Methods and systems for defining the boundaries of a gas plant

Abstract

Methods and systems are provided for defining the gas plant boundary during the refurbishment of a fluid catalytic cracking unit (FCCU) as part of an olefin production system. These methods and systems include a chiller unit within the gas concentration unit downstream of the FCCU. Other methods include installing a stripper unit downstream of the FCCU's regenerator or installing a quench line within the FCCU's reactor, thereby reducing the contact time between the hydrocarbon feedstock and the catalyst. These methods and systems may also lead to an increase in the propylene yield of the olefin production system.

Description

Detailed Description of the Invention

[0001] Inventors Madhavendra Kapkoti, Yi Yang, Rajeev Ranjan, Matthew James Griffith and Rahul Radhakrishna Pillai [Cross - Reference to Related Applications] This application claims priority to U.S. Non - Provisional Patent Application No. 18336931, filed on June 16, 2023, which is hereby incorporated by reference in its entirety. [Technical Field]

[0002] The present disclosure relates to methods and systems for defining the boundaries of a gas plant, for example, during the retrofit of a fluid catalytic cracking unit (FCCU). More specifically, the present disclosure relates to methods and systems for reducing the load on a gas compressor unit in a gas plant. [Background Art]

[0003] Fluid catalytic cracking (FCC) in an oil refinery is a major process for converting hydrocarbon feedstocks into valuable petrochemical products (e.g., ethylene and propylene). The FCCU utilizes a reactor (known as a riser) to contact the hydrocarbon feedstock with a catalyst to facilitate the conversion of the hydrocarbon feedstock into petrochemical products. Advances in FCCU technology (e.g., dual riser technology (KBR MAXOFIN (trademark) technology) use multiple risers, and in each riser, different hydrocarbon feedstocks are promoted to be converted into emissions rich in ethylene and / or propylene. Due to the increasing demand for propylene, it has become necessary to retrofit existing gas plants to install new FCC facilities and maximize propylene yields. Gas plants upgraded to the latest FCCU technology can easily facilitate an increase in propylene yields. However, the magnitude of the propylene yield is often constrained by the original design of the gas plant. [Summary of the Invention]

[0004] The applicant recognizes that existing gas plants can maximize propylene recovery rates by defining the boundaries of the gas plant by implementing one or more of the methods and systems described herein.

[0005] One embodiment includes an olefin production system for defining the boundary of a wet gas compressor in a gas concentration unit. In one embodiment, the olefin production system includes a fluid catalytic cracking unit, a fractional distillation unit, and a gas concentration unit, the gas concentration unit including an overhead condenser, chiller, receiver, and wet gas compressor. The fluid catalytic cracking unit has a riser reactor and a regenerator and is configured to receive hydrocarbon feedstock and produce a cracking product stream including light and heavy paraffinic hydrocarbons, naphtha, and aromatic and olefinic hydrocarbons. In one embodiment, the riser reactor may include a quench line for introducing a quench fluid into the riser reactor 1.5 seconds after the hydrocarbon feedstock comes into contact with the catalyst. In one embodiment, the riser reactor is a dual or multi-riser reactor. The fractional distillation unit is fluidly connected to the fluid catalytic cracking unit and is configured to receive the cracking product stream and separate it into (i) a vapor product stream containing ethylene, propylene, and light naphtha, (ii) a first wild naphtha product stream, and (iii) a liquid product stream containing one or more heavy naphtha, light cycle oil, and slurry oil. The overhead condenser is fluidly connected to the fractional distillation unit and is configured to receive the vapor product stream and produce a first cooled fluid stream with a temperature in the range of approximately 105 degrees Fahrenheit (°F) to approximately 120°F. The chiller is located within the gas concentration unit and is fluidly connected to the overhead condenser and is configured to receive the first cooled fluid stream and produce a second cooled fluid stream with a temperature in the range of approximately 55°F to approximately 100°F. The receiver is located within the gas concentration unit and is in fluid communication with the chiller. It is configured to receive a second cooled fluid stream and separate the second cooled fluid stream into a wet gas stream containing ethylene and propylene, and a second wild naphtha stream.A wet gas compressor is located within the gas concentration unit, fluidly connected to a receiver, and configured to increase the pressure of a wet gas stream containing ethylene and propylene to be fed downstream, thereby producing an olefin-rich product stream. In some embodiments, the wet gas compressor can increase the pressure of the wet gas stream from 20 pounds / square inch gauge (psig) to 225 psig to be fed downstream. In some embodiments, the temperature of the first cooled fluid stream may be in the range of about 105°F to about 115°F. In some embodiments, the temperature of the second cooled fluid stream may be in the range of about 55°F to about 75°F, or about 55°F to about 65°F. In some embodiments, a riser reactor is configured to receive two or more hydrocarbon feedstock streams and a catalyst. In some embodiments, when the temperature of the first cooled fluid stream drops from about 105°F to about 60°F, the volumetric flow rate of the wet gas stream decreases by about 35 volume%.

[0006] Another embodiment of an olefin production system includes a fluid catalytic cracking unit. The fluid catalytic cracking unit includes (i) a riser reactor configured to receive a hydrocarbon feedstock stream and a catalyst and produce a cracking product stream containing light and heavy paraffinic hydrocarbons, naphtha and aromatic and olefinic hydrocarbons together with the spent catalyst; (ii) a regenerator connected to the riser reactor, configured to receive the spent catalyst and regenerate the spent catalyst to produce an encompassed catalyst containing encompassed inert substances together with the regenerated catalyst; (iii) a stripper connected to the regenerator, configured to receive the encompassed catalyst and produce a regenerated catalyst by removing inert substances contained within the encompassed catalyst; and (iv) a conduit for supplying the regenerated catalyst to the riser reactor. The system also includes a fractional distillation unit in fluid communication with a fluid catalytic cracking unit, configured to receive a cracking product stream and separate it into (i) a vapor product stream containing ethylene, propylene, and light naphtha, (ii) a first wild naphtha product stream, and (iii) a liquid product stream containing one or more of heavy naphtha, light cycle oil, and slurry oil. The system also includes a vapor recovery unit in fluid communication with the fractional distillation unit, configured to receive a vapor product stream and produce an olefin-rich product stream. In some embodiments, the riser reactor is a dual or multi-riser reactor. In some embodiments, the regenerated catalyst is produced by removing about 75 percent of the inert material contained within the encompassed catalyst. In some embodiments, the regenerated catalyst is produced by removing about 85 percent of the inert material contained within the encompassed catalyst. In some embodiments, the riser reactor is configured to receive two or more hydrocarbon feedstock streams and catalysts. In one embodiment, the riser reactor includes a quench line for introducing a quench fluid into the riser reactor 1.5 seconds after the hydrocarbon feedstock stream comes into contact with the catalyst.

[0007] Another embodiment of an olefin production system includes a fluid catalytic cracking unit. The fluid catalytic cracking unit includes (i) a riser reactor configured to receive a hydrocarbon feedstock stream and a catalyst and produce a cracking product stream containing light and heavy paraffinic hydrocarbons, naphtha and aromatic and olefinic hydrocarbons together with the spent catalyst; (ii) a regenerator in contact with the riser reactor, configured to receive the spent catalyst and regenerate the spent catalyst to produce an encompassed catalyst containing encompassed inert substances together with the regenerated catalyst; (iii) a stripper in contact with the regenerator, configured to receive the encompassed catalyst and produce a regenerated catalyst by removing inert substances contained within the encompassed catalyst; and (iv) a conduit for supplying the regenerated catalyst to the riser reactor. The system may also include a fractional distillation unit fluid-connected to a fluid catalytic cracking unit, configured to receive a cracking product stream and separate it into (i) a vapor product stream containing ethylene, propylene, and light naphtha; (ii) a first wild naphtha product stream; and (iii) a liquid product stream containing heavy naphtha, one or more of light cycle oil and slurry oil. The system may also include a gas concentration unit, which may include an overhead condenser, a chiller, a receiver, and a wet gas compressor. The overhead condenser is fluid-connected to the fractional distillation unit and configured to receive a vapor product stream and produce a first cooled fluid stream with a temperature in the range of about 105°F to about 120°F. The chiller is located within the gas concentration unit and is fluid-connected to the overhead condenser and configured to receive the first cooled fluid stream and produce a second cooled fluid stream with a temperature in the range of about 55°F to about 100°F. The receiver is located within the gas concentration unit and is in fluid communication with the chiller. It is configured to receive a second cooled fluid stream and separate the second cooled fluid stream into a wet gas stream containing ethylene and propylene, and a second wild naphtha stream.A wet gas compressor is located within the gas concentration unit, fluidly communicates with a receiver, and may be configured to increase the pressure of a wet gas stream containing ethylene and propylene to be fed downstream to produce an olefin-rich product stream. In some embodiments, the wet gas compressor may increase the pressure of the wet gas stream from 20 pounds / square inch gauge (psig) to 225 psig to be fed downstream. In some embodiments, the temperature of the first cooled fluid stream may be in the range of about 105°F to about 115°F. In some embodiments, the temperature of the second cooled fluid stream may be in the range of about 55°F to about 75°F, or about 55°F to about 65°F. In some embodiments, the riser reactor is configured to receive two or more hydrocarbon feedstock streams. In some embodiments, the riser reactor is a dual or multi-riser reactor. In some embodiments, when the temperature of the first cooled fluid stream drops from about 105°F to about 60°F, the volumetric flow rate of the wet gas stream decreases by about 35 volume%. In one embodiment, the regenerated catalyst is produced by removing about 75 percent of the inert material contained within the encompassed catalyst. In another embodiment, the regenerated catalyst is produced by removing about 85 percent of the inert material contained within the encompassed catalyst. In another embodiment, the riser reactor includes a quench line for introducing a quench fluid into the riser reactor to reduce the contact time between one of two or more hydrocarbon feedstock streams and the catalyst by 0.5 seconds or more.

[0008] Defining the boundaries of a gas plant can reduce the load on the gas enrichment unit (GCU) (including the wet gas compressor). Combining MAXOFIN® technology with reduced load on the wet gas compressor can maximize propylene yield in a gas plant. This disclosure generally covers several embodiments of methods and systems for defining the boundaries of a gas plant to increase propylene yield during FCCU refurbishment.

[0009] These embodiments of the Disclosure, as well as other features, aspects, and advantages, will be better understood in conjunction with the following description, claims, and accompanying drawings. However, it should be noted that the drawings illustrate only some embodiments of the Disclosure and should therefore not be considered to limit the scope of the Disclosure. [Brief explanation of the drawing]

[0010] [Figure 1] This is an exemplary flow diagram of an olefin production system according to embodiments of the present disclosure, which includes an FCCU and a chiller system within a gas concentration unit for defining the boundary of a wet gas compressor. [Figure 2] This is an exemplary flow diagram of a contact disassembly unit equipped with a regenerator and a stripper according to an embodiment of the present disclosure. [Figure 3] This is an exemplary flow diagram of a catalytic cracking unit with a regenerator and a quench according to embodiments of the present disclosure. [Figure 4] This is an exemplary flow diagram of an olefin production system according to embodiments of the present disclosure, comprising (i) a catalytic cracking unit with a regenerator and a stripper, and (ii) a chiller in a gas concentration unit for defining the boundary of a wet gas compressor. [Modes for carrying out the invention]

[0011] This specification provides a more detailed description of the embodiments of the methods and systems disclosed herein, so that the features and advantages of the embodiments disclosed herein, as well as any other features and advantages that may become apparent, may be better understood. The following descriptions provide many details to ensure a good understanding of the various embodiments. In other cases, well-known processes, devices, and systems may not be described in particular detail, so as not to unnecessarily obscure the various embodiments. Furthermore, in the drawings of the various embodiments, certain features or details may be omitted, so as not to obscure the various embodiments.

[0012] This specification provides several methods and systems that can be implemented individually or in various combinations to define the boundaries of the gas plant in an olefin production system and promote increased propylene yield. Hydrocarbon feedstocks may consist of heavy feedstocks including heavy atmospheric gas oil, vacuum diesel, deasphalt oil (DAO), and / or atmospheric residue. Hydrocarbon feedstocks may also consist of light hydrocarbon feedstocks including light paraffinic, naphthenic, or olefinic hydrocarbons. FCCUs can be used to accelerate the decomposition of hydrocarbon feedstocks and convert them into high-value products (e.g., ethylene and propylene). Existing FCC units can be refurbished, or new grassroots FCC units can be designed using improved technologies (e.g., MAXOFIN® technology, available from KBR®) to produce light olefins (e.g., ethylene and propylene) from light naphtha streams. MAXOFIN® technology is a process that allows refiners to maximize propylene production by more than 20% with significantly less ethylene than conventional steam cracking. The olefin production system comprises three main sections: the FCCU, the main fractionation unit, and the gas plant section. The gas plant section may include a gas concentration unit (GCU) within a larger vapor recovery unit (VRU). In one embodiment, the olefin production system is a unit that incorporates MAXOFIN® technology. The GCU may include an overhead condenser, chiller, receiver, and wet gas compressor, which are in fluid communication with other equipment (e.g., strippers and primary absorbers) that may be used to process high-value products.

[0013] In this specification, the terms “heavy naphtha” or “full-range naphtha” refer to a mixture of C6 or higher hydrocarbons with a boiling point range of approximately 340°F to 460°F. “Wild naphtha” refers to a mixture of C6 or higher hydrocarbons with a boiling point range of approximately 330°F to 415°F, including some lighter components. “Light naphtha” refers to a mixture of C5 or higher hydrocarbons with a boiling point range of approximately 120°F to 350°F.

[0014] The term "approximately" refers to a range of values ​​that includes a specified value, which a person skilled in the art would reasonably consider to be equivalent to the specified value. In embodiments, "approximately" refers to a value within a standard deviation using generally acceptable measurements in the art. In one non-limiting embodiment, when the term "approximately" is used with a specific value, "approximately" refers to a range extending to ±10% of the specified value, or ±5% of the specified value, or ±1% of the specified value, or ±0.5% of the specified value. In embodiments, "approximately" refers to the specified value.

[0015] The term "rich in" a particular component refers to a stream that contains that component at a concentration of approximately 10% or more by weight, or approximately 15% or more by weight, or approximately 20% or more by weight, or approximately 25% or more by weight, or approximately 30% or more by weight.

[0016] Embodiments include an olefin production system for defining the boundary of a wet gas compressor in a gas concentration unit. One such system includes an FCCU, a fractional distillation unit, an overhead condenser, and a gas concentration unit, the gas concentration unit comprising a chiller, a receiver, and a wet gas compressor. The FCCU houses a riser reactor and a regenerator. Gas plant designs and operating conditions may include a riser reactor with two, three, four, or more risers. Hydrocarbon feedstocks are supplied to the FCCU and converted into decomposition product streams containing light and heavy paraffinic hydrocarbons, naphtha, and aromatic and olefinic hydrocarbons. In some embodiments, the riser reactor is configured to receive two or more different hydrocarbon feedstock streams and a catalyst. The riser reactor within the FCCU may include a quench line for introducing a quench fluid into the riser reactor 1.5 seconds after the hydrocarbon feedstock comes into contact with the catalyst. This interaction enables the creation of a specific product profile in the decomposition product stream (e.g., increased production of olefins). The fractional distillation unit is fluidly connected to the fluid catalytic cracking unit and is configured to receive a cracking product stream and separate it into (i) a vapor product stream containing ethylene, propylene, and light naphtha; (ii) a first wild naphtha product stream; and (iii) a liquid product stream containing one or more of heavy naphtha, light cycle oil, and slurry oil. The overhead condenser is fluidly connected to the fractional distillation unit and is configured to receive a vapor product stream and generate a first cooled fluid stream. In some embodiments, the temperature of the first cooled fluid stream is in the range of about 105°F to about 120°F. In some embodiments, the temperature of the first cooled fluid stream may be in the range of about 100°F to about 120°F, or about 105°F to about 115°F, or about 100°F to about 115°F, or about 100°F to about 110°F. The chiller is located within the gas concentration unit and is in fluid communication with the overhead condenser, configured to receive a first cooled fluid stream and generate a second cooled fluid stream.In one embodiment, the temperature of the second cooled fluid stream is in the range of approximately 55°F to approximately 100°F. In another embodiment, the temperature of the first cooled fluid stream may be in the range of approximately 55°F to approximately 90°F, or approximately 55°F to approximately 85°F, approximately 55°F to approximately 75°F, or approximately 55°F to approximately 65°F. A receiver is located within the gas concentration unit, fluidly connected to the chiller, and is configured to receive the second cooled fluid stream and separate it into a wet gas stream containing ethylene and propylene and a second wild naphtha stream. A wet gas compressor is located within the gas concentration unit, fluidly connected to the receiver, and is configured to increase the pressure of the wet gas stream containing ethylene and propylene to be fed downstream. In another embodiment, the wet gas compressor may increase the pressure of the wet gas stream from approximately 20 pounds / square inch gauge (psig) to approximately 225 psig to be fed downstream. In one embodiment, when the temperature of the first cooled fluid stream drops from about 105°F to about 60°F, the volumetric flow rate of the moist gas stream decreases by about 35 volume%. In another embodiment, the introduction of a chiller reduces the volumetric flow rate of the moist gas stream by about 5 volume%, or about 10 volume%, or about 15 volume%, or about 17 volume%, or about 20 volume%, or about 25 volume%, or about 30 volume%, or about 40 volume%. In another embodiment, the system described herein can increase the propylene yield by at least 3 wt.%, or about 4 wt.%, or about 5 wt.%, or about 5.5 wt.%, or about 6 wt.%, or about 6.5 wt.%, or about 7 wt.%, or about 8 wt.%, or about 10 wt.%, or about 15 wt.%, or about 20 wt.%.

[0017] Figure 1 is an exemplary flow diagram of an olefin production system comprising an FCCU and chiller system within a gas concentration unit for defining the boundary of a wet gas compressor, according to an embodiment of the present disclosure. In one embodiment, the olefin production system 100 includes a fluid catalytic cracking unit 130. The fluid catalytic cracking unit 130 has a reactor and a regenerator 102 with dual risers 104, 106. In such an embodiment, two or more hydrocarbon feedstock streams 101 and 103 are received by the dual risers 104 and 106, respectively. The two or more hydrocarbon feedstock streams may be the same feedstock or different feedstocks. The dual risers 104, 106 enable the generation of a cracking product stream 105. The cracking product stream 105 includes light and heavy paraffinic hydrocarbons, naphtha, and aromatic and olefinic hydrocarbons. The olefin production system 100 further includes a fractional distillation unit 114 that is in fluid contact with the fluid catalytic cracking unit 130. The fractional distillation unit 114 is configured to receive the decomposition product stream 105 from the dual risers 104, 106 and separate the decomposition product stream 105 into (i) a vapor product stream 111 containing ethylene, propylene, and light naphtha, (ii) a first wild naphtha product stream 109, and (iii) a liquid product stream 107 containing one or more of heavy naphtha, light cycle oil, and slurry oil. The olefin production system 100 includes a GCU, which includes one or more of an overhead condenser 116, a chiller 118, a receiver 120, and a wet gas compressor 122. The overhead condenser 116 is in fluid contact with the fractional distillation unit 114 and is configured to receive the vapor product stream 111 from the fractional distillation unit 114 and produce a first cooled fluid stream 113 having a temperature in the range of about 105°F to about 115°F. The chiller 118 is in fluid communication with the overhead condenser 116 and is configured to receive a first cooled fluid stream 113 from the overhead condenser 116 and generate a second cooled fluid stream 115 having a temperature in the range of approximately 60°F to approximately 100°F.The chiller lowers the temperature of the inlet stream to the downstream processing unit within the GCU, reducing the volumetric flow rate through the downstream processing unit.

[0018] The olefin production system 100 further includes a receiver 120 that fluidly communicates with a chiller 118. The receiver 120 is configured to receive a second cooled fluid stream 115 from the chiller 118 and process the second cooled fluid stream 115 to form a wet gas stream 117 containing ethylene and propylene, and a second wild naphtha stream.

[0019] The olefin production system 100 also includes a wet gas compressor 122 in fluid contact with a receiver 120. The wet gas compressor 122 receives a wet gas stream 117 from the receiver 120 and is configured to increase the pressure of the wet gas stream 117, which contains ethylene and propylene, from, for example, 20 psig to 225 psig. This increased-pressure wet gas stream 119 is then supplied to downstream processing. When a chiller 118 lowers the temperature of the wet gas stream 117 supplied to the wet gas compressor 122, the volumetric flow rate of the wet gas stream 117 through the wet gas compressor 122 decreases. The GCU may include a suction drum. The suction drum receives the wet gas stream 117 from the receiver 120 and is configured to remove heavier components from the wet gas stream 117 before it is supplied to the wet gas compressor 122. The pressure conditions of the moist gas stream 117 supplied to the moist gas compressor 122 may be equal to or equivalent to the pressure of the moist gas stream supplied to the compressor in a standard GCU without a chiller. The temperature of the moist gas stream 117 is significantly lower than the temperature of the moist gas stream supplied to the compressor in a standard GCU without a chiller. The reduction in volumetric flow rate may depend on the type of FCCU used with different hydrocarbon feedstocks, operating conditions (e.g., pressure and temperature), and other process conditions applied to the GCU. As a non-limiting example, when the temperature of the moist gas stream produced in the system described herein was reduced from about 100°F to about 60°F, the volumetric flow rate was reduced by 35% compared to moist gas processed in a standard GCU without a chiller. As a non-limiting example, a reduction in the suction flow rate of the moist gas stream produced in the system described herein resulted in an increase in propylene yield of at least about 6.6 wt.% based on modeling data.

[0020] Embodiments also include a method for defining the boundaries of a gas plant using a chiller system downstream of a fractional distillation overhead condenser during the refurbishment of an FCCU unit. One such method for defining the boundaries of a gas plant during the refurbishment of an FCCU includes guiding a hydrocarbon feedstock stream to a riser reactor in the FCCU. The riser reactor produces a decomposition product stream. The method further includes guiding the decomposition product stream from the riser reactor to a fractional distillation unit to produce a vapor product stream, a first wild naphtha stream, and a liquid product stream. The method further includes guiding the vapor product stream from the fractional distillation unit to a GCU including an overhead condenser, chillers, receivers, and a wet gas compressor. The overhead condenser and chillers reduce the temperature and flow rate of the vapor product stream. Reducing the temperature of the vapor product may also include guiding the vapor product stream from the fractional distillation unit to an overhead condenser to produce a first cooled fluid stream. The temperature of the first cooled fluid stream may be in the range of about 100°F to about 120°F. The method further includes guiding a first cooled fluid stream from an overhead condenser to a chiller to generate a second cooled fluid stream. The temperature of the second cooled fluid stream may be in the range of approximately 55°F to approximately 100°F. The method further includes guiding the second cooled fluid stream from the chiller to a receiver to generate a moist gas stream, and guiding the moist gas stream from the receiver to a moist gas compressor to generate a moist gas stream with increased pressure for downstream processing. As the temperature of the moist gas stream decreases before it is supplied to the moist gas compressor, the suction flow rate of the moist gas compressor also decreases.

[0021] The riser reactor may comprise two, three, four, or more riser reactors. In one embodiment, the riser reactor is configured to receive two or more hydrocarbon feedstock streams. Each riser reactor may receive one of the two or more hydrocarbon feedstock streams. The two or more hydrocarbon feedstock streams may be the same feedstock or different feedstocks.

[0022] Figure 2 is an exemplary flow diagram of a catalytic cracking unit with a regenerator and a stripper according to an embodiment of the present disclosure, which facilitates the definition of the wet gas compressor within the gas concentration unit of the olefin production system 200. The olefin production system 200 includes a fluid catalytic cracking unit 230 with dual riser reactors 204, 206. The reactors with dual risers 204, 206 are configured to receive two or more hydrocarbon feedstock streams 201 and 203 as well as a catalyst and produce a cracking product stream 205 containing light and heavy paraffinic hydrocarbons, naphtha, and aromatic and olefinic hydrocarbons, together with the spent catalyst. The fluid catalytic cracking unit 230 further includes a regenerator 202 in contact with the dual riser reactors 204, 206. The regenerator 202 is configured to receive the spent catalyst from the dual riser reactors 204, 206 and regenerate the spent catalyst to produce an encompassed catalyst containing encompassed inert material together with the regenerated catalyst. The regenerator 202 may operate in a temperature range of approximately 1250°F to approximately 1400°F and a pressure range of approximately 35 to approximately 55 psig. The fluid catalytic cracking unit 230 also includes strippers 224, 226 located downstream of the regenerator 202. The strippers 224, 226 are configured to receive encompassed catalyst from the dual riser reactors 204, 206 and produce a regenerated catalyst by removing inert material contained within the encompassed catalyst. The strippers may operate in a temperature and pressure range of approximately 1250°F to approximately 1400°F and a pressure range of approximately 35 to approximately 55 psig, near the temperature and pressure of the regenerator. The strippers may include structured packing and / or a vapor / gas stripping medium. The strippers may be supplied with air, vapor, nitrogen, or similar stripping gas to remove inert material or other material from the encompassed catalyst. The embodiment may include a single stripper that supplies the regenerated catalyst to two risers. The inert substances are combustion products resulting from the combustion of carbonaceous deposits on the spent catalyst, depending on the reactivity of the compound with the catalyst under FCC conditions. The inert substances include carbon oxide, hydrogen sulfide, sulfur oxides, water, and nitrogen.The fluid catalytic cracking unit 230 further includes conduits for supplying regenerated catalysts to the risers of the dual riser reactors 204, 206. The olefin production system 200 further includes a fractional distillation unit 214 which is in fluid contact with the fluid catalytic cracking unit 230. The fractional distillation unit 214 receives a cracking product stream 205 and is configured to separate the cracking product stream 205 into (i) a steam product stream 211 containing ethylene, propylene, and light naphtha, (ii) a first wild naphtha product stream 209, and (iii) a liquid product stream 207 containing one or more of heavy naphtha, light cycle oil, and slurry oil. The olefin production system 200 also includes a steam recovery unit 216 which is in fluid contact with the fractional distillation unit 214. The steam recovery unit receives the steam product stream 211 from the fractional distillation unit 214 and is configured to produce an olefin-rich product stream 213. In addition to the regeneration of spent catalyst by a regenerator, the removal of inert substances contained within the entrained catalyst using a stripper can increase the propylene yield by at least 1.15 wt.% based on FCC modeling data.

[0023] The embodiments also include a method for defining the boundaries of a gas plant using a regenerator and a stripper during the modification of an FCCU unit, such as the system described in FIG. 2. One such method for defining the boundaries of a gas plant during the modification of an FCCU includes introducing a hydrocarbon feed stream and a catalyst into a riser reactor. In the riser reactor, fluid catalytic cracking is performed on the hydrocarbon feed to produce a cracked product stream and a spent catalyst. The method further includes introducing the cracked product stream from the riser reactor into a fractionator to produce a vapor product stream, a first virgin naphtha stream, and a liquid product stream. The method may further include introducing the vapor product stream into a vapor recovery unit to produce an olefin-rich product stream. The method includes introducing the spent catalyst into a regenerator to regenerate the spent catalyst and produce a entrained catalyst. The method further includes introducing the entrained catalyst into a stripper to produce a regenerated catalyst. In certain embodiments, the regenerated catalyst is produced by removing about 40 percent of the inert material contained in the entrained catalyst. In certain embodiments, the regenerated catalyst is produced by removing about 50%, or about 60%, or about 65%, or about 70%, or about 75%, or about 80%, or about 85% of the inert material contained in the entrained catalyst. In certain embodiments, the regenerated catalyst is produced by removing substantially all of the inert material contained in the entrained catalyst. In certain embodiments, the systems and methods described herein can increase the propylene yield by at least 0.5 wt.%, or about 0.75 wt.%, or about 1 wt.%, or about 1.15 wt.%, or about 1.2 wt.%, or about 1.5 wt.%, or about 1.75 wt.%, or about 2 wt.%, or about 3 wt.%, or about 3.5 wt.%.

[0024] Figure 3 is an exemplary flow diagram of a catalytic cracking system with a regenerator and quench lines according to an embodiment of the present disclosure, which facilitates the definition of the wet gas compressor within the gas concentration unit of the olefin production system 300. In one embodiment, the olefin production system 300 includes a fluid catalytic cracking unit 330 with dual riser reactors 304, 306. The reactor with dual risers 304, 306 is configured to receive two or more hydrocarbon feedstock streams 301, 303 and a catalyst, and to produce a cracking product stream 305 containing light and heavy paraffinic hydrocarbons, naphtha, and aromatic and olefinic hydrocarbons. The two or more hydrocarbon feedstock streams may be the same feedstock or different feedstocks. The dual risers 304, 306 are configured to include two quench lines 308, 310, which reduce the catalytic reaction between the hydrocarbon feedstock and the catalyst by introducing a quench fluid. The quench fluid may be heavy naphtha and distillates. The quenching fluid is inert to decomposition and is, for example, water, steam, or a selected hydrocarbon. In one embodiment, the contact time between the hydrocarbon feedstock streams 301, 303 in the risers and the catalyst can be shortened by introducing the quenching fluid with a contact time of 1.5 seconds after the hydrocarbon feedstock has come into contact with the catalyst along the risers (compared to a contact time of 2 seconds in the basic case). The contact time may depend on the dimensions of the risers and the flow rate of the hydrocarbon feedstock through the risers. The introduction of the quenching fluid reduces the generation of dry gas and reduces the load on the wet gas compressor. The riser contact time can also be shortened by hardware changes for riser size. Contact times for different riser dimensions can be developed using modeling principles applicable to FCC reactions. The fluid catalytic cracking unit 330 includes a regenerator 302 that communicates with dual riser reactors 304, 306. The regenerator 302 is configured to receive spent catalyst from the dual risers 304, 306 and regenerate the spent catalyst to produce a regenerated catalyst. The fluid catalytic cracking unit 330 further includes conduits for supplying the regenerated catalyst to the risers of the dual riser reactors 304 and 306.The olefin production system 300 also includes a fractional distillation unit 314 in fluid contact with a fluid catalytic cracking unit 330. The fractional distillation unit 314 receives a cracking product stream 305 and is configured to separate the cracking product stream 305 into (i) a vapor product stream 311 containing ethylene, propylene, and light naphtha, (ii) a first wild naphtha product stream 309, and (iii) a liquid product stream 307 containing one or more of heavy naphtha, light cycle oil, and slurry oil. The olefin production system 300 further includes a vapor recovery unit 316 in fluid contact with the fractional distillation unit 314. The vapor recovery unit is configured to receive the vapor product stream 311 from the fractional distillation unit 314 and produce an olefin-rich product stream 313. As a non-limiting example, based on FCC modeling data, the reduction in reaction between hydrocarbon feedstocks and catalysts in the system described herein resulted in an increase of at least about 3.30 wt.% in propylene yield.

[0025] The embodiments also include a method for defining the boundary of a gas plant using a regenerator and a quench line during the modification of a FCCU unit. One such method for defining the boundary of a gas plant during the modification of a FCCU includes introducing a hydrocarbon feed stream and a catalyst into a riser reactor. In the riser reactor, fluid catalytic cracking is performed on the hydrocarbon feed to produce a cracked product stream and spent catalyst. The method may further include introducing a quench fluid from a quench line communicating with the riser reactor about 1.5 seconds after the hydrocarbon feed contacts the catalyst to shorten the contact time between the hydrocarbon feed and the catalyst. The method further includes introducing the cracked product stream from the riser reactor into a fractionator to produce a vapor product stream, a first virgin naphtha stream, and a liquid product stream. The method may further include introducing the vapor product stream into a vapor recovery unit to produce a product stream rich in olefins. In certain embodiments, the systems and methods described herein can increase the propylene yield by at least 1 wt.%, or about 1.5 wt.%, or about 2 wt.%, or about 2.25 wt.%, or about 2.5 wt.%, or about 3 wt.%, or about 3.1 wt.%, or about 3.2 wt.%, or about 3.3 wt.%, or about 3.5 wt.%, or about 4 wt.%, or about 4.5 wt.%, or about 5 wt.%, or about 6 wt.%.

[0026] Embodiments of the olefin production system include an improved FCCU comprising a riser reactor, a regenerator, and a stripper. The riser reactor is configured to receive a hydrocarbon feedstock stream and catalyst and produce a decomposition product stream containing light and heavy paraffinic hydrocarbons, naphtha, and aromatic and olefinic hydrocarbons, together with the spent catalyst. The regenerator is in communication with the riser reactor and is configured to receive the spent catalyst and regenerate the spent catalyst to produce a conjugated catalyst containing encompassed inert substances along with the regenerated catalyst. The stripper is positioned in communication with the regenerator and is configured to receive the conjugated catalyst and produce a regenerated catalyst by removing inert substances contained within the conjugated catalyst, and is provided with a conduit for supplying the regenerated catalyst to the riser reactor. In one embodiment, the fractional distillation unit is fluid-connected to a fluid catalytic cracking unit and is configured to receive a cracking product stream and separate it into (i) a vapor product stream containing ethylene, propylene, and light naphtha; (ii) a first wild naphtha product stream; and (iii) a liquid product stream containing one or more of heavy naphtha, light cycle oil, and slurry oil. In one embodiment, the vapor recovery unit is fluid-connected to the fractional distillation unit and is configured to receive a vapor product stream and produce an olefin-rich product stream. In one embodiment, the riser may include a quench line for introducing a quench fluid into the riser reactor after the hydrocarbon feedstock stream has come into contact with the catalyst. In one embodiment, the quench fluid is introduced to reduce the reaction time for the fluid cracking of the hydrocarbon feedstock stream by 10%, 20%, or 30% to achieve a specific product profile in the cracking product stream. The quench fluid may be added 1.5 seconds after the hydrocarbon feedstock comes into contact with the catalyst, compared to a basic reaction time of 2 seconds.

[0027] In one embodiment, the riser reactor is configured to receive two or more hydrocarbon feedstock streams and a catalyst. The riser reactor may comprise two, three, four, or more riser reactors. In one embodiment, the riser reactor is configured to receive two or more hydrocarbon feedstock streams. Each riser reactor may receive one of the two or more hydrocarbon feedstock streams. The two or more hydrocarbon feedstock streams may be the same feedstock or different feedstocks.

[0028] Figure 4 is an exemplary flow diagram of an olefin production system 400 according to an embodiment of the present disclosure, comprising a catalytic cracking unit 430 equipped with a regenerator and a stripper, and a chiller system in a gas concentration unit for defining the boundary of a wet gas compressor. The fluid cracking unit 430 includes dual riser reactors 404, 406. The dual riser reactors 404, 406 are configured to receive two or more hydrocarbon feedstocks 401, 403 and a catalyst and to produce a cracking product stream 405 containing light and heavy paraffinic hydrocarbons, naphtha, and aromatic and olefinic hydrocarbons, together with the spent catalyst. The dual riser reactors 404, 406 are configured to include two quench lines 408, 410, which reduce the catalytic reaction between the hydrocarbon feedstocks 401, 403 and the catalyst by introducing a quench fluid. The fluid cracking unit 430 further includes a regenerator 402 in contact with the dual risers 404, 406. The regenerator 402 is configured to receive spent catalyst from the dual riser reactors 404 and 406, regenerate the spent catalyst to produce an encompassed catalyst containing encompassed inert substances along with the regenerated catalyst. The fluid decomposition unit 430 also includes strippers 424 and 426 that communicate with the regenerator 402. The strippers are configured to receive the encompassed catalyst from the regenerator 402 and produce a regenerated catalyst by removing inert substances contained within the encompassed catalyst. The fluid decomposition unit 430 further includes conduits for supplying the regenerated catalyst to the risers of the dual riser reactors 404 and 406. The regenerated catalyst may be used together with two or more hydrocarbon feedstocks to produce a decomposition product stream.

[0029] The olefin production system 400 further includes a fractional distillation unit 414 which is in fluid contact with a fluid catalytic cracking unit 430. The fractional distillation unit 414 receives a cracking product stream 405 from dual risers 404, 406 and is configured to separate the cracking product stream 405 into (i) a vapor product stream 411 containing ethylene, propylene, and light naphtha, (ii) a first wild naphtha product stream 409, and (iii) a liquid product stream 407 containing one or more of heavy naphtha, light cycle oil, and slurry oil. The olefin production system 400 also includes an overhead condenser 416 which is in fluid contact with the fractional distillation unit 414. The overhead condenser 416 receives the vapor product stream 411 from the fractional distillation unit 414 and is configured to produce a first cooled fluid stream 413 having a temperature in the range of about 100°F to about 120°F. The olefin production system 400 further includes a chiller 418 in fluid communication with an overhead condenser 416. The chiller 418 is configured to receive a first cooled fluid stream 413 from the overhead condenser 416 and produce a second cooled fluid stream 415 having a temperature in the range of about 60°F to about 100°F. The olefin production system 400 also includes a receiver 420 in fluid communication with the chiller 418. The receiver 420 is configured to receive the second cooled fluid stream 415 from the chiller 418 and separate the second cooled fluid stream 415 into a wet gas stream 417 containing ethylene and propylene and a second wild naphtha stream 423. The olefin production system 400 also includes a wet gas compressor 422 in fluid communication with the receiver 420. The wet gas compressor 422 receives the wet gas stream 417 from the receiver 420 and is configured to increase the pressure of the wet gas stream 417, which contains ethylene and propylene to be supplied to the downstream treatment 419. In one embodiment, the pressure of the wet gas stream is increased from 20 psig to 225 psig to be supplied to the downstream treatment.

[0030] Embodiments also include methods for defining the boundaries of a gas plant using a chiller system on a fractional distillation overhead condenser during the refurbishment of an FCCU unit. One such method for defining the boundaries of a gas plant during FCCU refurbishment includes guiding a product stream rich in ethylene, propylene, or a combination thereof from a fluid catalytic cracking unit to a fractional distillation unit. The fluid catalytic cracking unit may include a single riser or a dual or multi-riser. For example, MAXOFIN® technology uses a dual riser system that maximizes propylene production by more than 20% while reducing ethylene production. MAXOFIN® technology has proven to be more efficient than conventional steam cracking. Furthermore, MAXOFIN® technology provides refineries with the flexibility to operate in various operating modes depending on market demand. These various operating modes include operating as a conventional FCC system to produce gasoline, or as a propylene FCC system to produce additional propylene. In some embodiments, the gas plant design and operating conditions include riser reactors with two, three, four, or more risers.

[0031] Different hydrocarbon feedstocks can be decomposed in a fluid catalytic cracking unit to produce a first and a second effluent. For example, a hydrocarbon feedstock containing heavy oil is supplied to the first riser, and a hydrocarbon feedstock containing light oil is supplied to the second riser. Additives may be added to the first and second risers. In one embodiment, a proprietary MAXOFIN® additive available from KBR may be added. Thus, the MAXOFIN® additive may provide further advantages in the production of propylene. In one embodiment, the catalyst includes an FCC-based catalyst and a ZSM additive catalyst. Crystalline aluminosilicates used for the decomposition of light hydrocarbon feedstocks are exemplified by ZSM-5 and similar catalysts. In one embodiment, a CO accelerator, sulfur oxide (SO4) X) Additives, and one or more of other additives, may be added to the regenerator and subsequently transported to the riser. In some embodiments, the catalyst is heated.

[0032] In some embodiments, the first riser conditions and the second riser conditions are different. These different conditions may include temperature, catalyst-to-oil ratio, hydrocarbon partial pressure, vapor-to-oil ratio, residence time, or a combination thereof. In other embodiments, the first riser conditions and the second riser conditions are the same. In some embodiments, the first and second emissions from the first and second risers are the same. In other embodiments, the first and second emissions differ either due to the introduction of different feedstocks or different operating conditions. In some embodiments, the method further includes processing the first and second emissions in a fractional distillation unit to fractionate them into several product streams. In some embodiments, the fractional distillation unit may have a top pressure of about 25 psig and a top temperature of about 250°F. The product stream may include (1) a vapor product stream containing fuel gas, C3, isobutylene (C4), and light naphtha; (2) a wild naphtha product stream; and (3) a fractional distillation unit liquid product stream containing one or more of heavy naphtha, light cycle oil, and slurry oil.

[0033] The method may further include directing the vapor product stream to a gas enrichment unit including an overhead condenser, chiller, receiver, and wet gas compressor. The overhead condenser and chiller reduce the temperature and flow rate of the vapor product stream. Reducing the temperature of the vapor product may also include directing the vapor product stream from the fractional distillation unit to the overhead condenser, thereby reducing the stream temperature to approximately 120°F, or approximately 115°F, or approximately 110°F, or approximately 105°F, or approximately 100°F. Reducing the temperature of the vapor product may also include directing the vapor product stream from the overhead condenser to the chiller system, reducing the stream temperature to approximately 90°F, or approximately 80°F, or approximately 75°F, or approximately 65°F, or approximately 62°F, or approximately 60°F, or approximately 55°F. The overhead condenser may affect the chiller configuration. The chiller system may depend on the residence time, physical dimensions, and cooling capacity of the chiller system. The chiller system is evaluated based on the cooling load. The method may further include directing a cooled fluid stream to a receiver and a wet gas compressor. The decrease in the suction temperature of the wet gas compressor also reduces the suction flow rate of the wet gas compressor. In one embodiment, the introduction of a chiller reduces the volumetric flow rate of the wet gas stream in the wet gas compressor by about 5 vol% or about 10 vol% or about 15 vol% or about 17 vol% or about 20 vol% or about 25 vol% or about 30 vol% or about 40 vol% or about 42 vol% or about 45 vol%. In a non-limiting example, the volumetric flow rate in the wet gas compressor may decrease by 40 percent when the temperature drops from about 105°F to about 60°F.

[0034] Embodiments include a method for defining a gas plant boundary using a regenerator catalyst stripper to reduce inert material encompassed to the catalyst during the refurbishment of an FCCU. In one embodiment, the method for defining a gas plant boundary during the refurbishment of an FCC unit includes guiding the spent catalyst from a riser in a fluid catalytic cracking unit to a regenerator. The regenerator produces an encompassed catalyst containing inert material encompassed with the regenerated catalyst. Removing the inert material from the encompassed catalyst increases the propylene yield. Steam may be introduced into a stripper downstream of the regenerator to remove the encompassed inert material. The stripper may have baffles, which may be angled and oriented to provide a uniform flow over the baffles and increase the contact time between the catalyst and the steam. The residence time of the stripper may be about 20 seconds to about 50 seconds. The stripper may operate at or near the temperature and pressure of the regenerator. The residence time may maximize the surface area for mass transfer and increase the efficiency of removing the encompassed inert material. The amount of entrained inert material removed can be up to 85% in the regenerated catalyst. The amount of inert material that can be removed is determined by the structured packing in the stripper and the stripping medium. The catalyst contact time can be approximately 30 seconds.

[0035] The method may further include guiding the steam product stream from the fractional distillation unit to a gas concentration unit. The method may also include guiding the fractional distillation unit steam product stream from the overhead condenser of the fractional distillation unit to a wet gas compressor. The amount of entrained inert material removed can reduce the carryover to the fluid catalytic cracking unit. The reduction in the carryover of entrained inert material can also reduce the load on the wet gas compressor. In one embodiment, the reduction in the load on the wet gas compressor increases the propylene yield.

[0036] Embodiments include a method for defining the boundaries of a gas plant during FCCU refurbishment by introducing a quench line to reduce the contact time between hydrocarbon feedstock and catalyst in a riser reactor. In one embodiment, the method for defining the boundaries of a gas plant during FCCU refurbishment may include introducing a first hydrocarbon feedstock and a first catalyst into a first riser. The first riser may have a quench line for introducing a quench fluid to bring the first hydrocarbon feedstock and the first catalyst into contact. In one embodiment, the method may also include quenching the first hydrocarbon feedstock by quenching at a first riser contact time of 1.5 seconds after the first hydrocarbon feedstock and the first catalyst are introduced into the first riser. In other embodiments, the riser contact time may be reduced by an alternative hardware change to a fluid catalytic cracking unit. In one embodiment, the method may further include introducing a second hydrocarbon feedstock and a second catalyst into a second riser. The second riser has a quench line for introducing a quench fluid to bring the second hydrocarbon feedstock and the second catalyst into contact. In one embodiment, the method may also include quenching the second hydrocarbon feedstock by quenching 1.5 seconds after the second hydrocarbon feedstock and the second catalyst are introduced into the second riser. In other embodiments, the inclusion of a quench fluid can reduce the contact time in the riser by at least 0.5 seconds compared to an FCCU without this quench line. Alternatively, the riser contact time of the first and second hydrocarbon feedstocks can be reduced by alternative riser modifications, as described herein.

[0037] One embodiment includes an olefin production method comprising the following steps: (i) leading a product stream rich in ethylene, propylene, or a combination thereof from a fluid catalytic cracking unit to a fractional distillation unit to separate the cracking product stream into three streams: a vapor product stream, a first wild naphtha product stream, and a liquid product stream; (ii) leading the vapor product stream to an overhead condenser to generate a first cooled fluid stream with a temperature in the range of about 100°F to about 120°F; (iii) leading the first cooled fluid stream to a chiller to generate a second cooled fluid stream with a temperature in the range of about 60°F to about 100°F; and (iv) supplying the second cooled fluid stream to a receiver to separate the second cooled fluid stream into a wet gas stream containing ethylene and propylene and a second wild naphtha stream. The wet gas stream is supplied to a wet gas compressor in a gas concentration unit to increase the pressure to be supplied to downstream processing. In one embodiment, the method further includes guiding the spent catalyst from the riser of the fluid catalytic cracking unit to a regenerator to generate a regenerated catalyst containing encompassed inert matter along with the regenerated catalyst. The encompassed catalyst is then passed through a stripper to remove inert matter from the encompassed catalyst, generating a regenerated catalyst from which a large amount of encompassed inert matter has been removed. The method may also include introducing a quenching fluid into the riser of the fluid catalytic cracking unit to reduce the contact time between the hydrocarbon feedstock and the catalyst in the riser by at least 0.5 seconds compared to an FCCU without this quenching line.

[0038] Where ranges are disclosed herein, a range from any lower limit may, in combination with any upper limit, describe ranges not expressly stated; similarly, a range from any lower limit may, in combination with any other lower limit, describe ranges not expressly stated; similarly, a range from any upper limit may, in combination with any other upper limit, describe ranges not expressly stated. Furthermore, references to values ​​indicated within a range include all values ​​within that range, even if not expressly stated. Thus, every point or individual value may function as its own lower or upper limit in combination with other points or individual values, or with other lower or upper limits, and may serve to describe ranges not expressly stated.

[0039] Other purposes, features, and advantages of this disclosure will become apparent from the preceding drawings, detailed description, and examples. These drawings, detailed description, and examples illustrate specific embodiments of this disclosure, but are for illustrative purposes only and are not intended to limit them. In further embodiments, features from a particular embodiment may be combined with features from other embodiments. For example, features from one embodiment may be combined with features from any of the other embodiments. In further embodiments, additional features may be added to the particular embodiments described herein. This disclosure includes certain aspects, embodiments, and optional features, but it should be understood that modifications, improvements, or changes to such aspects, embodiments, and optional features can be made by those skilled in the art, and such modifications, improvements, or changes are considered to be within the scope of this disclosure.

Claims

1. An olefin manufacturing system, wherein the system is A fluid catalytic cracking unit comprising a riser reactor and a regenerator, configured to receive hydrocarbon feedstock and produce a cracking product stream comprising light and heavy paraffinic hydrocarbons, naphtha, and aromatic and olefinic hydrocarbons, A fractional distillation apparatus having fluid communication with the fluid catalytic cracking unit, wherein the fractional distillation apparatus is configured to receive the cracking product stream and separate it into (i) a vapor product stream containing ethylene, propylene, and light naphtha, (ii) a first wild naphtha product stream, and (iii) a liquid product stream containing one or more of heavy naphtha, light cycle oil, and slurry oil, An overhead condenser in fluid communication with the fractional distillation apparatus, configured to receive the vapor product stream and generate a first cooled fluid stream with a temperature in the range of about 105 degrees Fahrenheit (°F) to about 120°F, A chiller provided within a gas concentration unit and in fluid communication with the overhead condenser, configured to receive the first cooled fluid stream and generate a second cooled fluid stream with a temperature in the range of approximately 55°F to approximately 100°F, A receiver provided within the gas concentration unit and in fluid communication with the chiller, configured to receive the second cooled fluid stream and separate the second cooled fluid stream into a wet gas stream containing the ethylene and the propylene and a second wild naphtha stream, An olefin production system comprising: a wet gas compressor provided within the gas concentration unit and in fluid communication with the receiver, configured to increase the pressure of the wet gas stream containing ethylene and propylene to be supplied to downstream processing, thereby generating an olefin-rich product stream.

2. The olefin production system according to claim 1, wherein the temperature of the first cooled fluid stream is in the range of about 105°F to about 115°F.

3. The olefin production system according to claim 1, wherein the temperature of the second cooled fluid stream is in the range of about 55°F to about 75°F.

4. The olefin production system according to claim 1, wherein the riser reactor is configured to receive two or more hydrocarbon feedstock streams and a decomposition catalyst.

5. The olefin production system according to claim 1, wherein the wet gas compressor increases the pressure of the wet gas stream from 20 pounds per square inch gauge (psig) to 225 psig to be supplied to the downstream processing.

6. The olefin production system according to claim 1, wherein the riser reactor includes a quench line for introducing a quench fluid into the riser reactor 1.5 seconds after the hydrocarbon raw material comes into contact with the catalyst.

7. The olefin production system according to claim 1, wherein when the temperature of the first cooled fluid stream decreases from about 105°F to about 60°F, the volumetric flow rate of the wet gas stream decreases by about 35 volume%.

8. An olefin manufacturing system, wherein the system is A fluid catalytic decomposition unit, A riser reactor configured to receive a hydrocarbon feedstock stream and a catalyst, and to produce a decomposition product stream containing light and heavy paraffinic hydrocarbons, naphtha, and aromatic and olefinic hydrocarbons together with the spent catalyst, A regenerator in contact with the riser reactor, configured to receive the spent catalyst, regenerate the spent catalyst, and produce an encompassed catalyst containing an inert substance encompassed with the regenerated catalyst, A stripper that communicates with the regenerator, configured to receive the entrained catalyst and generate the regenerated catalyst by removing the inert substance contained within the entrained catalyst, A fluid catalytic cracking unit including a conduit for supplying the regenerating catalyst to the riser reactor, A fractional distillation apparatus having fluid communication with the fluid catalytic cracking unit, wherein the fractional distillation apparatus is configured to receive the cracking product stream and separate it into (i) a vapor product stream containing ethylene, propylene, and light naphtha, (ii) a first wild naphtha product stream, and (iii) a liquid product stream containing one or more of heavy naphtha, light cycle oil, and slurry oil, An olefin production system comprising a steam recovery unit that is in fluid communication with the fractional distillation apparatus, the steam recovery unit configured to receive the steam product stream and generate an olefin-rich product stream.

9. The olefin production system according to claim 8, wherein the regenerated catalyst is produced by removing about 75 percent of the inert substance contained in the entrained catalyst.

10. The olefin production system according to claim 8, wherein the riser reactor is configured to receive two or more hydrocarbon feedstock streams and the catalyst.

11. The olefin production system according to claim 8, wherein the riser reactor includes a quench line for introducing a quench fluid into the riser reactor 1.5 seconds after the hydrocarbon feedstock stream comes into contact with the catalyst.

12. An olefin manufacturing system, wherein the system is A fluid catalytic decomposition unit, A riser reactor configured to receive a hydrocarbon feedstock stream and a catalyst, and to produce a decomposition product stream containing light and heavy paraffinic hydrocarbons, naphtha, and aromatic and olefinic hydrocarbons together with the spent catalyst, A regenerator in communication with the riser reactor, configured to receive the spent catalyst from the riser reactor, regenerate the spent catalyst, and produce an encompassed catalyst containing an inert substance encompassed with the regenerated catalyst, A stripper that communicates with the regenerator, configured to receive the entrained catalyst and generate the regenerated catalyst by removing the inert substance contained within the entrained catalyst, A fluid catalytic cracking unit including a conduit for supplying the regenerating catalyst to the riser reactor, A fractional distillation apparatus having fluid communication with the fluid catalytic cracking unit, wherein the fractional distillation apparatus is configured to receive the cracking product stream and separate the cracking product stream into (i) a vapor product stream containing ethylene, propylene, and light naphtha, (ii) a first wild naphtha product stream, and (iii) a liquid product stream containing one or more of heavy naphtha, light cycle oil, and slurry oil, An overhead condenser in fluid communication with the fractional distillation apparatus, configured to receive the vapor product stream and generate a first cooled fluid stream with a temperature in the range of about 105 degrees Fahrenheit (°F) to about 120°F, A chiller that fluidically communicates with the overhead condenser, configured to receive the first cooled fluid stream and generate a second cooled fluid stream with a temperature in the range of approximately 55°F to approximately 100°F, A receiver that fluidly communicates with the chiller, and is configured to receive the second cooled fluid stream and separate the second cooled fluid stream into a wet gas stream containing the ethylene and the propylene and a second wild naphtha stream, A fluid catalytic cracking unit comprising: a wet gas compressor in fluid communication with the receiver, configured to receive the wet gas stream and increase the pressure of the wet gas stream containing ethylene and propylene to be supplied to downstream processing to produce an olefin-rich product stream.

13. The olefin production system according to claim 12, wherein the temperature of the first cooled fluid stream is in the range of about 105°F to about 115°F.

14. The olefin production system according to claim 12, wherein the temperature of the second cooled fluid stream is in the range of about 55°F to about 75°F.

15. The olefin production system according to claim 12, wherein the riser reactor is configured to receive two or more hydrocarbon feedstock streams and the catalyst.

16. The olefin production system according to claim 12, wherein the wet gas compressor increases the pressure of the wet gas stream from 20 pounds per square inch gauge (psig) to 225 psig to be supplied to the downstream processing.

17. The olefin production system according to claim 12, wherein the regenerated catalyst is produced by removing about 75 percent of the inert substance contained in the entrained catalyst.

18. The olefin production system according to claim 12, wherein the regenerated catalyst is produced by removing about 85 percent of the inert substance contained in the entrained catalyst.

19. The olefin production system according to claim 12, wherein the riser reactor includes a quench line for introducing a quench fluid into the riser reactor 1.5 seconds after the hydrocarbon feedstock stream comes into contact with the catalyst.

20. The olefin production system according to claim 12, wherein when the temperature of the first cooled fluid stream in the chiller decreases from about 105°F to about 60°F, the volume flow rate of the wet gas stream decreases by about 35 volume%.

Images