Self-heat-balanced hsfcc systems and processes for upgrading hydrocarbon feeds

The FCC system with four reaction zones and a common regenerator balances heat using heavy and light hydrocarbon feeds with different API gravities, addressing heat imbalance issues and enhancing light olefin production without supplemental fuels or coolers.

US20260078309A1Pending Publication Date: 2026-03-19SAUDI ARABIAN OIL CO
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Patent Information

Application Number
US18/886524
Authority / Receiving Office
US · United States
Patent Type
Applications(United States)
Current Assignee / Owner
Filing Date
2024-09-16
Publication Date
2026-03-19

AI Technical Summary

Technical Problem

Existing fluid catalytic cracking (FCC) systems face challenges in heat balance, requiring supplemental fuels or catalyst coolers due to insufficient or excessive coke formation from hydrocarbon feeds, limiting the production of light olefins like ethylene and propylene.

Method used

A method for operating an FCC system with four reaction zones and a common regenerator, using heavy and light hydrocarbon feeds with different API gravities to balance heat load, eliminating the need for supplemental fuels or catalyst coolers by controlling the flow rate of regenerated catalyst.

Benefits of technology

Achieves heat balance in the FCC system without supplemental fuels or catalyst coolers, enabling efficient production of light olefins using widely available hydrocarbon feeds with minimal processing.

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Abstract

A process for upgrading hydrocarbon feeds in an FCC system includes passing portions of a heavy hydrocarbon feed to a first reactor and a second reactor and passing portions of a light hydrocarbon feed to a third reactor and a fourth reactor. The heavy hydrocarbon feed has an API gravity of from 10° to 35° and the light hydrocarbon feed has an API gravity of from 38° to 100°. A cracking catalyst is passed to the reactors and contacted with the portions of the heavy and light hydrocarbon feeds. Reaction mixtures from the reactors are separated to produce an FCC effluent and spent cracking catalyst. The spent cracking catalyst is regenerated and passed back to the reactors. A flow rate of the cracking catalyst to the reactors is controlled based on determined heat balance requirements of each of the reactors.
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