Fluid catalytic cracking process for producing light olefins from crude oil and equipment

Abstract

A reactor system configured for efficient removal of contaminants (e.g., CCR, nickel, vanadium, nitrogen, sodium, iron, calcium, chlorine) from the heavy fraction of crude oil is disclosed. The product is transferred to a common main fractionation section. The lean heavy feed may then be processed in a fluid catalytic cracking (FCC) unit, a comprehensive concept that utilizes a fluid catalytic reaction platform with a carbon rejection approach. Also disclosed is a reactor system for efficient crude oil processing in a fluid catalytic cracking unit using a dual reactor and dual catalyst system to maximize petrochemical components from various crude oils, such as ethylene, propylene, butenes, and BTX (benzene, toluene, and xylene)-rich naphtha.

Description

[Background technology]

[0001] When the final boiling point of the hydrocarbon mixture is high, for example, above 550° C., the hydrocarbon mixture typically cannot be directly processed. The presence of these heavy hydrocarbons can cause coke formation in the reactor, and such coking can occur quickly. Whole crude oil also typically contains, for example, Conradson carbon, metals, and other impurities that make the direct processing of whole crude oil more difficult.

[0002] Furthermore, the emergence of tight oil and shale oil provides abundant petroleum resources. However, due to differences in oil properties and chemical composition, it poses significant processing challenges. Specifically, one major challenge for processing tight oil / shale oil using FCC technology in refineries compared to processing conventional crude oil is the high concentration of metals such as iron and calcium that are not present in the conventional oil.

[0003] High concentrations of iron, calcium and other metals, for example, can cause iron and calcium deposits on the catalyst surface. The deposited iron and calcium can form a thick metal shell layer on the catalyst, causing diffusion losses of oil vapors. This results in loss of conversion and an increase in coke and heavy oil products. High concentrations of iron and calcium deposits on the catalyst can change catalyst properties, affect catalyst circulation, and lead to processing and performance problems. Summary of the Invention [Problem to be solved by the invention]

[0004] To minimize the impact of these unconventional metals, especially at the relatively high contaminant concentrations found in tight / shale oil, refiners typically must significantly increase their daily catalyst loading to mitigate metal buildup on the catalyst and facilitate catalyst circulation, but this comes at a dramatic increase in operational costs. [Means for solving the problem]

[0005] The disclosed embodiments relate to a reactor system configured for efficient removal of contaminants (CCR, nickel, vanadium, nitrogen, sodium, iron, calcium, etc.) from the heavy fraction of crude oil. The products are transferred to a common main fractionation section. The lean heavy feed may then be processed in a Fluid Catalytic Cracking (FCC) unit, which is a generic concept that uses a fluid catalytic reaction platform with a carbon rejection approach.

[0006] In one aspect, embodiments of the present disclosure relate to a system useful for catalytic cracking of whole crude oil. The system may include a separator for separating the whole crude oil into a low boiling fraction and a high boiling fraction. The system may also include a regenerator configured to regenerate a spent first catalyst and a spent second catalyst. The regenerator may, in various embodiments, include a first outlet for carrying a mixture of the regenerated first catalyst and the second catalyst, and a second outlet for carrying a mixture of the regenerated first catalyst and the second catalyst. The riser reactor may be configured to receive the regenerated catalyst mixture and may be used to contact the high boiling fraction with the catalyst mixture to convert the hydrocarbons in the high boiling fraction to lighter hydrocarbons. The catalyst mixture may include a first catalyst and a second catalyst, and the first catalyst may have a density higher than that of the second catalyst, an average particle size higher than that of the second catalyst, or both a higher density and an average particle size higher than that of the second catalyst. The riser reactor may include an inlet for receiving a catalyst mixture comprising the regenerated first catalyst and the second catalyst from the regenerator, and an outlet for conveying a mixture of the converted hydrocarbons and the catalyst mixture.

[0007] The system may also include a second reactor for contacting the low boiling fraction with a concentrated catalyst mixture comprising the first catalyst and the second catalyst, where the concentration of the first catalyst may be higher than the mixture received from the catalyst regenerator. The second reactor may include an inlet for receiving the catalyst mixture comprising the regenerated first catalyst and the second catalyst from the regenerator, and an outlet for conveying the mixture of the converted hydrocarbons, the first catalyst and the second catalyst to a catalyst separation system.

[0008] The catalyst separation system may be configured to separate the first catalyst from the mixture including the second catalyst and the converted hydrocarbons based on at least one of catalyst size or catalyst density, thereby generating a first stream including the separated first catalyst and a second stream including the second catalyst and the converted hydrocarbons. The catalyst separation system may feed an inlet to a second reactor for receiving the first stream including the separated first catalyst, thereby increasing the concentration of the first catalyst in the second reactor.

[0009] One or more separation vessels may be provided for separating the catalyst from the converted hydrocarbons. The separation vessel may include one or more inlets for receiving (i) a second stream comprising the second catalyst and the converted hydrocarbons and / or (ii) a mixture of the converted hydrocarbons and the catalyst mixture. The separation vessel may be configured to separate and recover a first effluent comprising the converted hydrocarbons and a second effluent comprising the mixture of the spent first catalyst and the second catalyst. A flow line may also be provided for carrying the mixture of the spent first catalyst and the second catalyst from the separation vessel to a regenerator.

[0010] In another aspect, an embodiment of the present disclosure relates to a method for catalytic cracking of whole crude oil, which may also include separating the whole crude oil into a low boiling fraction and a high boiling fraction. The high boiling fraction may then be converted in a first two-vessel reactor dual catalyst system to produce a converted hydrocarbon effluent. The low boiling fraction may then be converted in a second two-vessel reactor dual catalyst system to produce a converted hydrocarbon effluent.

[0011] The converted hydrocarbon effluents from each of the first and second two-vessel reactor dual catalyst systems may then be separated in a common fractionation system configured to separate the converted hydrocarbon fraction into two, three, or more hydrocarbon fractions, which may include, for example, one or more olefin-containing fractions and a treated fluid catalytic cracking feedstock.

[0012] The conversion of the high boiling fraction in the first two-vessel reactor dual catalyst system may include contacting the high boiling fraction with a residual fluid catalytic cracking catalyst and contacting the contaminated residual fluid catalytic cracking catalyst with a metal trap. The conversion of the low boiling fraction in the second two-vessel reactor dual catalyst system may include contacting the treated fluid catalytic cracking feedstock with a mixed catalyst system including the first catalyst and the second catalyst in the first reactor and contacting the low boiling fraction with a mixed catalyst system including the first catalyst and the second catalyst in the second reactor. In the second reactor, the first catalyst may be relatively more concentrated than that received from the first reactor and / or the catalyst regenerator. Following conversion, the effluents from each of the first and second reactors may be separated into a spent catalyst mixture and a converted hydrocarbon effluent. The converted hydrocarbon effluents from the first and second twin-reactor dual catalyst systems are then fed to a common fractionation system.

[0013] In yet another aspect, an embodiment of the present disclosure relates to a system useful for catalytic cracking of whole crude oil. The system may also include a separator for separating the whole crude oil into a low boiling fraction and a high boiling fraction. The system may also include a first two-vessel reactor dual catalyst system and a second two-vessel reactor dual catalyst system, each producing a converted hydrocarbon effluent. A common fractionation system may receive the converted hydrocarbon effluent from each of the first two-vessel reactor dual catalyst system and the second two-vessel reactor dual catalyst system, and the common fractionation system is configured to separate the converted hydrocarbon fraction into two or more hydrocarbon fractions including the fraction and one or more olefins containing treated fluid catalytic cracking feedstock.

[0014] The first two-vessel reactor dual catalyst system may be configured for contacting the high boiling fraction with the residual fluidized catalytic cracking catalyst and for contacting the contaminated residual fluidized catalytic cracking catalyst with the metal trap.

[0015] The second two-vessel dual catalyst system may include a first reactor for contacting the treated fluid catalytic cracking feed with a mixed catalyst system including the first catalyst and the second catalyst. The second two-vessel dual catalyst system may include a second reactor for contacting the low boiling fraction with a mixed catalyst system including the first catalyst and the second catalyst. As with other embodiments of the present disclosure, the first catalyst may be at a relatively higher concentration in the second reactor than that received from the first reactor or the catalyst regenerator.

[0016] The system may also include a catalyst separation vessel configured to receive and separate effluents from each of the first and second reactors from the second two-reactor dual catalyst system fed to the common fractionation system into a spent catalyst mixture and a converted hydrocarbon effluent.

[0017] Other aspects and advantages will become apparent from the following specification and appended claims. [Brief description of the drawings]

[0018] [Figure 1] 1 is a simplified flow diagram illustrating a catalyst concentration system useful in embodiments of the present disclosure. [Diagram 2] 1 is a simplified flow diagram illustrating a method for converting whole crude oil according to an embodiment of the present disclosure. [Diagram 3] 1 is a simplified flow diagram illustrating a method for converting whole crude oil according to an embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] As used in this disclosure, terms such as "catalyst" and "particles" may be used interchangeably. As summarized above and further described below, embodiments of the present disclosure separate mixed particulate materials on a size and / or density basis to achieve advantageous effects in the overall crude oil conversion system. The particles or particulate materials used to facilitate the reaction may include, for example, catalysts, absorbents, and / or catalytically inactive heat transfer materials.

[0020] The embodiments of the present disclosure generally relate to systems and methods for enhancing the processability of whole crude oil and other wide boiling range hydrocarbon mixtures. More specifically, the embodiments of the present disclosure relate to the productivity and / or flexibility of processing whole crude oil and other wide boiling range hydrocarbon mixtures by fluid catalytic cracking using mixed catalyst systems and / or mixed catalyst / sorbent systems. The methods and apparatuses disclosed in the present disclosure, in some embodiments, can be advantageous for the overall conversion of whole crude oil and other wide boiling range hydrocarbon mixtures to light olefins such as propylene and ethylene, and aromatics, and high octane gasoline and / or diesel, in very high yields.

[0021] Embodiments of the present disclosure include reaction or conditioning systems that may include a common regenerator that may be used to regenerate mixtures of particles that may include, for example, mixtures of two or more catalysts, mixtures of catalysts and pollutant trap additives, mixtures of two or more catalysts with pollutant trap additives, mixtures of pollutant trap additives and heat transfer particles, and possible combinations of other catalysts, pollutant trap additives, and / or inert particles.

[0022] Embodiments of the present disclosure may also include a catalyst concentration system or vessel, and / or a pollutant scavenging additive concentration system or vessel. Since a mixture of particles may be provided from a common regenerator, a catalyst / scavenging additive concentration system may be provided to increase the concentration of a desired catalyst or scavenging additive for use in a reactor or processor. In some embodiments, the catalyst or scavenging additive may be concentrated to a concentration 3 to 4 times higher than that received from the regenerator. The concentrated catalyst or additive may then provide a more favorable conversion or processing than a mixed particle system.

[0023] For example, catalyst concentration can also be performed in the separation system 2 as illustrated in Figures 1A and 1B, where like reference numerals represent like parts. The mixture including steam and catalyst can be fed to a solids separation device 6 via flow line 4. As illustrated in Figure 1A, the flow line 4 can be an outlet line from a moving or fluidized bed reactor 7 carrying a mixture of converted hydrocarbons and catalyst particles in some embodiments, or from a moving / fluidized bed contaminant removal vessel 7. In other embodiments, as illustrated in Figure 1B, the flow line 4 can be a riser reactor for contacting one or more hydrocarbon feeds 8, 10 with a mixture of catalyst received via flow line 12, such as from a catalyst regenerator (not shown). The mixture of steam and catalyst can include, for example, converted hydrocarbons, a first catalyst, and a second catalyst, which can be received from a riser reactor or a moving fluidized bed reactor for catalytically converting hydrocarbons. In other embodiments, the mixture fed to solids separator 6 may include a mixture of lift gas, catalyst, and metal trap, such as may be received from contaminant removal vessel 7.

[0024] The particles in the mixture fed to the solids separation device 6 may include a first particle type (such as a first catalyst used for residue cracking or metal trapping) and a second particle type (such as a second catalyst), where the first particle type may have at least one of a larger diameter or a higher density than the second particle type. Within the solids separation device 6, the vapor and mixed particles may be separated to recover a solids stream 20 including the larger and / or denser first particle type, and a mixed effluent stream 22 including the liftoff gas / converted hydrocarbons and the second particle type.

[0025] In some embodiments, as illustrated in Figure 1A, effluent 22 may be sent to a downstream unit (not shown). For example, effluent 22 may be fed to a separation vessel (not shown) for separating the second catalyst from the hydrocarbon vapors. As another example, effluent 22 may be fed to a catalyst regenerator (not shown) for separating the lift-off gas from the catalyst. The particles recovered via flow line 20 may be returned to reactor 7, thereby concentrating the particles (metal traps or first catalyst) in reactor 7.

[0026] 1B, the effluent 22 can be fed to a separator, such as a cyclone separator 24, to separate the effluent vapors recovered via flow line 26 from the catalyst recovered via flow line 28. The particles recovered via flow line 28 can then be returned to a catalyst regenerator (not shown) and the particles recovered via flow line 20 can be returned to the riser reactor 4, thereby concentrating the second catalyst in the riser reactor 4.

[0027] In some embodiments, a system useful for catalytic cracking of whole crude oil may include a single regenerator dual reactor system, also referred to in this disclosure as a two-vessel reactor dual catalyst system. The system may include at least two reactors, such as a moving or fluidized bed reactor and a riser reactor for processing whole crude oil, multiple riser reactors, or multiple moving or fluidized bed reactors. Each reactor vessel may receive catalyst from a single regenerator.

[0028] Referring to Figure 2, where like numbers represent like parts, a reactor system for processing whole crude oil is illustrated. The system may include a separator 30 for separating whole crude oil 32, for example, desalted whole crude oil, into a low boiling fraction 34 and a high boiling fraction 36. In some embodiments, separation of the whole crude oil into low boiling and high boiling fractions may include separation of the low boiling fraction from the high boiling fraction, with 95% of the low boiling fraction having a final boiling temperature within the range of about 300°C to about 420°C. However, the actual cut points for separation may be based on the particular crude oil being processed.

[0029] The system may also include a regenerator 38 for regenerating the spent first catalyst and the spent second catalyst. The catalyst mixture may include a first catalyst and a second catalyst, where the first catalyst has a higher density than the second catalyst, a larger particle size than the second catalyst, or both a higher density and a larger particle size than the second catalyst.

[0030] The regenerator 38 may include a first outlet 12 for carrying the mixture of regenerated first and second catalysts, and a second outlet 25 for carrying the mixture of regenerated first and second catalysts from the regenerator. The outlet 25 may feed the catalyst to the inlet 28 of the riser reactor 3, which may include the mixture of the first and second catalysts from the regenerator. The fluidizing gas 1a may be used, for example, to carry the catalyst to the reactor 3. In the riser reactor 3, the high boiling fraction 36 may contact the catalyst mixture, and the hydrocarbons in the high boiling fraction are converted to lighter hydrocarbons. An outlet 40 from the riser reactor may then carry the reactor effluent, a mixture of converted hydrocarbons and catalyst mixture, to a separation vessel 42.

[0031] The outlet 12 may provide the regenerated first and second catalysts to the second reactor 7 for contacting the low boiling fraction 34 with the concentrated catalyst mixture comprising the first and second catalysts. As previously described with respect to Figures 1A and 1B, the first catalyst may be concentrated in the second reactor 7 via the catalyst concentration and separation system 2 using the catalyst / solids separation system 6. The second reactor may include an inlet for receiving the catalyst mixture comprising the regenerated first and second catalysts from the regenerator. As described with respect to Figure 1A, the second reactor may also include an outlet 4 for conveying the mixture of the converted hydrocarbons, the first catalyst and the second catalyst to the catalyst / solids separation system 6, which may separate the first catalyst from the mixture comprising the second catalyst and the converted hydrocarbons based on at least one of catalyst size or catalyst density. A first stream 20 containing the separated first catalyst and a second stream 22 containing the second catalyst and converted hydrocarbons may be recovered from the catalyst separation system 6. The first catalyst stream 20 may then be fed to the inlet of reactor 7, thereby increasing the concentration of the first catalyst in the second reactor.

[0032] The effluents from the riser reactor 3 and the second reactor 7 may both be fed to a separation vessel 42. The separation vessel 42 may thus include one or more inlets 40 for receiving (i) the stream 22 comprising the second catalyst and converted hydrocarbons, and (ii) an effluent stream 40 from the reactor 3 comprising a combined stream of converted hydrocarbons and catalyst mixture. The separation vessel 42 may be configured to separate and recover a first effluent 44 comprising the converted hydrocarbons and a second effluent 46 comprising a mixture of the spent first catalyst and the second catalyst. A flow line 48 and a fluidizing gas 50 may be provided for carrying the mixture of the spent first catalyst and the second catalyst to a regenerator.

[0033] In other embodiments using an integrated reactor / separation system, such as that illustrated in FIG. 1B, the second catalyst may be fed to a regenerator via 75 for downstream processing, and the converted hydrocarbon stream 26 may be combined with stream 44 of FIG. 2. Such downstream processing may include, for example, separation of naphtha, light naphtha, or gasoline fractions, which may be fed via flow line 43 along with the low boiling fraction 34 to the second reactor 7 for conversion. In other embodiments, separation of the downstream effluent may produce a light cycle oil fraction, which may be used as the quench medium 55. Various other hydrocarbon streams recovered via downstream processing may be fed to the riser reactor 3 in some embodiments.

[0034] Referring to Figure 3, where like numbers represent like parts, a simplified process flow diagram of a system for catalytic cracking of whole crude oil is illustrated in accordance with another embodiment of the present disclosure. The system for catalytic cracking of whole crude oil may include a separation system 30 for separating whole crude oil 32 into a low boiling fraction 34 and a high boiling fraction 36. In some embodiments, the separation of the whole crude oil into low boiling and high boiling fractions may include separation of the low boiling fraction from the high boiling fraction, with 95% of the low boiling fraction having a final boiling temperature in the range of about 300°C to about 420°C. However, the actual cut points for separation may be based on the particular crude oil being processed.

[0035] The high boiling fraction 36 may be fed to a first two-vessel reactor dual catalyst system 60. The first two-vessel reactor dual catalyst system 60 may include, for example, a riser reactor and a contaminant trap concentrator vessel (not shown). The contaminant trap concentrator vessel may be similar to that illustrated in FIG. 1A or 1B and may be used to increase the concentration of metal traps in the vessel. Following reaction in the first two-vessel reactor dual catalyst system 60, a converted hydrocarbon effluent 62 may be recovered. In some embodiments, the catalyst in the first two-vessel reactor dual catalyst system 60 may include a residual fluid catalytic cracking catalyst.

[0036] The low boiling fraction 34 may be fed to a second two-vessel reactor dual catalyst system 64. The second two-vessel reactor dual catalyst system 64 may include a riser reactor and a second reactor, such as one similar to that illustrated in FIG. 2, which produces a converted hydrocarbon effluent 66.

[0037] A fractionation system 70 may be provided for separating the converted hydrocarbon effluents 62, 66 from each of the first two-vessel reactor dual catalyst system 60 and the second two-vessel reactor dual catalyst system 64. Separation of the converted hydrocarbon fractions in the common fractionation system 70 may result in the production of two, three, or more hydrocarbon fractions. In various embodiments, the two or more hydrocarbon fractions may include one or more olefins, including an ethylene fraction 72, a propylene fraction 74, a butenes or C4 fraction 76, and fractions such as a C5 fraction 78, a light naphtha fraction 80, a medium or heavy naphtha fraction 82, a light cycle oil 84, a slurry oil 86, and a processed FCC feedstock 88. The processed feedstock 88 may include processed hydrocarbons from a high boiling fraction that may be suitable for feeding, for example, a fluid catalytic cracking system, either in the system 64 or any reactor depicted in FIG. 2. The light naphtha fraction 80 and the C4 fraction 76 may also be excellent feeds for partial or complete recycling to a fluid catalytic cracking system, either in system 64 or in any reactor depicted in Figure 2. Light cycle oil may be fed to one or both of the reaction systems 60, 64, either as a post-reaction quench, diluent, or feedstock, as described above.

[0038] A second two-vessel reactor dual catalyst system 64 may be used to process the lighter fraction and the treated FCC feed. The treated FCC feed 88 may be fed to the riser reactor of the second two-vessel reactor dual catalyst system, and the lighter fraction may be fed to the catalyst concentration reactor. If desired, the heavy naphtha fraction 82 may be fed to either reactor system 60 or 64, depending on the demand as a feed or diluent.

[0039] In some embodiments, the medium or heavy naphtha 82 may be fed to an aromatics complex that may include, for example, a reforming reactor for converting the heavy naphtha hydrocarbons to aromatics and other associated equipment for converting, recovering, and / or separating various aromatic hydrocarbon fractions, such as benzene, toluene, and xylenes.

[0040] The catalyst system useful in the embodiments of the present disclosure may include one or more cracking catalysts. In some embodiments, the catalyst system may utilize two types of catalysts, each of which favors a different type of hydrocarbon feed. The first cracking catalyst may be useful for catalytic cracking and removing contaminants from heavy hydrocarbon feedstocks, such as metal-resistant FCC or RFCC catalysts or metal traps or other similar catalysts known in the art or additives for resid cracking. The second cracking catalyst may be a catalyst useful for cracking C4 or naphtha range hydrocarbons, or a combination of a Y-type zeolite catalyst with a ZSM-5 or ZSM-11 type catalyst that selectively produces light olefins, or other similar catalysts known in the art. To facilitate reactor schemes and processing in some embodiments disclosed in the present disclosure, the first cracking catalyst may have a first average particle size and density, and may be larger and / or denser than those of the second cracking catalyst, such that the catalysts may be separated on a density and / or size basis (e.g., based on terminal velocity or other characteristics of the catalyst particles). The present application is directed to the treatment of heavy hydrocarbon fractions of crude oil and the simultaneous further catalytic cracking of all fractions of crude oil into light olefins and aromatics. These catalytic systems can be used during the processing of sour or medium crude oils or heavy crude oils.

[0041] In other embodiments, the catalyst system may utilize two catalysts, each of which favors a different type of hydrocarbon feed. The first catalyst may be a catalyst useful for cracking C4 or naphtha range or processed heavy hydrocarbons, such as a combination of a Y-type zeolite catalyst with a ZSM-5 or ZSM-11 type catalyst that selectively produces light olefins, or other similar catalysts or additives known in the art. The second cracking catalyst may favor the cracking of heavy hydrocarbon feedstocks, such as a metal-tolerant FCC or RFCC catalyst or a metal trap or other similar catalysts or additives for resid cracking known in the art. To facilitate reactor schemes and processing in some other embodiments disclosed in this disclosure, the first cracking catalyst may have a first average particle size and density, and may be larger and / or denser than those of the second cracking catalyst, such that the catalyst may be separated on a density and / or size basis (e.g., based on terminal velocity or other characteristics of the catalyst particles). The primary objective of this application is to maximize the conversion of heavy hydrocarbon fractions of crude oil into middle or light fractions, and the subsequent catalytic cracking of all fractions of the crude oil into light olefins and aromatics (to achieve the highest product yields, selectivities of these petrochemical components from the cracking of the whole crude oil).

[0042] Adsorbents or pollutant-trapping additives useful in embodiments of the present disclosure may include compounds and structures that have a higher affinity for pollutants than the catalyst under conditions in the pollutant removal vessel. Thus, the pollutants may be preferentially absorbed or retained on the pollutant-trapping additive. In some embodiments of the present disclosure, to facilitate process schemes for separation of the pollutant-trapping additive from the catalyst, the pollutant-trapping additive may have a larger average particle size than the catalyst and / or a higher density than the catalyst, such that the pollutant-trapping additive can be separated from one or more catalysts on the basis of density and / or size.

[0043] Contaminants that may come into contact with various hydrocarbon feedstocks may include one or more of iron, copper, calcium, phosphorus, vanadium, nickel, chlorine, and sodium, among others. Such contaminants may have a detrimental effect on catalysts, such as cracking catalysts, including FCC catalysts, used to convert heavier hydrocarbons to lighter hydrocarbons. Various contaminants may harm the cracking catalyst and reduce its activity. The contaminants may also block pores or reduce the rate of diffusion through the catalyst pores, inhibiting the efficiency of the catalyst or resulting in mechanical damage or relatively high costs for process equipment.

[0044] As mentioned above, the pollutant trapping additive should have a higher affinity for the pollutant than the catalyst. Thus, the particular type of pollutant trapping additive used may depend on the particular pollutant being targeted. The pollutant trapping additive useful in some embodiments disclosed in this disclosure may include commercially available vanadium / nickel / iron traps (additives) manufactured by FCC catalyst vendors. In some embodiments, the metals trapping additive may include magnesium oxide and / or alumina based supports with calcium, tin, cesium, or other metal promotion for effective trapping of iron, copper, phosphorus, vanadium, nickel, sodium, calcium, chlorine, or other polluting metals that may be contained in the hydrocarbon feedstock. Efficient removal of these pollutants from the FCC catalyst (mainly responsible for catalytic cracking) can reduce their deleterious effects in the riser reactor.

[0045] To improve solids separation efficiency, the pollutant capture additive may have a larger average particle size and / or higher density than the cracking catalyst. For example, cracking catalysts, such as Y-type zeolite-based FCC cracking catalysts traditionally used in commercial FCC units, may have a typical average particle size in the range of about 20 microns to about 200 microns and an apparent bulk density in the range of about 0.60 g / cc to about 1.1 g / cc. These catalysts / additives used in the FCC and related cracking processes according to embodiments of the present disclosure may include a single type of catalyst or a mixture of catalysts. In other embodiments, the properties of these catalysts / additives are reversed depending on the application, purpose, and final process scheme described in Figures 1A, 1B, 2, and 3.

[0046] The pollutant-trapping additives useful in embodiments of the present disclosure may have a particle size larger than the cracking catalyst / additive used, such as a particle size in the range of about 20 microns to about 350 microns. Additionally or alternatively, the pollutant-trapping additives may have a bulk density greater than the bulk density of the catalyst, for example, a density in the range of about 0.7 g / cc to about 1.2 g / cc.

[0047] The size and / or density difference between the pollutant-trap additive and the catalyst can facilitate separation in a solids separator. Embodiments of the present disclosure may use a classifier / separator to separate the pollutant-trap additive from the catalyst. This equipment can be installed in either an existing FCC stripper or regenerator vessel.

[0048] Hydrocarbon mixtures that can be processed according to embodiments of the present disclosure may include mixtures of various hydrocarbons having a boiling range where the final boiling point of the mixture may be above 500°C, such as above 525°C, 550°C, or 575°C. The amount of high boiling hydrocarbons, such as hydrocarbons boiling above 550°C, may be as little as 0.1 wt%, 1 wt%, or 2 wt%, but may reach or exceed 10 wt%, 25 wt%, 50 wt%. Although the present disclosure is described in terms of crude oils, such as whole crude oils, any high boiling end point hydrocarbon mixture may be used. However, the methods disclosed in this disclosure may be applied to crude oils, condensates, and hydrocarbons with broad boiling curves and end points above 500°C. Such hydrocarbon mixtures may include whole crude oil, virgin crude oil, hydrotreated crude oil, gas oil, vacuum gas oil, heating oil, jet fuel, diesel, kerosene, gasoline, synthetic naphtha, raffinate reformate, Fischer-Tropsch liquids, Fischer-Tropsch gas, natural gasoline, distillates, virgin naphtha, natural gas condensate, atmospheric tube heater bottoms, vacuum tube heater streams containing bottoms, naphtha to gas oil condensates with wide boiling ranges, waste plastic derived oil, heavy non-virgin hydrocarbon streams from refineries, vacuum gas oil, heavy gas oil, atmospheric bottoms, hydrocracked wax, and Fischer-Tropsch wax, among others. In some embodiments, the hydrocarbon mixture may include hydrocarbon boilings ranging from naphtha range or lighter to vacuum gas oil range or heavier. When processing whole crude oil according to embodiments of the present disclosure, the methods and systems of the present disclosure may include a feed preparation section, which may include, for example, a desalter.

[0049] Crude oil includes compounds ranging from butanes to VGOs and the balance (material boiling above 550° C.) Materials with a wide boiling range, such as whole crude oil, can be prepared and processed according to embodiments of the present disclosure such that the fluid catalytic crackable feed can be sent to a downstream reactor, such as a riser reactor, for conversion of the fluid catalytic crackable feed to petrochemicals, such as ethylene, propylene, butenes, and aromatics, such as benzene, toluene, and xylene, as well as other cracked products.

[0050] As mentioned above, the high boiling compounds in crude oils are decomposed when they are sent to a fluid catalytic cracking unit. They tend to form coke and deposit impurities on the catalyst, which can cause significant operational problems. Therefore, the high boiling compounds are usually removed before sending the light fraction to a catalytic cracker or other petrochemical units such as a fluid catalytic cracker or aromatic hydrocarbon complex. The removal process increases the capital cost and reduces the profitability of the entire process, since the removed high boiling compounds can only be sold as low value fuels.

[0051] The configuration of systems and methods for conversion of whole crude oil and wide boiling range hydrocarbon mixtures according to embodiments described in this disclosure can maximize petrochemical conversion and efficiently handle residue conversion while maintaining low coking tendencies in fluid catalytic cracking units.

[0052] In some embodiments, the separation system used to separate the whole crude oil may be a Hot Oil Processing System (HOPS), such as a two-stage HOPS to separate the whole crude oil into light and heavy fractions. In other embodiments, the separation can be performed in an Integrated Separation Device (ISD), as disclosed in U.S. Patent Application Publication No. 20130197283, which is incorporated by reference herein and which can separate low boiling fractions from relatively high boiling liquid fractions based on a combination of centrifugal forces and cyclonic effects.

[0053] As previously described, systems according to embodiments of the present disclosure may include both a first two-vessel reactor dual catalyst system and a second two-vessel reactor dual catalyst system. In some embodiments, the two-vessel reactor dual catalyst system may include a regenerator, a separation vessel, a riser reactor, and a catalyst concentration reactor.

[0054] A regenerator may be provided for regenerating the spent first catalyst and the spent second catalyst, the regenerator may include a first outlet for conveying a mixture of the regenerated first catalyst and the second catalyst from the regenerator to the first reactor, and a second outlet for conveying the mixture of the regenerated first catalyst and the second catalyst to the catalyst concentration reactor. The first catalyst has a density higher than that of the second catalyst, a particle size larger than that of the second catalyst, or both a higher density and a larger particle size than that of the second catalyst.

[0055] The first reactor, which may be a riser reactor, may be used to contact the high boiling fraction with a mixture of the regenerated first catalyst and the second catalyst to convert a portion of the hydrocarbons in the high boiling fraction to lighter hydrocarbons. The riser reactor may include an inlet for receiving the catalyst mixture comprising the regenerated first catalyst and the second catalyst from the regenerator, and an outlet for conveying the mixture of the converted hydrocarbons and the catalyst mixture.

[0056] The second reactor, which may be a catalyst concentration reactor, may be a moving or fluidized bed reactor for contacting the low boiling fraction with a concentrated catalyst mixture comprising the first catalyst and the second catalyst. The second reactor may include an inlet for receiving the catalyst mixture comprising the regenerated first catalyst and the second catalyst from the regenerator, and an outlet for conveying the mixture of converted hydrocarbons, the first catalyst and the second catalyst to a catalyst separation system.

[0057] The catalyst separation system may be a cyclone or other vessel in which solids and gas are introduced into a common inlet and particles are separated on a size and / or density basis by degassing, inertial and centripetal forces in favor of smaller particles being entrained into a vapor outlet, while most of the larger particles are collected and can be returned to the catalyst concentration reactor via a dense phase column or dipleg. Thus, the catalyst separation system may be configured to separate the first catalyst from the mixture containing the second catalyst and the converted hydrocarbons on the basis of at least one of catalyst size or catalyst density, thereby producing a first stream containing the separated first catalyst and a second stream containing the second catalyst and the converted hydrocarbons. The catalyst concentration reactor may include an inlet for receiving the first stream containing the separated first catalyst, thereby increasing the relative concentration of the first catalyst in the second reactor.

[0058] The separation vessel may include one or more inlets for receiving (i) a second stream comprising the second catalyst and converted hydrocarbons from the particle separation system and / or (ii) a mixture of the converted hydrocarbons and catalyst mixture from the riser reactor. The separation vessel may include, for example, a cyclone configured to separate and recover the first effluent comprising the converted hydrocarbons and the second effluent comprising the mixture of the spent first and second catalysts. The separation vessel may also include injection of steam or an inert gas to completely remove or strip the hydrocarbons from the catalyst particles. A flow line may then be used to carry the stripped mixture of the spent first and second catalysts to a regenerator.

[0059] The first two-vessel dual catalyst system may include a first reactor for contacting a residual fluid catalytic cracking catalyst or other catalyst suitable for converting heavy components in the high boiling portion of the whole crude oil. The residual fluid catalytic cracking catalyst may be contacted with a hydrocarbon feedstock to convert at least a portion of the hydrocarbon feedstock to lighter hydrocarbons.

[0060] A separator may be provided for separating lighter hydrocarbons from the spent residual fluidized catalytic cracking catalyst, and a feed line may be provided for feeding the separated spent cracking catalyst from the separator to the catalyst regenerator. The catalyst transfer line may be used for transferring a portion of the spent cracking catalyst from the catalyst regenerator to the pollutant removal vessel. In the pollutant removal vessel, the spent catalyst may be contacted with a pollutant trap additive, and the pollutant trap additive (metal trap) may have at least one of an average particle size or density greater than that of the residual fluidized catalytic cracking catalyst. A second separator may be provided for separating the overhead stream from the pollutant removal vessel into a first stream containing the residual fluidized catalytic cracking catalyst and the lift gas, and a second stream containing the pollutant trap additive. A recycle line may be provided for transferring the pollutant trap additive recovered in the second separator to the pollutant removal vessel, thereby concentrating the metal traps in the pollutant removal vessel. A bottoms product line may be provided for recovering the pollutant-trapping additive from the pollutant removal vessel, and another outlet may be provided for transferring the first stream containing the catalyst having reduced pollutant concentrations to a catalyst regenerator.

[0061] In some embodiments, the low boiling fraction may include butanes and other C4s, pentanes and other C5s, and lighter hydrocarbons such as naphtha, heavy naphtha, or gas oil range hydrocarbons in the crude oil. For example, the light fraction may include hydrocarbons having a boiling point of up to about 90° C. (e.g., the 90° C. fraction), up to about 100° C., up to about 110° C., up to about 120° C., up to about 130° C., up to about 140° C., up to about 150° C., up to about 160° C., up to about 170° C., up to about 180° C., up to about 190° C., up to about 200° C., up to about 210° C., up to about 220° C., up to about 230° C., up to about 240° C., up to about 250° C. (e.g., the 250° C. fraction), up to about 300° C., up to about 320° C., up to about 340° C., up to about 360° C., up to about 380° C., or up to about 400° C. Embodiments of the present disclosure also contemplate light fractions that are hydrocarbons having a boiling point up to temperatures intermediate to the aforementioned ranges.

[0062] Following the separation of the whole crude oil into desired heavy and light fractions, the fractions may then be processed in a reactor section. The reactor section according to embodiments of the present disclosure may include a dual reactor system. A first reactor may be provided for the conversion of a heavy hydrocarbon fraction that may be catalytically cracked into naphtha, middle distillates and light olefins. In some embodiments, the first reactor may be a riser reactor, which is an air-flow co-current reactor (catalyst and hydrocarbons flow through and are collected together from the reactor as effluent).

[0063] A second reactor may be provided for conversion of lighter hydrocarbons, such as C4 and naphtha range hydrocarbons. The second reactor may be a riser reactor in some embodiments. In other embodiments, the second reactor may be a catalyst concentration reactor system, as described further below.

[0064] The reactor section for embodiments of the present disclosure may also include a dual reactor conditioning system. A first conditioning reactor may be provided for the removal of contaminants. In some embodiments, the first conditioning reactor may be a contaminant capture additive concentration system, as described further below. A second conditioning reactor may be provided for partial conversion of the hydrocarbon feedstock. For example, as previously described, either in the first reactor or in the second reactor, the second conditioning reactor may convert the heavy hydrocarbons contained in the whole crude oil into lighter hydrocarbons suitable for processing.

[0065] Other embodiments of the disclosed systems may include pollutant and catalyst concentration systems, such as particulate and solids separation systems that may include one or more separation steps to separate catalysts and metal traps for concentration in various reactors.

[0066] The enrichment system may be used to effectively convert the whole crude oil in a fluid catalytic cracking system. For example, as previously described with respect to Figures 2 and 3, a common catalyst regenerator includes both a dual reactor system including a riser reactor and a catalyst enrichment reactor system for the conversion of light boiling fractions. And, as described with respect to Figure 3, an embodiment of the present disclosure may include both a dual reactor system including a riser reactor and a catalyst enrichment reactor system, and a second reactor system including a common regenerator with a riser reactor and a pollutant capture additive enrichment reactor system.

[0067] In yet other contemplated embodiments, a system for processing whole crude oil may include only a single regenerator that includes a reactor for cracking heavy hydrocarbons, such as a riser reactor, a reactor for cracking lighter hydrocarbons, and a pollutant capture reactor for treating and / or conditioning the hydrocarbons.

[0068] The disclosed embodiments can be used to process light and sweet crude oils that are not high in feed contaminants (Scenario 1). This scheme can correspond to FIG. 2, but with HOPS or equipment 30 in FIG. 3 to separate the lighter and heavier hydrocarbon fractions. The heavy fraction is sent to the FCC riser with a second catalyst (RFCC, low concentration of ZSM-5), while the lighter stream is processed in a second reactor (FIG. 1B) with a solids separation device 6 to concentrate ZSM-5, producing higher yields of light olefins and aromatics. ZSM-5 is now larger and denser particles, while the RFCC catalyst is smaller and lighter. The second reactor is of the single reactor dual catalyst (SRDC) type for ZSM-5 concentration (FIG. 1A or 1B).

[0069] The embodiments of the present disclosure may be used to process sour and heavy crude oils (i.e., with relatively high concentrations of contaminants / impurities) (Scenario 2). This scheme may correspond to FIG. 3. The scheme may include HOPS as equipment 30 of FIG. 3 to separate lighter and heavy hydrocarbon fractions. The heavy fraction is sent to a single reactor dual catalyst (SRDC) type reactor with contaminant removal catalyst (RFCC catalyst, metal trap, additives, etc.) in equipment / process 60. Part 1 of the scheme may use only metal traps or contaminant removal additives in a conventional FCC scheme. Part 2 of the scheme may include an FCC riser to crack the medium crude fraction (HVGO range) in the first riser with (FCC catalyst + ZSM-5 and small amount of metal traps). The heaviest fraction of the crude oil is sent to a single reactor dual catalyst (SRDC) reactor where contaminants are removed from the oil, and further solids separation equipment helps concentrate the metal trap or contaminant removal additive. The metal trap particles are large and dense, while the FCC catalyst and ZSM-5 are the same but small and light compared to the metal trap. This refers to the combination scheme of Figure 1A and Figure 2. The light crude oil fraction from the facility 30 and most of the recycle stream from the fractionator 70 are processed in a facility / process 64 that corresponds to the combination of the schemes in Figure 1A or 1B and Figure 2. Furthermore, the above process 64 is similar to scenario 1 using FCC / RFCC catalyst and ZSM-5 in that it concentrates the ZSM-5 for producing light olefins and aromatics at a higher yield. In process 64, the ZSM-5 is now a larger and denser particle, while the FCC / RFCC catalyst is smaller and lighter.

[0070] The majority of the light crude fraction from unit 30 and the recycle stream from fractionator 70 are processed in unit / process 64, which corresponds to a combination of the schemes in Figures 1A or 1B and 2. Additionally, process 64 above is similar to scenario 1 using FCC / RFCC catalyst and ZSM-5 in that it concentrates the ZSM-5 for producing higher yields of light olefins and aromatics. In process 64, the ZSM-5 is now larger and more dense particles, while the FCC / RFCC catalyst is smaller and lighter.

[0071] As previously mentioned, embodiments of the present disclosure may also include a reactor system used in an FCC / RFCC unit to remove contaminants (CCR, nickel, vanadium, nitrogen, sodium, iron, calcium, etc.) from the heavy parts of the crude oil. The products may be sent to a common main fractionation section. The heavy feed with less contaminants can then be processed in an FCC unit. The additive in this unit may be spent catalyst from an FCC unit with metal traps. This concept uses a fluid catalytic reaction platform with a carbon rejection approach.

[0072] Fresh naphtha and gas oil from crude oil split (e.g. HOPS top) along with catalytic naphtha recycled from conventional gas plants can also be recycled back to another single regenerator dual catalyst reactor system attached to the FCC unit regenerator. The additional reactor used in the FCC / RFCC unit can be used to increase the productivity of naphtha and / or C4s processed in the reactor using a suitable catalyst to maximize the production of light olefins, high octane gasoline and aromatics. Single regenerator dual catalyst (SRDC) technology using a built-in solids separator (SSD) may be utilized in some embodiments to increase the concentration of additives (such as ZSM-5 or metal traps) by separating them from the FCC / RFCC catalyst in the FCCU / RFCC system. Using SSD, 1.5-5X additive concentration, such as 3-4X, and an increase in total residual amount can be achieved from a mixture of FCC catalyst and additives (metal traps or ZSM-5 particles, which are denser and larger particles compared to FCC / RFCC catalyst). Therefore, the method according to the embodiments of the present disclosure can solve the above problems of processing whole crude oil, achieving excellent conversion of crude oil to light olefins, and also improved removal of feed contaminants which improves catalyst life and activity.

[0073] As already mentioned, the embodiments of the present disclosure relate to the catalytic conversion of crude oil from various sources to light olefins, which is carried out simultaneously with the removal of contaminants in the crude oil. The method of the present disclosure may be a stand-alone process as described above. Alternatively, the above-mentioned contaminant removal step may be integrated or replaced with LC-Fining, LC-MAX, ARDS, or other systems suitable for handling residual or other high boiling fractions of crude oil. The reactor and catalyst characteristics of the embodiments of the present disclosure may also be considered as part of a high severity FCC process aimed at maximizing light olefins or chemical routes from crude oil. The LummusINDMAX FCC design / configuration provides a great alternative to implement the desired hardware features of the embodiments of the present disclosure that are within the scope of FCC. In addition, the embodiments of the present disclosure may also be integrated with conventional FCC processes aimed at producing gasoline or middle distillates, for example by sending naphtha produced from FCC to a high density recycle riser, as described in this disclosure, to maximize light olefins. Embodiments of the present disclosure can also be integrated with the Lummus Olefin Conversion Technology (OCT) for high-yield conversion of ethylene and butenes, among other olefins, to propylene.

[0074] While the present disclosure is limited in the number of embodiments, it will be appreciated that those skilled in the art having the benefit of this disclosure may devise other embodiments that do not depart from the scope of the present disclosure.

Claims

1. 1. A system useful for catalytic cracking of whole crude oil, comprising: The system includes a separator for separating the whole crude oil into a low boiling fraction and a high boiling fraction; a reactor / pollutant removal vessel system and a dual reactor dual catalyst system, each of which produces a converted hydrocarbon effluent; a common fractionation system for receiving the converted hydrocarbon effluent from each of the reactor / pollutant removal vessel system and the catalyst separation vessel, the common fractionation system being configured to separate the converted hydrocarbon effluent into two or more hydrocarbon fractions, at least one of the two or more hydrocarbon fractions comprising olefins, and at least one of the two or more hydrocarbon fractions containing a treated fluid catalytic cracking feedstock; and a catalyst separation vessel configured to receive and separate effluents from each of the first and second reactors of the two-vessel reactor dual catalyst system into a spent catalyst mixture and the converted hydrocarbon effluent that is fed to the common fractionation system; the reactor / pollutant removal vessel system is configured to contact the high boiling fraction with a residual fluidized catalytic cracking catalyst in a reactor, and to transfer the contaminated residual fluidized catalytic cracking catalyst through a catalyst transfer line to contact the pollutant capture additive in a pollutant removal vessel; The two-reactor dual catalyst system includes a first reactor for contacting the treated fluid catalytic cracking feedstock separated in the common fractionation system with a mixture of catalysts comprising a first catalyst and a second catalyst; a second reactor for contacting the low boiling fraction with a mixture comprising a first catalyst and a second catalyst, the first catalyst being at a higher concentration in the second reactor compared to the first reactor.

2. 2. The system of claim 1, wherein the separator for separating whole crude oil into a low boiling fraction and a high boiling fraction is configured to separate a low boiling fraction having a 95% distillation temperature in the range of about 300° C. to about 420° C. from the high boiling fraction.

3. said reactor / contamination removal vessel system comprising: a reactor for contacting said residual fluid catalytic cracking catalyst with a heavy fraction to convert at least a portion of the hydrocarbon feedstock to lighter hydrocarbons; a separator for separating said hydrocarbon product vapor comprising lighter hydrocarbons from said spent residual fluid catalytic cracking catalyst; a feed line for feeding the spent residual fluid catalytic cracking catalyst separated from the separator to a catalyst regenerator; a catalyst transfer line for transferring a portion of the spent residual fluid catalytic cracking catalyst from the catalyst regenerator to the pollutant removal vessel; a pollutant removal vessel for contacting the spent residual fluidized catalytic cracking catalyst with a pollutant-trapping additive having at least one of an average particle size or density greater than the average particle size or density of the residual fluidized catalytic cracking catalyst; a second separator for separating the overhead stream from said pollutant removal vessel into a first stream comprising residual fluid catalytic cracking catalyst and lift gas and a second stream comprising the pollutant capture additive; a recycle line for transferring the pollutant-capturing additive recovered in said second separator to said pollutant removal vessel; a resid product line for recovering the pollutant capture additive from said pollutant removal vessel; and a line carrying said first stream to said catalyst regenerator The system of claim 1 , comprising:

4. The system of claim 1, wherein the common fractionation system is configured to separate the converted hydrocarbon effluent into three or more hydrocarbon fractions, the three or more hydrocarbon fractions comprising one or more olefin fractions, the treated fluid catalytic cracking feedstock, and one or more of a C5 fraction, an FCC naphtha fraction, a heavy naphtha fraction, a light cycle oil fraction, or a slurry oil fraction.

5. The system described in claim 4, further comprising a flow line for supplying the FCC naphtha fraction to the second reactor.

6. 5. The system of claim 4, further comprising an olefin conversion unit for receiving at least one of a C4 fraction and said C5 fraction and for converting at least one of olefins or paraffins therein to at least one of ethylene or propylene.

7. The system of claim 4, further comprising an aromatic hydrocarbon combine configured to reform the heavy naphtha fraction and recover one or more aromatic product streams.

8. The system of claim 1, further comprising a second separator for separating the high boiling fraction into a medium boiling fraction and a residual fraction, the residual fraction being supplied to the reactor / pollutant removal vessel system as the high boiling fraction and the medium boiling fraction being supplied to the first reactor of the two-tank reactor dual catalyst system.

9. 1. A process for catalytic cracking of whole crude oil, the process comprising: separating the whole crude oil into a low boiling fraction and a high boiling fraction; converting said heavy fraction in a reactor / pollutant removal vessel system to recover a converted hydrocarbon effluent; converting said low boiling fraction in a two-vessel reactor dual catalyst system to recover a converted hydrocarbon effluent; Separating the converted hydrocarbon effluent from each of the reactor / pollutant removal vessel system and the catalyst separation vessel in a common fractionation system configured to separate the converted hydrocarbon effluent into two or more hydrocarbon fractions, at least one of the two or more hydrocarbon fractions comprising olefins, and at least one of the two or more hydrocarbon fractions comprising a treated fluid catalytic cracking feedstock. Including, converting the high boiling fraction in the reactor / pollutant removal vessel system includes contacting the high boiling fraction with a residual fluid catalytic cracking catalyst in a reactor, and transferring the contaminated residual fluid catalytic cracking catalyst through a catalyst transfer line and contacting it with a pollutant capture additive in a pollutant removal vessel; converting the low boiling fraction in the two-vessel reactor dual catalyst system, contacting the treated fluid catalytic cracking feedstock separated in the common fractionation system with a mixture comprising a first catalyst and a second catalyst in a first reactor of the two-reactor dual catalyst system; contacting the low boiling fraction with a mixture comprising a first catalyst and a second catalyst in a second reactor of the two-reactor dual catalyst system, the first catalyst being relatively more concentrated in the second reactor than in the first reactor; and separating the effluents from each of the first and second reactors of the two-reactor dual catalyst system using the catalyst separation vessel into a spent catalyst mixture and the converted hydrocarbon effluent which is fed to the common fractionation system. A method comprising:

10. 10. The method of claim 9, wherein said step of separating whole crude oil into a low boiling fraction and a high boiling fraction comprises separating a low boiling fraction having a 95% boiling temperature within the range of about 300° C. to about 420° C. from said high boiling fraction.

11. said reactor / contamination removal vessel system comprising: a reactor for contacting said residual fluid catalytic cracking catalyst with a high boiling fraction separated in said step of separating at least the whole crude oil into a low boiling fraction and a high boiling fraction for converting said high boiling fraction into lighter hydrocarbons; a separator for separating said lighter hydrocarbons from the spent residual fluid catalytic cracking catalyst; a feed line for feeding the spent residual fluid catalytic cracking catalyst separated from the separator to a catalyst regenerator; a catalyst transfer line for transferring a portion of the spent residual fluid catalytic cracking catalyst from the catalyst regenerator to the contaminant removal vessel; a pollutant removal vessel for contacting the spent residual fluidized catalytic cracking catalyst with a pollutant-trapping additive having at least one of an average particle size or density greater than the average particle size or density of the residual fluidized catalytic cracking catalyst; a second separator for separating the overhead stream from said pollutant removal vessel into a first stream comprising residual fluid catalytic cracking catalyst and lift gas and a second stream comprising the pollutant capture additive; a recycle line for transferring the pollutant-capturing additive recovered in said second separator to said pollutant removal vessel; a resid product line for recovering the pollutant capture additive from said pollutant removal vessel; and a line carrying said first stream to said catalyst regenerator 10. The method of claim 9, comprising:

12. The method of claim 9, wherein the common fractionation system separates the converted hydrocarbon effluent into three or more hydrocarbon fractions, the three or more hydrocarbon fractions comprising one or more olefin fractions, the treated fluid catalytic cracking feedstock, and one or more of a C4 fraction, a C5 fraction, an FCC naphtha fraction, a heavy naphtha fraction, a light cycle oil fraction, or a slurry oil fraction.

13. The method of claim 12, further comprising the step of supplying the C4 fraction and the FCC naphtha fraction to the second reactor, wherein the FCC naphtha fraction comprises one or more of a light naphtha fraction, a medium naphtha fraction, a heavy naphtha fraction, or a full range naphtha fraction.

14. 13. The method of claim 12, further comprising the step of supplying light cycle oil (LCO) or a treated fluid catalytic cracking feedstock or a slurry oil as a recycle feed or diluent to either the first reactor or the second reactor.

15. The method of claim 12, further comprising the steps of supplying at least one of the C4 fraction and the C5 fraction to an olefin conversion unit, and converting at least one of the olefins or paraffins therein to at least one of ethylene or propylene.

16. The method of claim 13, further comprising supplying the medium naphtha fraction or the heavy naphtha fraction to an aromatic hydrocarbon complex to reform the medium naphtha fraction or the heavy naphtha fraction and recover one or more aromatic product streams.

17. The method of claim 9, further comprising separating the high boiling fraction into a mid boiling fraction and a residue fraction, wherein the residue fraction is fed to the reactor / pollutant removal vessel system as the high boiling fraction and the mid boiling fraction is fed to the first reactor of the two-tank reactor dual catalyst system.

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