply pipe 204. The second material outlet of the second-stage catalyst separator 2-52 is connected to the second regeneration zone 3-2 via a second spent catalyst supply pipe 206. The residual oil and gas outlet of the second-stage catalyst separator 2-52 is connected to the top of the separation apparatus via an oil and gas supply pipe 207. The catalyst supply rate can be adjusted by a valve in the catalyst supply pipe. The first regeneration zone 3-1 and the second regeneration zone 3-2 of the composite catalyst regenerator are arranged in series, with a regenerator partition 3-3 installed between them. The incompletely regenerated exhaust gas generated in the first regeneration zone 3-1 is introduced into the second regeneration zone 3-2, where the regeneration reaction continues.The resulting regenerated exhaust gas 304A is separated from the catalyst by a cyclone separator 3-41 and then flows into the downstream exhaust gas treatment system through the discharge device of the gas collection chamber 3-5. The first regenerated catalyst outlet of the first regenerated zone 3-1 is connected to the bottom of the first reaction zone 1-1 via a first regenerated catalyst supply pipe 302. The second regenerated catalyst outlet of the second regenerated zone 3-2 is connected to the bottom of the second reaction zone 1-2 via a second regenerated catalyst supply pipe 303. The catalyst supply rate can be adjusted by a valve in the catalyst supply pipe.

[0101] In a particularly preferred embodiment, in the catalytic conversion method, heavy feedstock 101 is preheated to 180-340°C. Then, it is injected into first reaction zone 1-1 through a nozzle and contacts and reacts with a first catalyst introduced into the bottom of first reaction zone 1-1 through first regenerated catalyst supply pipe 302 under conditions of a reaction temperature of 520-620°C, preferably 540-600°C, a catalyst-to-oil ratio of 2-25, preferably 3-20, and a reaction time of 1-15 seconds, preferably 2-10 seconds. The first oil-catalyst mixture after the reaction is introduced into second reaction zone 1-2 and contacts and reacts with a second catalyst introduced into second reaction zone 1-2 through second regenerated catalyst supply pipe 303 under conditions of a reaction temperature of 540-640°C, preferably 560-620°C, and a catalyst density of 20-300 kg / m. 3 , preferably 100 to 200 kg / m 3 , space velocity is 2~15h -1 , preferably 5 to 10 hours -1, and the oil and gas contact and react under conditions of a residence time of 0.2 to 8 seconds, preferably 1 to 4 seconds. The second oil-catalyst mixture after the reaction is separated by a cyclone separator 2-7, and the resulting reaction oil and gas 208 is collected by a gas collection chamber 2-8 and introduced into a subsequent product separation system. The resulting spent catalyst is introduced into the stripping section 2-2 and stripped. The mixed spent catalyst after stripping is introduced into the first-stage catalyst separator 2-51 via the spent catalyst supply pipe 200. The separated first spent catalyst is introduced into the first regeneration zone 3-1 via the first spent catalyst supply pipe 202. The regeneration temperature is 640 to 700°C, preferably 660 to 680°C, and the catalyst density is 50 to 400 kg / m 3 , preferably 100 to 300 kg / m 3 The separated first spent catalyst is brought into contact with main air 301A introduced into the first regeneration zone 3-1 under conditions of a main air residence time of 0.5 to 20 seconds, preferably 2 to 10 seconds, and a regeneration reaction takes place. Incomplete regeneration takes place in the first reaction zone 3-1. The resulting incompletely regenerated exhaust gas is introduced into the second reaction zone 3-2 through a regeneration buff 3-3. The resulting first regenerated catalyst is introduced into the bottom of the first reaction zone 1-1 through a first regenerated catalyst supply pipe 302 and reused. The light materials separated by the first catalyst separator 2-51 are introduced into the second catalyst separator 2-52 via a gas-solid mixture supply pipe 204. The separated second regenerated catalyst is introduced into the second regenerated zone 3-2 through the second regenerated catalyst supply pipe 206, where it comes into contact with the incompletely regenerated exhaust gas from the first regenerated zone 3-1, and is heated to a regeneration temperature of 670 to 730°C, preferably 690 to 710°C, and a catalyst density of 30 to 350 kg / m 3 , preferably 80 to 250 kg / m 3The regeneration reaction is carried out under conditions of a main air residence time of 0.5 to 15 seconds, preferably 2 to 10 seconds. Complete regeneration is carried out in the second reaction zone 3-2. The resulting fully regenerated exhaust gas 304A is separated from the catalyst by a cyclone separator 3-41, collected in a gas collection chamber 3-5, and introduced into the regenerated exhaust gas treatment system. The resulting second regenerated catalyst is introduced into the bottom of the second reaction zone 1-2 through a second regenerated catalyst supply pipe 303 and recycled. The residual oil and gas separated by the second-stage catalyst separator 2-52 is introduced into the separation device through an oil and gas supply pipe 207 and mixed with the reaction oil and gas 208 before being introduced into the subsequent product separation system. The reaction oil and gas 208 enters the subsequent product separation system. In the product separation system, the catalytic cracking products are separated into products such as dry gas, cracked gas, gasoline, diesel, and oil slurry. The cracked gas is then subjected to product separation and purification to obtain polymerization-grade propylene product and C4-C8 hydrocarbon mixture. The stripping vapor from the stripping section 2-2 directly enters the settling zone 2-1 and is separated together with other oils and gases by the cyclone separator 2-7, and then discharged from the separator with the reacted oil and gas 208.

[0102] Second Type of Embodiment The catalytic conversion method of the second type of embodiment comprises the steps of: 1) contacting a heavy feedstock with a first catalyst in a first reactor / reaction zone of the fast bed reactor type to carry out a first catalytic conversion reaction to obtain a first oil-catalyst mixture; 2) introducing the first oil-catalyst mixture into a second reactor / reaction zone of the fast bed reactor type and contacting it with a second catalyst to undergo a second catalytic conversion reaction to obtain a second oil-catalyst mixture; 3) introducing the second oil-catalyst mixture into a catalyst separator in a separator and separating the second oil-catalyst mixture to obtain a first spent catalyst and a third oil-catalyst mixture; 4) separating and stripping the third oil mixture to obtain a reaction oil and gas, a stripping product, and a second spent catalyst; 5) subjecting the first spent catalyst to a first stripping and a first regeneration treatment, and then returning it to step 1) as a first catalyst to participate in a first catalytic conversion reaction; and subjecting the second spent catalyst to a second stripping and a second regeneration treatment, and then returning it to step 2) as a second catalyst to participate in a second catalytic conversion reaction.

[0103] In this type of embodiment, all of the materials that have undergone the first catalytic conversion in the first reactor / reaction zone (including the first catalyst, reaction oil and gas, and fluidization medium) enter the second reactor / reaction zone without separation and contact the second catalyst to undergo the second catalytic conversion reaction, i.e., the first catalytic conversion reaction and the second catalytic conversion reaction may be carried out in a relay manner.

[0104] In certain preferred embodiments, the reaction conditions in the first reactor / reaction zone include a reaction temperature of 520-620°C, preferably 540-600°C; a catalyst-to-oil ratio of 2-25, preferably 3-20; and a reaction time of 1-15 seconds, preferably 2-10 seconds. Optionally, the heavy feedstock can be preheated to 180-340°C and then injected into the first reactor / reaction zone through a nozzle.

[0105] In certain preferred embodiments, the reaction conditions in the second reactor / reaction zone include a reaction temperature of 540-640°C, preferably 560-620°C; a catalyst-to-oil ratio of 3-30, preferably 5-25; and a reaction time of 1-10 seconds, preferably 2-8 seconds.

[0106] Optionally, the catalytic conversion process further comprises the step of introducing a prelifting gas into the bottom of the first reactor / reaction zone, wherein the prelifting gas can be one or more selected from steam, nitrogen, and dry gas, preferably steam.

[0107] In a particularly preferred embodiment, as shown in Figure 15, a fluidized catalytic conversion system includes a composite fluidized-bed reactor having a first reaction zone 1-1 in the form of a fast-bed reactor and a second reaction zone 1-2 in the form of a fast-bed reactor; a separator having a first settling zone 2-1 and a second settling zone 2-3; and a composite catalyst regenerator having a first regeneration zone 3-1 and a second regeneration zone 3-2. The outlet of the first reaction zone 1-1 is connected to the inlet of the second reaction zone 1-2, and the outlet of the second reaction zone 1-2 is connected to a catalyst separator 2-50 within the separator. The catalyst separator 2-50 is located within the separator. A separator partition 2-6 separates the first and second settling zones 2-1 and 2-3. The first material outlet of the catalyst separator 2-50 is located within the first settling zone 2-1. The second material outlet is located within the second settling zone 2-3. A cyclone separator 2-7 is also provided in the separation apparatus to separate the catalyst contained in the reaction oil and gas. The inlet of the cyclone separator 2-7 is located at the top of the second settling zone 2-3. The catalyst outlet of the cyclone separator 2-7 is positioned so that the catalyst therein enters the second settling zone 2-3. The oil and gas outlets of the cyclone separator 2-7 are connected to an oil-gas separation system. The resulting reaction oil and gas 208 are discharged from the apparatus. The bottom of the first settling zone 2-1 is connected to the first stripping section 2-2. After being stripped in the first stripping section 2-2, the first spent catalyst is introduced into the first regeneration zone 3-1 through the first spent catalyst supply pipe 202 for regeneration. The bottom of the second settling zone 2-3 is connected to the second stripping section 2-4. After being stripped in the second stripping section 2-4, the second spent catalyst is introduced into the second regeneration zone 3-2 through the second spent catalyst supply pipe 206 for regeneration. The first regeneration zone 3-1 and the second regeneration zone 3-2 of the composite catalyst regenerator are arranged in series. A regenerator partition 3-3 is arranged between them, and a first regeneration exhaust gas outlet is arranged above it. Incompletely regenerated exhaust gas produced in the first regeneration zone 3-1 is introduced into the second regeneration zone 3-2 for continuous regeneration reaction.The resulting regenerated exhaust gas 304A is separated from the catalyst carried by the cyclone separator 3-41 and then flows into the subsequent exhaust gas treatment system through the outlet device of the gas collection chamber 3-5. The first regenerated catalyst outlet of the first regenerated zone 3-1 is connected to the bottom of the first reaction zone 1-1 via a first regenerated catalyst supply pipe 302. The second regenerated catalyst outlet of the second regenerated zone 3-2 is connected to the bottom of the second reaction zone 1-2 via a second regenerated catalyst supply pipe 303. The catalyst supply rate can be adjusted by a valve in the catalyst supply pipe.

[0108] In a preferred embodiment, in the catalytic conversion process, heavy feedstock 101 is preheated to 180-340°C and then injected into first reaction zone 1-1 via a nozzle. The first catalyst is introduced into the bottom of first reaction zone 1-1 via first regenerated catalyst supply pipe 302. The resulting oil-catalyst mixture is then introduced into second reaction zone 1-2, where it is contacted and reacted with second catalyst introduced into second reaction zone 1-2 via second regenerated catalyst supply pipe 303 under the following conditions: reaction temperature: 540-640°C, preferably 560-620°C; catalyst-to-oil ratio: 3-30, preferably 5-25; and reaction time: 1-10 seconds, preferably 2-8 seconds. The second oil-catalyst mixture after the reaction is introduced into the catalyst separator 2-50 and separated into a first spent catalyst and a third oil-catalyst mixture. The first spent catalyst is introduced through the first settling zone 2-1 into the first stripping section 2-2 and stripped. The stripped first spent catalyst is introduced into the first regeneration zone 3-1 through the first spent catalyst supply pipe 202 and regenerated. The regenerated first catalyst is introduced into the bottom of the first reaction zone 1-1 through the first catalyst supply pipe 302. The third oil-catalyst mixture is separated in the cyclone separator 2-7 in the second settling zone 2-3 to obtain oil and gas products and a second regenerated catalyst. The second spent catalyst is introduced through the second settling zone 2-3 into the second stripping section 2-4 and stripped. The stripped second spent catalyst is introduced into the second regeneration zone 3-2 via the second spent catalyst supply pipe 206 and regenerated. The regenerated second catalyst is introduced into the bottom of the second reaction zone 1-2 via the second catalyst supply pipe 303. Main air 301A is introduced into the first regeneration zone 3-1 and mixed with the first spent catalyst introduced into the first regeneration zone 3-1 at a regeneration temperature of 640 to 700°C, preferably 660 to 680°C; and a catalyst density of 50 to 400 kg / m 3 , preferably 100 to 300 kg / m 3The regeneration reaction is carried out by contacting the catalyst with the main air under the conditions of a main air residence time of 0.5 to 20 seconds, preferably 2 to 10 seconds. The incomplete regeneration is carried out in the first regeneration zone 3-1. The resulting incompletely regenerated exhaust gas is introduced into the second regeneration zone 3-2 through the regenerator partition 3-3, where the regeneration temperature is 670 to 730°C, preferably 690 to 710°C, and the catalyst density is 30 to 350 kg / m. 3 , preferably 80 to 250 kg / m 3 The regeneration reaction is carried out under the condition of a main air residence time of 0.5 to 15 seconds, preferably 2 to 10 seconds. Full regeneration is carried out in the second regeneration zone 3-2. The resulting fully regenerated exhaust gas 304A is separated from the transported catalyst by a cyclone separator 3-41, then collected by a gas collection chamber 3-5 and introduced into the regeneration exhaust gas treatment system. The reaction oil and gas 208 then enters the product separation system, where the catalytic cracking products are separated into products such as dry gas, cracked gas, gasoline, diesel, and oil slurry. The cracked gas then undergoes product separation and purification to obtain polymerization-grade ethylene and propylene products and a C4-C8 hydrocarbon mixture. The stripping vapors from the first stripping section 2-2 and the second stripping section 2-4, as well as the residual oil and gas, can directly enter the second settling zone 2-3. After being separated from the other oil and gas by the cyclone separator 2-7, the stripping vapor and residual oil and gas are discharged from the separator with the reacted oil and gas 208.

[0109] In certain preferred embodiments, the present application provides the following technical solutions: 1. A catalytic conversion system having a reactor and a catalyst separator arranged in series, The catalytic conversion system includes a first upflow-bed reactor, a second upflow-bed reactor, a separation device, a catalyst separator, and a regenerator; the first upflow-bed reactor has a first catalyst inlet and a first oil-catalyst mixture outlet; the second upflow-bed reactor has a second catalyst inlet and a second oil-catalyst mixture outlet; the first oil-catalyst mixture outlet is connected to the lower part of the second upflow-bed reactor; the separation device has an oil-catalyst mixture inlet and a mixed spent catalyst outlet, the oil-catalyst mixture inlet connected to the second oil-catalyst mixture outlet; the catalyst separator having a material inlet connected to the mixed spent catalyst outlet, a first spent catalyst outlet, and a second spent catalyst outlet; A regenerator partition is provided within the regenerator, and the regenerator partition divides the regenerator into a first regeneration zone and a second regeneration zone; a first spent catalyst is transported and connected between the first spent catalyst outlet and the first regeneration zone; a second spent catalyst is transported and connected between the second spent catalyst outlet and the second regeneration zone; a first regenerated catalyst is transported and connected between the first regeneration zone and the first upflow bed reactor; and a second regenerated catalyst is transported and connected between the second regeneration zone and the second upflow bed reactor.

[0110] 2. In the catalytic conversion system described in item 1, the first upflow reactor has an upflow first catalyst; the second upflow reactor has an upflow second catalyst and an upflow first catalyst; the particle size and density of the first catalyst are larger than those of the second catalyst; and the outlet of the first spent catalyst is located lower than the outlet of the second spent catalyst.

[0111] 3. In the catalytic conversion system described in item 1 or 2, a first feedstock oil inlet and a bed material inlet are further provided at the bottom of the first upflow bed reactor, and a second feedstock oil inlet is further provided at the bottom of the second upflow bed reactor.

[0112] 4. In the catalytic conversion system according to item 1 or 2, the first upflow bed reactor and the second upflow bed reactor are each independently a riser reactor, a fast bed reactor, or a fluidized bed reactor.

[0113] 5. In the catalytic conversion system described in item 1 or 2, the catalyst separator is disposed outside the separation device, and a part or all of the second upflow bed reactor is disposed within the separation device.

[0114] 6. In the catalytic conversion system according to item 1 or 2, the catalyst separator is one or more combinations selected from a cyclone type high-speed separator, a trilobe type high-speed separator, a ballistic high-speed separator, a U-tube separator, and a wall-cutting high-speed separator, and is preferably a cyclone type high-speed separator; The number of the catalyst separators connected to the outside of each of the separation devices is one or more, and the plurality of catalyst separators are connected in series and / or in parallel.

[0115] 7. In the catalytic conversion system described in item 6, the separation device is externally connected to a first-stage catalyst separator, the lower part of which is provided with a first spent catalyst discharge port, and the upper part of which is provided with a light material outlet; the light material outlet is connected to the material inlet of a second-stage catalyst separator; the upper part of the second-stage catalyst separator is provided with a residual reaction oil and gas outlet, and the lower part of the second-stage catalyst separator is provided with a second spent catalyst outlet.

[0116] 8. In the catalytic conversion system according to item 1 or 2, a stripper is provided at the bottom of the separation device, an oil and gas product outlet is provided at the top of the separation device, and a gas-solid separation device is further provided inside the separation device.

[0117] 9. In the catalytic conversion system according to item 1 or 2, the first regeneration zone and the second regeneration zone are arranged in series, one above the other, with the first regeneration zone being located below the second regeneration zone.

[0118] 10. The catalytic conversion system according to item 9, wherein a first regeneration exhaust gas outlet is provided above the regenerator partition.

[0119] 11. A catalytic conversion system, comprising: a first upflow-bed reactor, a second upflow-bed reactor, a separator, and a regenerator; the first upflow-bed reactor has a first catalyst inlet and a first oil-catalyst mixture outlet; the second upflow-bed reactor has a second catalyst inlet and a second oil-catalyst mixture outlet; and the first oil-catalyst mixture outlet is connected to a lower portion of the second upflow-bed reactor; the separation device includes a settling zone divider and a catalyst separator, the settling zone divider dividing the settling zone into a first settling zone and a second settling zone, the catalyst separator having a material inlet connected to the second oil-catalyst mixture outlet, a first material outlet opening into the first settling zone, and a second material outlet opening into the second settling zone; The regenerator is provided with a regenerator partition, which divides the regenerator into a first regeneration zone and a second regeneration zone in parallel; a first spent catalyst is transported and connected between the first settling zone and the first regeneration zone; a second spent catalyst is transported and connected between the second settling zone and the second regeneration zone; a first regenerated catalyst is transported and connected between the first regeneration zone and the first upflow bed reactor; and a second regenerated catalyst is transported and connected between the second regeneration zone and the second upflow bed reactor.

[0120] 12. In the catalytic conversion system described in Item 11, the first upflow reactor has an upflow first catalyst, the second upflow reactor has an upflow second catalyst and an upflow first catalyst, the particle size and density of the first catalyst are larger than the particle size and density of the second catalyst, the first settling zone is located below the settling zone partition, and the second settling zone is located above the settling zone partition.

[0121] 13. In the catalytic conversion system according to item 11 or 12, the lower part of the first upflow reactor is further provided with a first feedstock oil inlet and a bed material inlet, and the lower part of the second upflow reactor is further provided with a second feedstock oil inlet.

[0122] 14. In the catalytic conversion system according to item 11 or 12, the first upflow bed reactor and the second upflow bed reactor are each independently a riser reactor, a fast bed reactor, or a fluidized bed reactor.

[0123] 15. In the catalytic conversion system described in Item 11 or 12, the catalyst separator is fixed on a partition of the settling zone, and part or all of the second upflow bed reactor is disposed within the first settling zone or the second settling zone.

[0124] 16. In the catalytic conversion system according to item 11 or 12, the catalyst separator is any one or more combinations of a cyclone high-speed separator, a trilobe high-speed separator, a ballistic high-speed separator, a U-tube separator, and a wall-cutting high-speed separator, preferably a cyclone high-speed separator; The number of the catalyst separators in each of the separation devices is one or more, and the plurality of catalyst separators are connected in series and / or parallel.

[0125] 17. The catalytic conversion system according to item 11 or 12, wherein a second stripper is provided at the bottom of the second settling zone, and a second stripping material inlet is provided at the top of the second settling zone.

[0126] 18. The catalytic conversion system according to item 17, wherein a first stripper is provided in the first spent catalyst transport connection, and a first stripping material outlet is provided at the top of the first stripper.

[0127] 19. In the catalytic conversion system according to item 11 or 12, the first regeneration zone and the second regeneration zone are arranged side by side.

[0128] 20. In the catalytic conversion system described in Item 19, the upper portions of the first regeneration zone and the second regeneration zone are connected, and the first regeneration zone and the second regeneration zone each include a gas-solid separator, and the upper end of the regenerator partition is higher than the solid outlet of the gas-solid separator.

[0129] 21. A catalytic conversion process for producing light olefins, the catalytic conversion process comprising the steps of: 1) contacting a heavy feedstock with a first catalyst in a riser reactor to carry out a first catalytic conversion reaction to obtain a first oil-catalyst mixture; 2) introducing the first oil-catalyst mixture into a fluidized bed reactor and contacting it with a second catalyst to carry out a second catalytic conversion reaction to obtain a second oil-catalyst mixture; 3) subjecting the second oil-catalyst mixture to gas-solid separation and stripping in a separator to obtain an oil and gas product and a mixed spent catalyst; 4) introducing the mixed spent catalyst into a catalyst separation device and separating it to obtain a first spent catalyst and a second spent catalyst, wherein the catalyst separation device comprises a first stage catalyst separator and a second stage catalyst separator; 5) subjecting the first spent catalyst to a first regeneration, returning it to step 1) as a first catalyst and participating in a first catalytic conversion reaction, and subjecting the second spent catalyst to a second regeneration, returning it to step 2) as a second catalyst and participating in a second catalytic conversion reaction.

[0130] 22. The catalytic conversion process according to item 21, wherein the particle size and density of the first catalyst are greater than the particle size and density of the second catalyst.

[0131] 23. The catalytic conversion method according to item 21, wherein the first catalyst contains 60 to 100 mass% of a heavy oil catalyst and 0 to 40 mass% of a light oil catalyst; and the second catalyst contains 0 to 40 mass% of a heavy oil catalyst and 60 to 100 mass% of a light oil catalyst; Preferably, the first catalyst contains 80 to 100 mass % of a heavy oil catalyst and 0 to 20 mass % of a light oil catalyst, and the second catalyst contains 0 to 20 mass % of a heavy oil catalyst and 80 to 100 mass % of a light oil catalyst.

[0132] 24. The catalytic conversion method according to item 23, wherein the heavy oil catalyst comprises a modified or unmodified Y-type molecular sieve, a clay, a binder, an optional modified or unmodified β-molecular sieve, an optional modified or unmodified ZSM-5 molecular sieve, and an optional heat transfer agent; Based on the total weight of the heavy oil catalyst, the content of the modified or unmodified Y-type molecular sieve is 10-80%, preferably 30-60%, the content of the clay is 10-80%, preferably 15-60%, the content of the binder is 10-30%, preferably 10-20%, the content of the modified or unmodified β-type molecular sieve is 0-40%, preferably 0-20%, the content of the modified or unmodified ZSM-5-type molecular sieve is 0-40%, preferably 0-20%, and the content of the heat transfer agent is 0-40%, preferably 0-20%, and the heat transfer agent is one or more mixtures selected from SiO2, MgO, CaO, BaO, and MnO2; The particle size of the heavy oil catalyst is in the range of 60 to 250 μm, preferably 80 to 200 μm, and the particle density is 1200 to 1600 kg / m 3 , preferably 1300 to 1500 kg / m 3 is within the range.

[0133] 25. The catalytic conversion process according to item 23 or 24, wherein the gas oil catalyst comprises modified or unmodified ZSM-5 molecular sieve, clay, binder, optionally modified or unmodified Y molecular sieve, optionally modified or unmodified β molecular sieve, and optionally a heat transfer agent; Based on the total weight of the catalyst, the content of the modified or unmodified ZSM-5 molecular sieve is 10-60%, preferably 20-50%, the content of the clay is 10-80%, preferably 20-70%, the content of the binder is 10-30%, preferably 10-20%, the content of the modified or unmodified Y molecular sieve is 0-40%, preferably 0-20%, the content of the modified or unmodified β molecular sieve is 0-40%, preferably 0-20%, the content of the heat transfer agent is 0-40%, preferably 0-20%, and the heat transfer agent is one or more mixtures selected from SiO2, MgO, CaO, BaO, and MnO2; The particle size of the diesel catalyst is in the range of 10 to 100 μm, preferably 30 to 80 μm, and the particle density is 800 to 1200 kg / m 3 , preferably 900 to 1100 kg / m 3 is.

[0134] 26. The catalytic conversion method according to item 21, wherein the first regeneration zone and the second regeneration zone are arranged in series, the first regeneration zone employs incomplete regeneration, and the second regeneration zone employs complete regeneration, and the incompletely regenerated exhaust gas produced in the first regeneration zone is introduced into the second regeneration zone to continue the regeneration reaction.

[0135] 27. The catalytic conversion method according to item 21, wherein the regeneration temperature of the first regeneration zone is 640 to 700°C, preferably 660 to 680°C, and the catalyst distribution density is 50 to 400 kg / m 3 , preferably 100 to 300 kg / m 3 and the main air residence time is 0.5 to 20 seconds, preferably 2 to 10 seconds; The regeneration temperature of the second regeneration zone is 670 to 730°C, preferably 690 to 710°C, and the catalyst distribution density is 30 to 350 kg / m 3 , preferably 80 to 250 kg / m 3 and the main air residence time is 0.5 to 15 seconds, preferably 2 to 10 seconds.

[0136] 28. The catalytic conversion method according to item 21, wherein the reaction temperature in the riser reactor is 520 to 620°C, preferably 540 to 600°C; the catalyst-to-oil ratio is 2 to 25, preferably 3 to 20; and the reaction time is 1 to 15 seconds, preferably 2 to 10 seconds; The reaction temperature of the fluidized bed reactor is 540 to 640°C, preferably 560 to 620°C; and the catalyst distribution density is 20 to 300 kg / m 3 , preferably 100 to 200 kg / m 3 and the space velocity is 2 to 15 h -1 , preferably 5 to 10 hours -1 and the residence time of the oil and gas is 0.2 to 8 seconds, preferably 1 to 4 seconds.

[0137] 29. The catalytic conversion process according to Item 21, wherein the heavy feedstock is selected from any one of vacuum gas oil, atmospheric residue, vacuum residue, coker gas oil, deasphalted oil, furfural refinery raffinate oil, coal liquid oil, asphalt, shale oil, Fischer-Tropsch synthetic distillate oil, animal and vegetable oils, crude oil, and biomass oil, or a mixture thereof.

[0138] 30. A catalytic conversion system, comprising: a riser reactor, a fluidized bed reactor, a separator, a stripper, a catalyst separator, and a regenerator; the upper end of the riser reactor is connected to the lower end of the fluidized bed reactor; an upper end of the fluidized bed reactor connected to a lower end of the separation device; a gas-solid separation device is also provided within the separation device; The lower end of the fluidized bed reactor is also connected to a stripper; the solid outlet of the gas-solid separator is located within the stripper or at an upper portion of the stripper; and the lower portion of the stripper has a mixed spent catalyst outlet; the catalyst separation apparatus comprises a first stage catalyst separator and a second stage catalyst separator, the first stage catalyst separator having a material inlet connected to the mixed spent catalyst outlet, a first spent catalyst outlet, and a gas-solid mixture outlet, the second stage catalyst separator having a material inlet connected to the gas-solid mixture outlet of the first stage catalyst separator, a second spent catalyst outlet, and an oil and gas feed outlet; A regenerator partition is provided within the regenerator, and the regenerator partition divides the regenerator into a first regeneration zone and a second regeneration zone; a first spent catalyst is transported and connected between the first spent catalyst outlet and the first regeneration zone; a second spent catalyst is transported and connected between the second spent catalyst outlet and the second regeneration zone; a first regenerated catalyst is transported and connected between the first regeneration zone and the riser reactor; and a second regenerated catalyst is transported and connected between the second regeneration zone and the fluidized bed reactor.

[0139] 31. A catalytic conversion process for producing ethylene and propylene, the catalytic conversion process comprising the steps of: 1) contacting a heavy feedstock with a first catalyst in a first fast bed reactor to carry out a first catalytic conversion reaction to obtain a first oil-catalyst mixture; 2) introducing the first oil-catalyst mixture into a second fast-bed reactor and contacting it with a second catalyst to carry out a second catalytic conversion reaction to obtain a second oil-catalyst mixture; 3) introducing the second oil-catalyst mixture into a catalyst separation device and separating it to obtain a first spent catalyst and a third oil-catalyst mixture; 4) subjecting the third oil-catalyst mixture to gas-solid separation to obtain an oil and gas product and a second spent catalyst; 5) subjecting the first spent catalyst to a first stripping and a first regeneration treatment, and then returning it to step 1) as a first catalyst to participate in a first catalytic conversion reaction, and subjecting the second spent catalyst to a second stripping and a second regeneration treatment, and then returning it to step 2) as a second catalyst to participate in a second catalytic conversion reaction.

[0140] 32. The catalytic conversion process according to item 31, wherein the particle size and density of the first catalyst are greater than the particle size and density of the second catalyst.

[0141] 33. The catalytic conversion method according to item 31 or 32, wherein the first catalyst contains 60 to 100 mass% of a heavy oil catalyst and 0 to 40 mass% of a light oil catalyst; the second catalyst contains 0 to 40 mass% of a heavy oil catalyst and 60 to 100 mass% of a light oil catalyst; Preferably, the first catalyst contains 80 to 100 mass % of a heavy oil catalyst and 0 to 20 mass % of a light oil catalyst, and the second catalyst contains 0 to 20 mass % of a heavy oil catalyst and 80 to 100 mass % of a light oil catalyst.

[0142] 34. The catalytic conversion method according to item 33, wherein the heavy oil catalyst comprises a modified or unmodified Y-type molecular sieve, a clay, a binder, an optional modified or unmodified β-molecular sieve, an optional modified or unmodified ZSM-5 molecular sieve, and an optional heat transfer agent; Based on the total weight of the heavy oil catalyst, the content of the modified or unmodified Y-type molecular sieve is 10-80%, preferably 30-60%, the content of the clay is 10-80%, preferably 15-60%, the content of the binder is 10-30%, preferably 10-20%, the content of the modified or unmodified β-type molecular sieve is 0-40%, preferably 0-20%, the content of the modified or unmodified ZSM-5 molecular sieve is 0-40%, preferably 0-20%, and the content of the heat transfer agent is 0-40%, preferably 0-20%, and the heat transfer agent is a mixture of one or more selected from SiO2, MgO, CaO, BaO, and MnO2; The particle size of the heavy oil catalyst is in the range of 60 to 250 μm, preferably 80 to 200 μm, and the particle density is 1200 to 1600 kg / m 3 , preferably 1300 to 1500 kg / m 3 is within the range of The particle size of the heavy oil catalyst is in the range of 60 to 250 μm, preferably 80 to 200 μm, and the particle density is 1200 to 1600 kg / m 3 , preferably 1300 to 1500 kg / m3 is within the range.

[0143] 35. The catalytic conversion process of claim 33 or 34, wherein the gas oil catalyst comprises modified or unmodified ZSM-5 molecular sieve, clay, binder, optionally modified or unmodified Y molecular sieve, optionally modified or unmodified β molecular sieve, and optionally a heat transfer agent; Based on the total weight of the catalyst, the content of the modified or unmodified ZSM-5 molecular sieve is 10-60%, preferably 20-50%, the content of the clay is 10-80%, preferably 20-70%, the content of the binder is 10-30%, preferably 10-20%, the content of the modified or unmodified Y molecular sieve is 0-40%, preferably 0-20%, the content of the modified or unmodified β molecular sieve is 0-40%, preferably 0-20%, and the content of the heat transfer agent is 0-40%, preferably 0-20%, and the heat transfer agent is a mixture of one or more selected from SiO2, MgO, CaO, BaO, and MnO2.

[0144] The particle size of the diesel catalyst is in the range of 10 to 100 μm, preferably 30 to 80 μm, and the particle density is 800 to 1200 kg / m 3 , preferably 900 to 1100 kg / m 3 is.

[0145] 36. The catalytic conversion method according to Item 31, wherein the first regeneration and the second regeneration are carried out in a first regeneration zone and a second regeneration zone of a regenerator, respectively; the first regeneration zone and the second regeneration zone are arranged in series, the first regeneration zone employs incomplete regeneration, and the second regeneration zone employs complete regeneration, and the incompletely regenerated exhaust gas produced in the first regeneration zone is introduced into the second regeneration zone to continue the regeneration reaction.

[0146] 37. The catalytic conversion method according to item 31, wherein the regeneration temperature of the first regeneration zone is 640 to 700°C, preferably 660 to 680°C, and the distribution density of the catalyst is 50 to 400 kg / m 3 , preferably 100 to 300 kg / m 3and the main air residence time is 0.5 to 20 seconds, preferably 2 to 10 seconds; The regeneration temperature of the second regeneration zone is 670 to 730°C, preferably 690 to 710°C, and the catalyst distribution density is 30 to 350 kg / m 3 , preferably 80 to 250 kg / m 3 and the main air residence time is 0.5 to 15 seconds, preferably 2 to 10 seconds.

[0147] 38. The catalytic conversion method according to item 31, wherein the reaction temperature of the first fast bed reactor is 520-620°C, preferably 540-600°C; the catalyst-oil ratio is 2-25, preferably 3-20; and the reaction time is 1-15 seconds, preferably 2-10 seconds; The reaction temperature of the second fast bed reactor is 540-640°C, preferably 560-620°C, the catalyst-oil ratio is 3-30, preferably 5-25; and the reaction time is 1-10 seconds, preferably 2-8 seconds.

[0148] 39. The catalytic conversion method according to Item 31, wherein the heavy feedstock is a mixture of one or more selected from vacuum gas oil, atmospheric residue, vacuum residue, coker gas oil, deasphalted oil, furfural refined raffinate oil, coal liquid oil, asphalt, shale oil, Fischer-Tropsch synthetic distillate oil, animal and vegetable oils, crude oil, and biomass oil.

[0149] 40. A catalytic conversion system for producing ethylene and propylene, the catalytic conversion system comprising a first fast-bed reactor, a second fast-bed reactor, a separator, and a regenerator; an upper end of the first fast-bed reactor is connected to a lower end of the second fast-bed reactor; the separator comprises a separator partition and a catalyst separator, the separator partition separating the separator into a first settling zone and a second settling zone, a material inlet of the catalyst separator connected to an upper end of the second fast-bed reactor, the catalyst separator further having a first material outlet opening into the first settling zone and a second material outlet opening into the second settling zone; a first stripper is disposed below the first settling zone, and a second stripper is disposed outside the second settling zone; A regenerator partition is provided within the regenerator, and the regenerator is divided into a first regeneration zone and a second regeneration zone by the regenerator partition; a first spent catalyst is transported and connected between the first stripper and the first regeneration zone; a second spent catalyst is transported and connected between the second stripper and the second regeneration zone; a first regenerated catalyst is transported and connected between the first regeneration zone and the first fast-bed reactor; and a second regenerated catalyst is transported and connected between the second regeneration zone and the second fast-bed reactor.

[0150] [Example] The present application will be described in further detail through the following examples, but the present application is not limited to these specific examples.

[0151] In the following examples and comparative examples: The gaseous products were analyzed using an Agilent HP5890A purified gas analyzer, and the liquid products were analyzed by simulated distillation using an Agilent HP6890 gas chromatograph. The gasoline and diesel cut points were 221 °C and 343 °C, respectively.

[0152] The conversion rate was calculated as follows: Conversion rate = (weight of dry gas + weight of liquefied gas + weight of gasoline + weight of coke) / weight of raw feedstock × 100%; The yield was calculated as follows: Ethylene yield = weight of ethylene product separated from reaction product / raw feedstock feed amount × 100%; Propylene yield = weight of propylene product separated from reaction product / raw feedstock feed × 100%.

[0153] Unless otherwise specified, all raw materials and reagents used in the following examples and comparative examples are commercially available products, and the purity of the reagents used is chemically pure.

[0154] Example I Series Three catalysts were used in the first series of examples and comparative examples: catalytic cracking catalyst GOR-II, catalytic cracking catalyst RAG-6, and catalytic cracking catalyst RBC. All were commercially available catalysts manufactured by Sinopec Catalyst Corporation, Jinan Branch. The specific properties of the three catalysts are shown in Table 1. The heavy oil catalyst GOR-II contained 40 wt% Y molecular sieve. The RBC catalyst contained 33 wt% Y molecular sieve, 5 wt% β molecular sieve, and 5 wt% heat transfer agent (a mixture of BaO and CaO). The light oil catalyst RAG-6 contained 35 wt% ZSM-5 molecular sieve. Before testing, the catalysts were aged at 800°C in 100% steam for 17 hours.

[0155] [Table 1]

[0156] The feedstocks used in the examples and comparative examples of Series I were gas oil and light gasoline, the specific properties of which are shown in Tables 2 and 3.

[0157] [Table 2]

[0158] [Table 3]

[0159] Example I-1 The reactor used in this example (see Figure 3) comprised a riser reaction zone and a dense bed reaction zone connected in series. The riser reaction zone had an inner diameter of 16 mm and a length of 3200 mm, while the dense bed reaction zone had an inner diameter of 64 mm and a height of 500 mm. A catalyst separator (see Figure 12) was installed within the separator, allowing the catalyst to be separated into two parts with different particle sizes and densities. The type of catalyst separator is shown in Figure 6. Preheated gas oil and the first catalyst were introduced into the bottom of the riser reaction zone and reacted in the riser reaction zone. The reacted oil-catalyst mixture was introduced into the dense bed reaction zone, where it reacted with the second catalyst. The reacted oil-catalyst mixture flowed into the catalyst separator. The catalyst with larger particle size and density was separated into the first settling zone, and the catalyst with smaller particle size and density, together with the reacted oil and gas, was separated into the second settling zone. They were then separated by a cyclone separator within the separator. The catalyst in the first settling zone and the catalyst in the second settling zone were stripped and then introduced into the first regeneration zone and the second regeneration zone of the regenerator (see Figure 13), respectively. The regenerated catalyst was recycled to the riser reaction zone and the dense bed reaction zone, respectively. The oil and gas were introduced into the fractionation system for separation. The reaction conditions and results are shown in Table 4.

[0160] Comparative example I-1 The experiment was carried out according to the method of Example I-1, except that the catalyst used in the riser reaction zone and the dense bed reaction zone was a mixed catalyst obtained by mixing GOR-II catalyst and RAG-6 catalyst in a mass ratio of 1:1. The mixed catalyst was added to the dense bed reaction zone, and the two catalysts were not separated or independently regenerated within the catalytic conversion system. The reaction conditions and results are shown in Table 4.

[0161] Example I-2 The experiment was carried out according to the method of Example I-1, except that the catalyst separator was placed outside the separator (see Figure 9), the regenerator was of the type shown in Figure 10, and preheated light gasoline was introduced into the dense phase bed reaction zone. The reaction conditions and results are shown in Table 4.

[0162] Example I-3 The experiment was carried out according to the method of Example I-2, except that the RBC catalyst was used instead of the GOR-II catalyst as the heavy oil catalyst. The reaction conditions and results are shown in Table 4.

[0163] Comparative example I-2 The experiment was carried out according to the method of Comparative Example I-1, except that preheated light gasoline was also introduced into the dense phase bed reaction zone. The reaction conditions and results are shown in Table 4.

[0164] Comparative Examples 1-3 The reactor used in this comparative example was equipped with a riser reactor and a dense-phase bed reactor, each independent of the other. The riser reactor had a diameter of 16 mm and a length of 3,200 mm, while the dense-phase bed reactor had a diameter of 64 mm and a height of 500 mm. Preheated gas oil and a first catalyst (GOR-II catalyst) were introduced into the bottom of the riser reactor and reacted in the riser reactor. The oil mixture after the reaction was introduced into a cyclone separator and separated to obtain a first reaction product and a first spent catalyst. The first spent catalyst was introduced into a first regenerator for regeneration and reuse. The first reaction product was introduced into the dense-phase bed reactor and reacted with a second catalyst (RAG-6 catalyst). The oil-catalyst mixture after the reaction was introduced into a cyclone separator and separated to obtain a second reaction product and a second spent catalyst. The second spent catalyst was introduced into a second regenerator for regeneration and reuse. The oil and gas were introduced into a fractionation system and separated. The reaction conditions and results are shown in Table 4.

[0165] [Table 4] JPEG2026504030000006.jpg98169

[0166] From Table 4, it can be seen that compared with the comparative example, the catalytic conversion system and method of the present application can improve the yield in producing light olefins such as ethylene and propylene by cracking heavy crude oil.

[0167] Example II-III Series In the following II-III series of examples and comparative examples, three commercially available catalysts manufactured by Sinopec Catalyst Corporation, Jinan Branch, were used: catalytic cracking catalyst GOR-II, catalytic cracking catalyst RAG-6, and catalytic cracking catalyst DMMC-2. The specific properties of catalysts GOR-II and RAG-6 are listed in Table 1 above, and the specific properties of catalyst DMMC-2 are listed in Table 5. Here, DMMC-2 was a catalyst containing 15 wt. % Y molecular sieve and 15 wt. % ZSM-5 molecular sieve. Before testing, the catalysts were aged at 800°C for 17 hours under 100% steam conditions.

[0168] The feedstock used in the Examples and Comparative Examples of Series II-III was gas oil, the specific properties of which are shown in Table 2 above.

[0169] [Table 5]

[0170] Examples II-1 to II-2 The test was conducted in the apparatus shown in Figure 14. This apparatus was equipped with a riser reaction zone and a dense-phase bed reaction zone connected in series. The riser reaction zone had an inner diameter of 16 mm and a length of 3200 mm, while the dense-phase bed reaction zone had an inner diameter of 64 mm and a height of 500 mm. Preheated feed oil and a first catalyst rich in GOR-II catalyst were introduced into the bottom of the riser reaction zone and reacted there. The resulting oil-catalyst mixture was introduced into the dense-phase bed reaction zone and continued to react with a second catalyst rich in RAG-6 catalyst. The resulting oil-catalyst mixture was separated using a cyclone separator in the separation unit. The catalyst was stripped in the stripping section and introduced into a two-stage catalyst separator. The types of each stage of the catalyst separator were as shown in Figure 7, and the resulting mixture was separated into a first spent catalyst rich in GOR-II catalyst and a second spent catalyst rich in RAG-6 catalyst. The two catalysts to be regenerated were introduced into the first and second regeneration zones, respectively. The regenerated catalyst was recycled back to the riser reaction zone and the dense bed reaction zone, and the oil and gas were introduced into the fractionation system and separated. The reaction conditions and results are shown in Table 6.

[0171] Comparative Example II-1 The test equipment used in this comparative example consisted of a riser reaction zone and a dense bed reaction zone connected in series. The riser reaction zone had an inner diameter of 16 mm and a length of 3200 mm, while the dense bed reaction zone had an inner diameter of 64 mm and a height of 500 mm. Preheated feed oil and DMMC-2 catalyst were introduced into the bottom of the riser reaction zone. They contacted and reacted in the riser reaction zone. The resulting oil-catalyst mixture was introduced into the dense bed reaction zone for further reaction. The resulting oil-catalyst mixture was separated by a cyclone separator in the separation unit. The catalyst was stripped in the stripping section and then regenerated in the regenerator. The regenerated catalyst was returned to the riser reaction zone for recycling, and the oil and gas were introduced into the fractionation system for separation. The reaction conditions and results are shown in Table 6.

[0172] Comparative Example II-2 The test equipment used in this comparative example consisted of a riser reaction zone and a dense bed reaction zone connected in series. The riser reaction zone had an inner diameter of 16 mm and a length of 3200 mm, while the dense bed reaction zone had an inner diameter of 64 mm and a height of 500 mm. Preheated feed oil and a 1:1 mass ratio mixed catalyst of GOR-II and RAG-6 catalysts were introduced into the bottom of the riser reaction zone. They contacted and reacted in the riser reaction zone. The resulting oil-catalyst mixture was introduced into the dense bed reaction zone to continue the reaction. The resulting oil-catalyst mixture was separated using a cyclone separator in the separation device. The spent catalyst was stripped in the stripping section and then regenerated in the regenerator. The regenerated mixed catalyst was returned to the riser reaction zone for reuse. The oil and gas were introduced into a fractionation system and separated. The reaction conditions and results are shown in Table 6.

[0173] [Table 6]

[0174] Table 6 shows that, compared to the comparative example, the catalytic conversion system and method of the present application can improve the yield of light olefins, such as ethylene and propylene, produced by cracking heavy feedstock.

[0175] Examples III-1 to III-2 The test was conducted in the apparatus shown in Figure 15. This apparatus contained two fast-bed reactor-type reaction zones connected in series. Each reaction zone had a diameter of 40 mm and a length of 1500 mm. Preheated feed oil and a first catalyst enriched in GOR-II catalyst were introduced into the bottom of the first reaction zone. They contacted and reacted in the first reaction zone. The resulting oil-catalyst mixture was introduced into the second reaction zone, where it continued to contact a second catalyst enriched in RAG-6 catalyst. The resulting oil-catalyst mixture was introduced into a catalyst separator of the type shown in Figure 7, located within the separation device. The oil-catalyst mixture was separated into a first spent catalyst enriched in GOR-II catalyst and a second spent catalyst enriched in RAG-6 catalyst. The two catalysts to be regenerated were introduced into the first and second regeneration zones, respectively. The regenerated catalyst was returned to the first and second reaction zones for reuse. The oil and gas were introduced into a fractionation system and separated. The reaction conditions and results are shown in Table 7.

[0176] Comparative example III-1 The equipment used in this comparative example contained two fast-bed reactor-type reaction zones connected in series. The reaction zones had a diameter of 40 mm and a length of 1500 mm. Preheated feed oil and DMMC-2 catalyst were introduced into the bottom of the first reaction zone. They contacted and reacted in the first reaction zone. The oil-catalyst mixture after the reaction was introduced into the second reaction zone for further reaction, and DMMC-2 catalyst was added. The oil-catalyst mixture after the reaction was separated using a cyclone separator in the separation unit. The spent catalyst was stripped in the stripping section and then regenerated in the regenerator. The regenerated catalyst was returned to the first reaction zone for reuse. The oil and gas were introduced into a fractionation system and separated. The reaction conditions and results are shown in Table 7.

[0177] Comparative example III-2 The equipment used in this comparative example contained two fast-bed reactor-type reaction zones connected in series. The reaction zones had a diameter of 40 mm and a length of 1500 mm. Preheated feedstock oil and a 1:1 mass ratio mixed catalyst of GOR-II and RAG-6 catalysts were introduced into the bottom of the first reaction zone. They reacted in the first reaction zone. The resulting oil-catalyst mixture was introduced into the second reaction zone for further reaction, where the mixed catalyst was added. The resulting oil-catalyst mixture was separated using a cyclone separator in the separation unit. The spent catalyst was stripped in the stripping section and then regenerated in the regenerator. The regenerated mixed catalyst was returned to the first reaction zone for reuse. The oil and gas were introduced into the fractionation system and separated. The reaction conditions and results are shown in Table 7.

[0178] Comparative example III-3 The reactor used in this comparative example contained two independent fast-bed reactors. The reactors had a diameter of 40 mm and a length of 1500 mm. Preheated feedstock oil and the first catalyst (GOR-II catalyst) were introduced into the bottom of the first reactor. They contacted and reacted with each other in the first reactor. The oil mixture after the reaction was introduced into a cyclone separator and separated to obtain a first reaction product and a first spent catalyst. The first spent catalyst was introduced into a first regenerator for regeneration and reuse. The first reaction product was introduced into a second reactor and reacted with a second catalyst (RAG-6 catalyst). The oil-catalyst mixture after the reaction was introduced into a cyclone separator and separated to obtain a second reaction product and a second spent catalyst. The second spent catalyst was introduced into a second regenerator for regeneration and reuse. The oil and gas were introduced into a fractionation system and separated. The reaction conditions and results are shown in Table 7.

[0179] [Table 7] JPEG2026504030000010.jpg85169

[0180] Table 7 shows that, compared to the comparative example, the catalytic conversion system and method provided herein can improve the yield of light olefins such as ethylene and propylene produced by cracking heavy feedstock.

[0181] The preferred embodiments of the present application have been described in detail above. However, the present application is not limited to the specific details in the above embodiments. Within the scope of the technical concept of the present application, various simple modifications can be made to the technical solutions of the present application, and all of these simple modifications fall within the protection scope of the present application.

[0182] Furthermore, the various specific technical features described in the above specific embodiments may be combined in any suitable manner without contradiction, and in order to avoid unnecessary repetition, the present application will not further describe the various possible combinations.

[0183] Furthermore, various embodiments of the present application can be combined in any manner, and these should be considered as the contents disclosed in the present application unless they are contrary to the concept of the present application. [Brief explanation of the drawings]

[0184] [Figure 1] FIG. 1 is a schematic structural diagram illustrating a preferred embodiment of a reaction unit of the system of the present application. [Figure 2] FIG. 2 is a schematic structural diagram illustrating another preferred embodiment of the reaction unit of the system of the present application. [Figure 3] FIG. 2 is a schematic structural diagram illustrating another preferred embodiment of the reaction unit of the system of the present application. [Figure 4] 1 is a schematic structural diagram illustrating a preferred embodiment of a catalyst separator of the present system. [Figure 5] FIG. 2 is a schematic structural diagram illustrating another preferred embodiment of the catalyst separator of the system of the present application. [Figure 6] FIG. 2 is a schematic structural diagram illustrating another preferred embodiment of the catalyst separator of the system of the present application. [Figure 7]FIG. 2 is a schematic structural diagram illustrating another preferred embodiment of the catalyst separator of the system of the present application. [Figure 8] 1 is a schematic structural diagram of a catalytic conversion system according to an embodiment of the present application; [Figure 9] 1 is a schematic structural diagram illustrating one embodiment of a catalyst separation unit of the present application. [Figure 10] FIG. 2 is a schematic structural diagram showing an embodiment of a regenerator according to the present application. [Figure 11] 1 is a schematic structural diagram of a catalytic conversion system according to an embodiment of the present application; [Figure 12] 1 is a schematic structural diagram illustrating one embodiment of a catalyst separation unit of the present application. [Figure 13] FIG. 1 is a schematic structural diagram showing an embodiment of a regenerator of the present application. [Figure 14] 1 is a schematic structural diagram of a catalytic conversion system according to an embodiment of the present application; [Figure 15] 1 is a schematic structural diagram of a catalytic conversion system according to an embodiment of the present application;

Claims

1. a reaction unit in which a reaction feedstock contacts and reacts with a catalyst to produce an oil-catalyst mixture, the reaction unit comprising a first fluidized bed reactor and a second fluidized bed reactor connected in series, or a composite fluidized bed reactor having a first reaction zone and a second reaction zone connected in series; the first fluidized bed reactor or the first reaction zone of the composite fluidized bed reactor has a first feedstock inlet, a first catalyst inlet, and a first oil-catalyst mixture outlet; the second fluidized bed reactor or the second reaction zone of the composite fluidized bed reactor has an oil-catalyst mixture inlet, a second catalyst inlet, a second oil-catalyst mixture outlet, and an optional second feedstock inlet, wherein the first oil-catalyst mixture outlet of the first fluidized bed reactor or the first oil-catalyst mixture outlet of the first reaction zone of the composite fluidized bed reactor is connected to the oil-catalyst mixture inlet of the second fluidized bed reactor or the oil-catalyst mixture inlet of the second reaction zone of the composite fluidized bed reactor; a catalyst separation unit for separating the oil-catalyst mixture from the reaction unit to obtain oil, gas products, and spent catalyst; the catalyst separation unit comprises a separation device and a catalyst separator located inside or outside the separation device, the separation device comprising a gas-solid separator, at least one settling zone, and at least one stripping section connected to the bottom of the settling zone, and having an oil-catalyst mixture inlet, an oil and gas product outlet, and at least one catalyst outlet located at the bottom of the stripping section, the catalyst separator having a material inlet, a first material outlet, and a second material outlet, wherein the oil-catalyst mixture inlet of the separation device is connected to the second oil-catalyst mixture outlet of the second fluidized bed reactor or the second oil-catalyst mixture outlet of the second reaction zone of the composite fluidized bed reactor; and a catalyst regeneration unit for regenerating the spent catalyst from the catalyst separation unit and recycling it to the reaction unit; the catalyst regeneration unit includes a first catalyst regenerator and a second catalyst regenerator, or a composite catalyst regenerator having a first regeneration zone and a second regeneration zone, wherein the first catalyst regenerator or the first regeneration zone of the composite catalyst regenerator has a first spent catalyst inlet and a first regenerated catalyst outlet, and the second catalyst regenerator or the second regeneration zone of the composite catalyst regenerator has a second spent catalyst inlet and a second regenerated catalyst outlet; a catalyst regeneration unit, wherein the first spent catalyst inlet and the second spent catalyst inlet are respectively connected to the catalyst outlet of the separation device or the first material outlet and the second material outlet of the catalyst separator, the first regenerated catalyst outlet is connected to the first catalyst inlet of the first fluidized bed reactor or the first catalyst inlet of the first reaction zone of the composite fluidized bed reactor, and the second regenerated catalyst outlet is connected to the second catalyst inlet of the second fluidized bed reactor or the second catalyst inlet of the second reaction zone of the composite fluidized bed reactor; 1. A fluid catalytic conversion system comprising:

2. In the catalyst separation unit, the catalyst separator is disposed outside the separation device, the catalyst outlet of the separation device is connected to the material inlet of the catalyst separator, the first material outlet of the catalyst separator is connected to the first spent catalyst inlet of the first catalyst regenerator or the first spent catalyst inlet of the first regeneration zone of the composite catalyst regenerator, and the second material outlet is connected to the second spent catalyst inlet of the second catalyst regenerator or the second spent catalyst inlet of the second regeneration zone of the composite catalyst regenerator; or The catalyst separator is disposed inside the separation device, and the separation device has a first settling zone, a first stripping section connected to the bottom of the first settling zone, a first catalyst outlet disposed at the bottom of the first stripping section, a second settling zone, a second stripping section connected to the bottom of the second settling zone, and a second catalyst outlet disposed at the bottom of the second stripping section, and the second oil-catalyst mixture outlet of the second fluidized-bed reactor or the second oil-catalyst mixture outlet of the second reaction zone of the composite fluidized-bed reactor is connected to the oil catalyst of the separation device. a catalyst separator connected to a material inlet through a catalyst mixture inlet, a first material outlet and a second material outlet of the catalyst separator connected to a first settling zone and a second settling zone of the separation device, respectively; a first catalyst outlet of the separation device connected to the first spent catalyst inlet in the first catalyst regenerator or the first spent catalyst inlet in the first regeneration zone of the composite catalyst regenerator; and a second catalyst outlet of the separation device connected to the second spent catalyst inlet in the second catalyst regenerator or the second spent catalyst inlet in the second regeneration zone of the composite catalyst regenerator; 10. The fluid catalytic conversion system of claim 1.

3. 3. The fluid catalytic conversion system of claim 1, further comprising a first catalyst injected into the first fluidized bed reactor or into a first reaction zone of the composite fluidized bed reactor through the first catalyst inlet, and a second catalyst injected into the second fluidized bed reactor or into a second reaction zone of the composite fluidized bed reactor through the second catalyst inlet, wherein the particle size and density of the first catalyst are greater than the particle size and density of the second catalyst, respectively.

4. the first fluidized bed reactor and the second fluidized bed reactor, or the first reaction zone and the second reaction zone of the composite fluidized bed reactor, are independently of each other in the form of an upflow bed or a downflow bed, preferably both in the form of an upflow bed; 4. The fluidized catalytic conversion system according to claim 1, wherein the upflow bed is preferably one or a combination of types selected from a bubbling bed, a turbulent bed, a high velocity bed, and a dilute transport bed, and is preferably a type selected from a riser reactor, a high velocity bed reactor, or a high density bed reactor.

5. the first fluidized bed reactor and the second fluidized bed reactor, or the first reaction zone and the second reaction zone of the combined fluidized bed reactor, are independently selected from an upflow type riser reactor, a fast bed reactor, or a dense phase bed reactor; The first reaction zone of the first fluidized bed reactor or the composite fluidized bed reactor is provided with the first feedstock oil inlet, the first catalyst inlet, and the fluidized medium inlet at a lower portion thereof, and the first oil-catalyst mixture outlet at an upper portion thereof; 4. The fluidized catalytic conversion system according to claim 1, wherein the second fluidized bed reactor or the second reaction zone of the combined fluidized bed reactor is provided with the oil-catalyst mixture inlet, the second catalyst inlet, and an optional second feedstock oil inlet at a lower portion thereof, and the second oil-catalyst mixture outlet at an upper portion thereof.

6. 6. The fluidized catalytic conversion system according to claim 1, wherein the second fluidized bed reactor or the second reaction zone of the composite fluidized bed reactor is of the upflow type and is partially or completely located within at least one settling zone of the separation device.

7. The catalyst separator is one or a combination selected from a cyclone high-speed separator, a trilobe high-speed separator, a ballistic high-speed separator, a U-tube separator, and a wall-cutting high-speed separator, and is preferably a cyclone high-speed separator; Alternatively, the catalyst separator is arranged in the form of a plurality of separators connected in parallel, or in the form of a multi-stage separator connected in series, or in the form of a combination thereof, wherein each separator or each stage of the multi-stage separator is independently a cyclonic high-speed separator, a trilobe high-speed separator, a ballistic high-speed separator, a U-tube separator, or a wall-cut high-speed separator, preferably a cyclonic high-speed separator.

8. the catalyst separator is disposed outside the separation device and has the form of two separator stages connected in series, the inlet of the first stage separator is connected to the catalyst outlet of the separation device, the first stage separator has the first material outlet at a lower part and a light material outlet at an upper part, the inlet of the second stage separator is connected to the light material outlet of the first stage separator, the second stage separator has the second material outlet at a lower part and a residual reaction oil and gas outlet at an upper part, Optionally, the residual reaction oil and gas outlet of the second stage separator is connected to the top of the separation device via a pipeline.

7. A fluid catalytic conversion system according to any one of claims 1 to 6.

9. 8. The fluidized catalytic conversion system of claim 2, wherein the catalyst separator is disposed within the separation apparatus, and the separation apparatus is provided with a settling zone divider separating the first and second settling zones, the first settling zone being located below the settling zone divider and the second settling zone being located above the settling zone divider, and the catalyst separator is secured to the settling zone divider of the separation apparatus such that its first material outlet is located within the first settling zone and its second material outlet is located within the second settling zone.

10. the composite catalyst regenerator is provided with a regenerator divider separating the first regeneration zone from the second regeneration zone; The regenerator partition is vertically disposed, the first regeneration zone and the second regeneration zone are disposed on the left and right sides of the regenerator partition, and optionally, the tops of the first regeneration zone and the second regeneration zone are connected, and a gas-solid separator is disposed therein, and the top end of the regenerator partition is located higher than the solid outlet of each of the gas-solid separators; or 10. The fluidized catalytic conversion system of claim 1, wherein the regenerator partition is horizontally disposed, the first regeneration zone and the second regeneration zone are disposed above and below the regenerator partition, and optionally the first regeneration zone is disposed below the second regeneration zone, and the regenerator partition is provided with a first regeneration exhaust gas outlet, thereby allowing regeneration exhaust gas from the first regeneration zone to flow into the second regeneration zone.

11. 11. Use of a fluid catalytic conversion system according to any one of claims 1 to 10 for catalytic conversion of hydrocarbon oils, in particular for catalytic conversion of heavy feedstocks to produce light olefins, comprising: Preferably, the heavy feedstock is selected from vacuum gas oil, atmospheric residue, vacuum residue, coker gas oil, deasphalted oil, furfural refined raffinate oil, coal liquid oil, asphalt, shale oil, Fischer-Tropsch synthetic distillate oil, animal oil, vegetable oil, crude oil, biomass oil, or mixtures thereof.

12. 11. A method for catalytic conversion of hydrocarbon oils, particularly heavy feedstocks, using a fluid catalytic conversion system according to any one of claims 1 to 10, comprising the steps of: 1) in a first fluidized bed reactor or a first reaction zone of a composite fluidized bed reactor of a reaction unit of the fluidized catalytic conversion system, contacting a hydrocarbon oil feedstock with a first catalyst to carry out a first catalytic conversion reaction and obtain a first oil-catalyst mixture; 2) contacting the first oil-catalyst mixture with a second catalyst in a second fluidized bed reactor or a second reaction zone of a combined fluidized bed reactor of the reaction unit of the fluidized catalytic conversion system to carry out a second catalytic conversion reaction and obtain a second oil-catalyst mixture; 3) separating the second oil-catalyst mixture in a catalyst separation unit of the fluid catalytic conversion system to obtain an oil and gas product, a first spent catalyst, and a second spent catalyst; 4) regenerating the first spent catalyst in a first catalyst regenerator or a first regeneration zone of a combined catalyst regenerator of a catalyst regeneration unit of the fluid catalytic conversion system, and returning the resulting first regenerated catalyst to step 1) as the first catalyst; and 5) regenerating the second spent catalyst in a second catalyst regenerator or a second regeneration zone in a combined catalyst regenerator of a catalyst regeneration unit of the fluid catalytic conversion system, and returning the resulting second regenerated catalyst to step 2) as a second catalyst; Preferably, the particle size and density of the first catalyst are greater than those of the second catalyst.

13. The first catalyst contains 60 to 100 mass%, preferably 80 to 100 mass%, of a heavy oil catalyst and 0 to 40 mass%, preferably 0 to 20 mass%, of a light oil catalyst, and the second catalyst contains 0 to 40 mass%, preferably 0 to 20 mass%, of a heavy oil catalyst and 60 to 100 mass%, preferably 80 to 100 mass%, of a light oil catalyst, where: Based on the total weight of the heavy oil catalyst, the heavy oil catalyst comprises: 10-80%, preferably 30-60%, of modified or unmodified Y-type molecular sieves; 0-40%, preferably 0-20%, of modified or unmodified β molecular sieve; 0 to 40%, preferably 0 to 20%, of modified or unmodified ZSM-5 molecular sieve; 10-80%, preferably 15-60% clay; 10-30%, preferably 10-20%, of a binder; and, 0-40%, preferably 0-20%, of a heat transfer agent, wherein said heat transfer agent is SiO ２ , MgO, CaO, BaO, and MnO ２ or any mixture thereof; Based on the total weight of the diesel catalyst, the diesel catalyst comprises the following components: 10 to 60%, preferably 20 to 50%, of modified or unmodified ZSM-5 molecular sieve; 0-40%, preferably 0-20%, of modified or unmodified Y molecular sieve; 0-40%, preferably 0-20%, of modified or unmodified β-structure molecular sieves; 10-80%, preferably 20-70% clay; 10-30%, preferably 10-20%, of a binder; and, 0-40%, preferably 0-20%, of a heat transfer agent, wherein said heat transfer agent is SiO ２ , MgO, CaO, BaO, and MnO ２ or any mixture thereof; Preferably, the heavy oil catalyst has a particle size range of 60 to 250 μm, preferably 80 to 200 μm, and a particle density of 1200 to 1600 kg / m ３ , preferably 1300 to 1500 kg / m ３ The diesel catalyst has a particle size range of 10 to 100 μm, preferably 30 to 80 μm, and a particle density of 800 to 1200 kg / m ３ , preferably 900 to 1100 kg / m ３ The method of claim 12, wherein

14. The first fluidized bed reactor or the first reaction zone of the combined fluidized bed reactor is a riser reactor, wherein the reaction conditions include: a reaction temperature of 520-620°C, preferably 540-600°C; a catalyst-to-oil ratio of 2-25, preferably 3-20; a reaction time of 1-15 seconds, preferably 2-10 seconds; and / or The second fluidized bed reactor or the second reaction zone of the composite fluidized bed reactor is a type of dense phase bed reactor, wherein the reaction conditions include: reaction temperature is 540-640°C, preferably 560-620°C; catalyst distribution density is 20-300 kg / m ３ , preferably 100 to 200 kg / m ３ , space velocity is 2 to 15 h －１ , preferably 5 to 10 hours －１ oil and gas residence time of 0.2 to 8 seconds, preferably 1 to 4 seconds; The method according to claim 12 or 13, wherein

15. The first fluidized bed reactor or the first reaction zone of the combined fluidized bed reactor is a fast bed reactor, wherein the reaction conditions include: a reaction temperature of 520-620°C, preferably 540-600°C; a catalyst-to-oil ratio of 2-25, preferably 3-20; a reaction time of 1-15 seconds, preferably 2-10 seconds; and / or The second fluidized bed reactor or the second reaction zone of the composite fluidized bed reactor is a type of fast bed reactor, wherein the reaction conditions include: reaction temperature is 540-640°C, preferably 560-620°C, agent-to-oil ratio is 3-30, preferably 5-25, and reaction time is 1-10 seconds, preferably 2-8 seconds; The method according to claim 12 or 13, wherein

16. The first catalyst regenerator or the first regeneration zone of the composite catalyst regenerator employs partial regeneration, and the second catalyst regenerator or the second regeneration zone of the composite catalyst regenerator employs complete regeneration; 16. The method according to any one of claims 12 to 15, wherein the incompletely regenerated exhaust gas produced in the first catalyst regenerator or the first regeneration zone of the composite catalyst regenerator is introduced into the second catalyst regenerator or the second regeneration zone of the composite catalyst regenerator to continue the regeneration reaction.

17. The regeneration conditions in the first catalyst regenerator or the first regeneration zone of the composite catalyst regenerator include: a regeneration temperature of 640-700°C, preferably 660-680°C; a catalyst distribution density of 50-400 kg / m ３ , preferably 100 to 300 kg / m ３ , a main air residence time of 0.5 to 20 seconds, preferably 2 to 10 seconds; and / or The regeneration conditions in the second catalyst regenerator or the second regeneration zone of the composite catalyst regenerator include: a regeneration temperature of 670-730°C, preferably 690-710°C; a catalyst distribution density of 30-350 kg / m ３ , preferably 80 to 250 kg / m ３ , the main air residence time is 0.5 to 15 seconds, preferably 2 to 10 seconds; 17. The method of any one of claims 12 to 16, wherein

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