Co-feeding BIO-derived renewable feedstocks to a catalytic cracking unit

Abstract

The present disclosure relates to a catalytic cracking unit and feed nozzle wherein the catalytic cracking unit includes a riser reactor configured to combine a hydrocarbon feedstock with a biofeed and a catalyst to form a cracked product and a spent catalyst, the riser reactor including a reactor body configured to receive the hydrocarbon feedstock, the biofeed, and the catalyst during the cracking process; a hydrocarbon feed nozzle connected to the reactor body, the hydrocarbon feed nozzle configured to feed the hydrocarbon feedstock to the reactor body; and a biofeed nozzle connected to the reactor body, the biofeed nozzle configured to feed the biofeed to the reactor body, the biofeed nozzle including a hollow cylindrical body including a mixing zone forming a top end, at least one fluid receiver port forming a bottom end, an outside surface, and an inside surface wherein at least one of the mixing zone or the at least one fluid receiver port is configured to induce turbulent flow.

Description

Attorney Docket No. 23-22 PCTCO-FEEDING BIO-DERIVED RENEWABLE FEEDSTOCKS TO A CATALYTIC CRACKING UNITCROSS REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to U.S. Provisional Patent Application having Serial No. 63 / 754,239 filed on February 5, 2025, which is incorporated by reference herein.TECHNICAL FIELD

[0002] The present disclosure relates to catalytic cracking systems having lower carbon emissions, thereby increasing the renewable content of fuels produced from residue fluid catalytic cracking and fluid catalytic cracking units used in refining industries.BACKGROUND

[0003] Increasing concentrations of greenhouse gases, such as carbon dioxide (CO2), in the atmosphere may be responsible for altering the Earth's climate, changing the pH of the ocean, and other disclosed damaging effects. Countries around the world, including the United States, are seeking ways to mitigate emissions of these greenhouse gases. The refinery sector may be an industrial sector that produces millions of tons of greenhouse gases annually.

[0004] Production of greenhouse gases in the refining process occurs when operating catalytic cracking units, such as fluid catalytic cracking (FCC) units and residual fluid catalytic cracking (RFCC) units. These units create greenhouse gases during the process of upgrading heavy hydrocarbon feedstocks into lighter products. During the cracking process, the cracking catalyst becomes covered in coke, a by-product of the cracking process. The coke may be later removed from the spent catalyst through combustion to prepare the spent catalyst for reuse.Attorney Docket No. 23-22 PCTThrough the combustion process, the coke may be converted into flue gas, which may be utilized and filtered within the refinery before being emitted to the atmosphere in the form of carbon dioxide gas. Cracked products created from the cracking process are often later converted into energy through combustion, such as when gasoline may be used for transportation in combustion engines. This combustion of cracked hydrocarbons also emits greenhouse gases.

[0005] An area of particular interest for refiners has been the processing of bio-derived feedstocks (i.e., biofeeds) in catalytic cracking units to reduce greenhouse gas emissions. Processing biofeeds may be one of the few viable options to address the largest part of the refining system’s greenhouse gas emissions — Scope 3 downstream emissions (i.e., the carbon dioxide emitted during use, such as from the combustion of gasoline and diesel in vehicles). Compared to carbon dioxide (CO2) from traditional fossil-based sources, CO2 from biofeeds may not be accretive to global atmospheric CO2 inventories since the biofeeds comprise CO2 taken from the current global inventory. Therefore, when fuels based on biofeeds are produced and consumed, global CO2 inventories and the CO2 footprint of refiners are not increased.

[0006] Unfortunately, using biofeeds in catalytic cracking units poses many obstacles for refiners. The decomposition temperature point of biofeeds is often much lower than the typical feed preheat temperature for fossil-derived heavy hydrocarbon feedstocks, requiring cooling systems for mixed biofeeds and heavy feedstocks. The difference in miscibility and viscosity of biofeeds also creates issues for refiners. For example, since biofeeds and typical fossil-derived feeds have different properties, the feed nozzle technology used for processing biofeeds needs to be uniquely designed to ensure proper atomization and to prevent overheating of the biofeeds in the nozzle. Therefore, systems and methods for improving co-feeding of biofeeds to catalyticAttorney Docket No. 23-22 PCTcracking units alongside the fossil -derived hydrocarbon feedstock (e.g., heavy hydrocarbon feedstock) are needed.SUMMARY

[0007] The present disclosure relates to a catalytic cracking unit for cracking a feedstock. The catalytic cracking unit may include a riser reactor configured to combine a hydrocarbon feedstock with a biofeed and a catalyst to form a cracked product and a spent catalyst. The riser reactor may include (a) a reactor body comprising a reactor configured to receive the hydrocarbon feedstock, the biofeed, and the catalyst during the cracking process. The riser reactor may include (b) a hydrocarbon feed nozzle connected to the reactor body, the hydrocarbon feed nozzle configured to feed the hydrocarbon feedstock to the reactor body. The riser reactor may include (c) a biofeed nozzle connected to the reactor body, the biofeed nozzle configured to feed the biofeed to the reactor body. The biofeed nozzle may include (i) a hollow cylindrical body containing a mixing zone forming a top end, at least one fluid receiver port forming a bottom end, an outside surface, and an inside surface wherein at least one of the mixing zone or the at least one fluid receiver port is configured to induce turbulent flow.

[0008] In examples, the biofeed nozzle may include one or more reliefs in the mixing zone to induce the turbulent flow. The one or more reliefs may include at least one concentric ring and / or at least one discontinuous stepped ring.

[0009] In examples, the biofeed nozzle may include a static mixer in the at least one fluid receiver port to induce the turbulent flow. The static mixer may include one or more helical ribbons.

[0010] In examples, the at least one fluid receiver port of the biofeed nozzle may include multi-stage injection points to introduce a dispersion medium. The injection points may be offset,Attorney Docket No. 23-22 PCTperpendicular, arranged to induce a swirling effect, arranged to inject the dispersion medium counter-current to the flow of the biofeed, or co-current with the flow of the biofeed.

[0011] The present disclosure relates to a catalytic cracking unit for cracking a feedstock. The catalytic cracking unit may include a riser reactor configured to combine a hydrocarbon feedstock with a biofeed and a catalyst to form a cracked product and a spent catalyst. The riser reactor may include (a) a reactor body comprising a reactor configured to receive the hydrocarbon feedstock, the biofeed, and the catalyst during the cracking process. The riser reactor may include (b) a hydrocarbon feed nozzle connected to the reactor body, the hydrocarbon feed nozzle configured to feed the hydrocarbon feedstock to the reactor body. The riser reactor may include (c) a biofeed nozzle connected to the reactor body, the biofeed nozzle configured to feed the biofeed to the reactor body. The biofeed nozzle may include (i) a hollow cylindrical body containing a mixing zone forming a top end. at least one fluid receiver port forming a bottom end, an outside surface, and an inside surface; and (ii) at least one concentric rings located within the mixing zone.

[0012] In some embodiments, the present disclosure relates to a catalytic cracking unit for cracking a feedstock, the catalytic cracking unit including a riser reactor configured to combine a hydrocarbon feedstock with a biofeed and a catalyst to form a cracked product and a spent catalyst. The riser reactor may include (a) a reactor body including a reactor configured to receive the hydrocarbon feedstock, the biofeed, and the catalyst during the cracking process; (b) a hydrocarbon feed nozzle connected to the reactor body, the hydrocarbon feed nozzle configured to feed the hydrocarbon feedstock to the reactor body; and (c) a discontinuous stepped-ring biofeed nozzle connected to the reactor body. The discontinuous stepped-ring biofeed nozzle configured to feed the biofeed to the reactor body, the discontinuous stepped-ring biofeed nozzle including (i) aAttorney Docket No. 23-22 PCThollow cylindrical body comprising a mixing zone forming a top end, at least one fluid receiver port forming a bottom end, an outside surface, and an inside surface; and (ii) at least one discontinuous stepped ring located within the mixing zone.

[0013] A catalytic cracking unit for cracking a feedstock, the catalytic cracking unit including: a riser reactor configured to combine a hydrocarbon feedstock with a biofeed and a catalyst to form a cracked product and a spent catalyst, the riser reactor including: (a) a reactor body comprising a reactor configured to receive the hydrocarbon feedstock, the biofeed, and the catalyst during the cracking process; (b) a hydrocarbon feed nozzle connected to the reactor body, the hydrocarbon feed nozzle configured to feed the hydrocarbon feedstock to the reactor body; and (c) a swirling biofeed nozzle connected to the reactor body, the swirling biofeed nozzle configured to feed the biofeed to the reactor body. The swirling biofeed nozzle may include (i) a hollow cylindrical body comprising a nozzle tip forming a top end, a fluid receiver port forming a bottom end, an outside surface, and an inside surface; (ii) a swirling feed tube located within the inside surface of the body; and (iii) a baffle plug comprising a plurality of vanes.

[0014] A catalytic cracking unit may further include a catalyst regenerator connected to the riser reactor, the catalyst regenerator including a heater and a regenerator cyclone, and configured to: (i) receive the spent catalyst from the riser reactor; (ii) bum coke off of the spent catalyst with heat provided by the heater and combustion gases to form a hot catalyst mixture; and (iii) separate, in the catalyst regenerator, the hot catalyst mixture into the regenerated catalyst and the combustion gases; and (iv) convey the regenerated catalyst to the riser reactor. The catalytic cracking unit may further include a distillation column connected to the riser reactor, the distillation column comprising a heat source and a distillation plate, the distillation columnAttorney Docket No. 23-22 PCTconfigured to: receive the cracked product; and separate the cracked product into at least one of a product gas, a naphtha, a light cycle oil, and a heavy cycle oil.

[0015] A biofeed nozzle may include eight concentric rings. Each of the concentric rings may be spaced apart by a distance that is proportional to from about 1 % to about 50 % of a total length of the biofeed nozzle. Each of the concentric rings may have a width that is proportional to from about 1 % to about 10 % of a total length of the biofeed nozzle . Each of the concentric rings may have a height that is proportional to from about 1 % to about 25 % of a tube diameter of the biofeed nozzle. The biofeed nozzle comprises a metal comprised of carbon steel, a 9 Cr-1 Mo steel, a chromium, a nickel, a molybdenum, a titanium, alloys thereof, and combinations thereof. The catalytic cracking unit may further include a natural gas dispersion medium tank configured to provide the catalytic cracking unit with natural gas for dispersing at least one of the hydrocarbon feedstock and the biofeed. Each of the discontinuous stepped rings may be spaced apart by a distance that is proportional to from about 1 % to about 50 % of a total length of the discontinuous stepped-ring biofeed nozzle. Each of the discontinuous stepped rings may have a width that is proportional to from about 1 % to about 10 % of a total length of the discontinuous stepped-ring biofeed nozzle. Each of the discontinuous stepped rings may have a height that is proportional to from about 1 % to about 25 % of a tube diameter of the discontinuous stepped-ring biofeed nozzle. The nozzle tip of the swirling biofeed nozzle is a swirling biofeed nozzle slotted tip.

[0016] In some embodiments, the present disclosure relates to a biofeed nozzle connected to a reactor body and configured to feed the biofeed to the reactor body, the biofeed nozzle may include a hollow cylindrical body comprising a mixing zone forming a top end; at least one fluid receiver port forming a bottom end; an outside surface; and an inside surface, wherein at least one of the mixing zone or the at least one fluid receiver port is configured to induce turbulent flow.Attorney Docket No. 23-22 PCT

[0017] The biofeed nozzle may include one or more reliefs in the mixing zone to induce the turbulent flow. The one or more reliefs comprise at least one concentric ring or at least one discontinuous stepped ring. The at least one concentric ring may include eight concentric rings. In examples, each of the reliefs has a width that is proportional to from about 1 % to about 10 % of a total length of the biofeed nozzle. In examples, each of the reliefs has a height that is proportional to from about 1 % to about 25 % of a tube diameter of the biofeed nozzle. In examples, the biofeed nozzle may include at least two reliefs, wherein each relief is spaced apart by a distance that is proportional to from about 1 % to about 50 % of a total length of the biofeed nozzle.

[0018] In examples, the biofeed nozzle includes a metal comprised of carbon steel, a 9 Cr-1 Mo steel, a chromium, a nickel, a molybdenum, a titanium, alloys thereof, and combinations thereof.

[0019] In examples, the biofeed nozzle includes a static mixer in the at least one fluid receiver port to induce the turbulent flow. The static mixer may include one or more helical ribbons.

[0020] In examples, the at least one fluid receiver port of the biofeed nozzle includes multistage injection points to introduce a dispersion medium. The multi-stage injection points can be arranged offset from each other or perpendicular to each other. The multi-stage injection points can be arranged offset from each to induce a swirling effect. The multi-stage injection points can be arranged to inject the dispersion medium counter-current to a flow of the biofeed or co-current with the flow of the biofeed.

[0021] In examples, the biofeed nozzle may include a baffle plug comprising a plurality of vanes.Attorney Docket No. 23-22 PCT

[0022] In examples, the biorfeed nozzle may include a nozzle slotted tip.

[0023] In examples, provided is a method of feeding biofeed to a catalytic cracking unit including a riser reactor configured to combine a hydrocarbon feedstock with a biofeed and a catalyst to form a cracked product and a spent catalyst, the method including injecting a biofeed and a dispersion medium into the riser reactor using a feed nozzle in accordance with any of the preceding stated features, wherein the dispersion medium is a natural gas.

[0024] Any combination of the above-listed features may be implemented without departing from the spirit or scope of this disclosure. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the disclosure as claimedBRIEF DESCRIPTION OF THE DRAWINGS

[0025] The disclosure may be illustrated by way of example and not by way of limitation in the figures of the accompanying drawings. Like reference numerals in the figures may be used to refer to similar elements. It may be emphasized that various features may not be drawn to scale, and the dimensions of various features may be arbitrarily increased or reduced for clarity of discussion. Further, some components may be omitted in certain figures for clarity of discussion. It may be expressly understood that the description and drawings are only for the purpose of illustration and as an aid to understanding and are not intended as a definition of the limits of the disclosure.

[0026] FIG. 1 illustrates a disclosed high-level demonstration-scale unit schematic drawing for a fluid catalytic cracking unit, in accordance with some embodiments of this disclosure.Attorney Docket No. 23-22 PCT

[0027] FIG. 2A illustrates a disclosed system diagram of a feed preheat system for cofeeding biofeeds and hydrocarbon feedstocks to catalytic cracking units in accordance with some embodiments of this disclosure.

[0028] FIG. 2B illustrates a disclosed system diagram of a feed preheat system for cofeeding biofeeds and hydrocarbon feedstocks to catalytic cracking units in accordance with some embodiments of this disclosure.

[0029] FIG. 3 illustrates a disclosed unit schematic drawing for a fluid catalytic cracking unit, in accordance with some embodiments of this disclosure.

[0030] FIG. 4A illustrates a disclosed embodiment of a biofeed nozzle for injecting biofeed into a riser reactor of a fluid catalytic cracking unit, in accordance with some embodiments of this disclosure.

[0031] FIG. 4B illustrates a close-up view of a disclosed embodiment of a biofeed nozzle for injecting biofeed into a riser reactor of a fluid catalytic cracking unit, in accordance with some embodiments of this disclosure.

[0032] FIG. 5A illustrates a disclosed embodiment of a biofeed nozzle cap for injecting biofeed, in accordance with some embodiments of this disclosure.

[0033] FIG. 5B illustrates a disclosed embodiment of a biofeed nozzle cap for injecting biofeed, in accordance with some embodiments of this disclosure.

[0034] FIGS. 6A and 6B show disclosed embodiments of a biofeed nozzle for injecting biofeed while preventing preferential flashing of the aqueous phase and degradation of the pyrolysis oil fraction, in accordance with some embodiments of this disclosure.Attorney Docket No. 23-22 PCT

[0035] FIG. 6C shows a disclosed embodiment of a biofeed nozzle for injecting biofeed while preventing preferential flashing of the aqueous phase and degradation of the pyrolysis oil fraction, in accordance with some embodiments of this disclosure.

[0036] FIG. 6D shows a disclosed embodiment of a biofeed nozzle for injecting biofeed while preventing preferential flashing of the aqueous phase and degradation of the pyrolysis oil fraction, in accordance with some embodiments of this disclosure.

[0037] FIG. 6E shows a disclosed embodiment of a biofeed nozzle for preventing preferential flashing of the aqueous phase and degradation of the pyrolysis oil fraction, in accordance with some embodiments of this disclosure.

[0038] FIG. 7 A shows a disclosed embodiment of steam injection method into a biofeed nozzle, in accordance with some embodiments of this disclosure.

[0039] FIG. 7B shows a disclosed embodiment of steam injection method into a biofeed nozzle, in accordance with some embodiments of this disclosure.

[0040] FIG. 7C shows a disclosed embodiment of steam injection method into a biofeed nozzle, in accordance with some embodiments of this disclosure.DETAILED DESCRIPTION

[0041] Aspects of this disclosure relate to reducing greenhouse gas (e.g., carbon dioxide (CO2)) emissions from catalytic cracking units, such as fluid catalytic cracking (FCC) units and residue fluid catalytic cracking (RFCC) units, used in hydrocarbon cracking processes. This disclosure may be relevant for increasing the renewable content of fuels produced from catalytic cracking units via a process that enables co-feeding of bio-derived renewable feedstocks (i.e., biofeeds) to catalytic cracking units alongside the main fossil-derived heavy hydrocarbonAttorney Docket No. 23-22 PCTfeedstock ("hydrocarbon feedstock"). Disclosed systems and methods advantageously co-feed bioderived renewable feedstocks using natural gas as a fluidization dispersion medium instead of steam, which promotes dispersion without degrading the bioderived renewable feedstocks. In some embodiments, disclosed systems and methods incorporate feed nozzles designed to advantageously promote co-feeding of bioderived renewable feedstocks into catalytic cracking units using natural gas as the fluidization dispersion medium. For example, disclosed systems include a variety feed nozzles including (1) a biofeed nozzle containing concentric rings and a rotated mixing zone, (2) a discontinuous stepped-ring biofeed nozzle containing discontinuous stepped rings and a mixing zone, and (3) a swirling biofeed nozzle having a swirling feed tube and a baffle with a plurality of vanes.Co-feeding Bioderived Renewable Feedstocks to Catalytic Cracking Units

[0042] Disclosed catalytic cracking units may incorporate biofeeds, or a renewable biomass material, like plant oils or algae, that is used as an input in a refinery to be processed alongside traditional fossil fuels. Biofeeds may include triglyceride-based oils (e.g., soybean oil, palm oil, animal fats / tallow, canola / rapeseed oil, algae oil, etc.), waste oils (e.g., used cooking oil), pyrolysis oils from thermal decomposition of lignocellulosic biomass in the absence of oxygen (e.g., multiple biomass sources, such as forest residues, crop residues, energy crops, etc. may be pyrolyzed), mixtures thereof, and others. Quality of the biofeed may vary depending on the grade and source of the biofeed. Incorporation of biofeeds into a catalytic cracking unit may increase a renewable content of fuels produced from the catalytic cracking unit but designing a feed system around biofeeds requires additional considerations.Attorney Docket No. 23-22 PCT

[0043] For a hydrocarbon feedstock incorporated into a disclosed catalytic cracking unit, a hydrocarbon feed nozzle may atomize the hydrocarbon feedstock into small droplets that may be atomized into a catalytic cracking unit riser reactor. Higher feedstock temperatures may help reduce viscosity and aid atomization of the hydrocarbon feedstock. In known systems. Medium Pressure (MP) steam may be used to aid atomization of a hydrocarbon feedstock in the hydrocarbon feed nozzle. In other known systems, High Pressure (HP) or High Hydrostatic Pressure (HHP) steam may be used to aid atomization of a hydrocarbon feedstock in the hydrocarbon feed nozzle. However, disclosed systems and methods instead use natural gas as a dispersion medium instead of steam which advantageously provides for the benefits of co-feeding bioderived renewable feedstocks with the hydrocarbon feedstock without degrading the bioderived renewable feedstocks. Further, disclosed systems and methods using natural gas as the dispersion medium do not require cooling systems or methods to maintain an adequately low temperature of the bioderived renewable feedstocks as to prevent degradation, features not found in known systems. The natural gas used as the dispersion medium may be provided by a tank containing the natural gas or any other direct feed line.

[0044] When designing a feed system for biofeeds for a disclosed catalytic cracking unit, temperature, miscibility, viscosity, and metallurgy concerns may need to be addressed. Regarding temperature, feeding certain biofeeds to the catalytic cracking unit at temperatures above 50-120 °C can result in degradation of the biofeeds. Triglyceride oils are limited to a temperature ranging between about 0 °C and 120 °C - above this temperature polymerization reactions are more likely to occur. For example, the temperature of the triglyceride oils may be a temperature of around 0 °C, or about 10 °C, or about 20 °C, or about 30 °C, or about 40 °C, or about 50 °C, or about 60 °C, or about 70 °C. or about 80 °C, or about 90 °C, or about 100 °C, or about 110 °C, or about 120Attorney Docket No. 23-22 PCT°C, where about includes plus or minus 5 °C. Tn some embodiments, pyrolysis oils are limited to temperatures between about 0-60 °C - above this temperature polymerization reactions and coke formation reactions are accelerated. For example, the temperature of the pyrolysis oils may be a temperature of around 0 °C, or about 10 °C, or about 20 °C, or about 30 °C, or about 40 °C, or about 50 °C, or about 60 °C, where about includes plus or minus 5 °C. Acceleration of polymerization reactions and coke formation reactions can increase viscosity, leading to the fouling of piping, equipment, and feed nozzles. Instead of cooling systems, disclosed systems and methods incorporate at least one of a natural gas based dispersion medium and disclosed dispersion nozzles that synergistically function together to maintain adequate temperature ranges of the biofeeds. A natural gas may include a gaseous mixture of naturally occurring gaseous hydrocarbons. The natural gas may be primarily methane, such as about 95 % methane or greater. In some embodiments, the natural gas may include trace amounts of higher alkanes, carbon dioxide, nitrogen, hydrogen sulfide, and / or helium. The natural gas disclosed herein is different than a syngas, or synthesis gas, which is a gas mixture consisting mostly of carbon monoxide and hydrogen gas, while containing trace amounts of carbon dioxide and methane. The natural gas may be distinct from an Fluidic Catalytic Cracking (FCC) gas, which is a gas produced by the FCC process in petroleum refineries that break down larger gas oil molecules into smaller molecules. FCC gases, in contrast, mostly include methane, ethane, alkenes, and light alkenes.

[0045] A maximum temperature requirement for transferring biofeed within a biofeed preheat system of a disclosed catalytic cracking unit may be dependent upon a specific type of biofeed. In some embodiments, factors include a smoke point and boiling point of the biofeed may be considered since temperature of these points be at temperatures lower than typical biofeed catalytic cracking maximum temperature requirements. In some embodiments, the biofeed may be blendedAttorney Docket No. 23-22 PCTwith the hydrocarbon feedstock which may be preheated to between about 200 to about 350 °C, depending on biofeed source and heat balance requirements of the catalytic cracking unit. For example, the hydrocarbon feedstock may be preheated to a temperature of about 200 °C, or about 210 °C, or about 220 °C, or about 230 °C, or about 240 °C, or about 250 °C, or about 260 °C, or about 270 °C, or about 280 °C. or about 290 °C, or about 300 °C, or about 310 °C, or about 320 °C, or about 330 °C. or about 340 °C, or about 350 °C, where about includes plus or minus 5 °C.

[0046] In some embodiments, a temperature of a dispersion medium (e.g., natural gas) as well as heat exchanged from a nozzle may also be a consideration. In known systems, significant heat may be transferred from a nozzle to a dispersion medium and ultimately to the biofeed and feedstock. In some embodiments, lowering the preheat temperature of the hydrocarbon feedstock may be a possibility. This may increase catalyst circulation and conversion to products but may decrease the hydrocarbon feedstock viscosity, resulting in poor atomization of the hydrocarbon feedstock and poor selectivity to desired products. Additionally, coke yield would increase, although this may be constrained by blower capacity. Disclosed nozzles advantageously limit significant heat transfer to any one of the dispersion medium and biofeed, so there is no need to lower the preheat temperature of the hydrocarbon feedstock.

[0047] Some biofeeds incorporated in disclosed catalytic cracking units, including triglyceride-based oils, may be miscible with, and can therefore be blended with a hydrocarbon feedstock. However, if the miscible biofeed is blended with a hydrocarbon feedstock, a temperature of the miscible biofeed may increase to a feed preheat temperature and decomposition will likely occur. Pyrolysis oils are biofeeds that are immiscible with the hydrocarbon feedstock, so they may not fully mix with the feedstock. Stability of biofeed comprising pyrolysis oils may be poor due to high oxygen content, which may lead to oxidation. Bio-derived pyrolysis oil which,Attorney Docket No. 23-22 PCTto be processed in an FCC, may be mixed with lipidic feeds of biological origin or with more typical FCC feeds (VGO, HVGO, LVGO, AR, VR) for co-processing. A wide range of mixing ratios can be used, from 0 to 100% biological feedstock.

[0048] In some embodiments, a viscosity of some biofeeds used in disclosed catalytic cracking units may be high depending on an original biofeed source. In some cases, the viscosity of these biofeeds, such as a pyrolysis oil, may need to be reduced for movement and efficiency purposes. Increasing biofeed preheat temperature may be a way to reduce viscosity of the biofeed, but a maximum temperature of the biofeed may be limited as mentioned previously.

[0049] Certain triglyceride-based biofeeds, used in disclosed catalytic cracking units, may contain Free Fatty Acids (FFA’ s). The amount of FFA’ s may be a function of a grade, type, storage conditions, etc., of the triglyceride-based biofeeds. The quantity of FFA’s may impact the Total Acid Number (TAN) value, as more FFA’s means higher TAN values. Similarly, with pyrolysisbased biofeeds, the TAN value may be higher due to the presence of organic acid compounds contained in the oil. The metallurgy selected for the hydrocarbon feedstock system may not be suitable for these biofeeds due to the higher TAN value. If the TAN value of the biofeed may be higher than about 0.5, where about includes plus or minus 0.25, heating the biofeed to a temperature higher than 232 °C may require costly high-grade metallurgy such as 317 stainless steels or low chrome alloyed 316 stainless steels. This would likely be the case if the biofeed is mixed with the hydrocarbon feedstock. In some embodiments, cheaper, lower grade metallurgy may be used if the temperature may be below 232 °C and TAN values are lower than 0.25. The cheaper, lower grade metallurgy may comprise a steel or low chrome alloy variant.

[0050] The present disclosure includes a catalytic cracking unit that supplies a biofeed to a catalytic cracking unit riser reactor via a feed system that may be dedicated to the biofeed andAttorney Docket No. 23-22 PCTseparate from a hydrocarbon feedstock feed system that supplies the hydrocarbon feedstock to the riser reactor. In some embodiments, substantially all of the biofeed may be handled in this separate system. The separate system may enable a temperature of the biofeed fed to nozzles to be kept below a maximum allowable temperature, thereby avoiding production of degradation products.

[0051] In some embodiments, a hydrocarbon feedstock used in disclosed catalytic cracking units may continue to be fed to a riser reactor via one or more hydrocarbon feed nozzles that is separated from one or more biofeed nozzles. For example, the hydrocarbon feedstock may be fed to a hydrocarbon feed nozzle and the biofeed may be fed to the biofeed nozzle. In some embodiments, a dedicated biofeed nozzle (or nozzles, depending on flowrate) may be used to inject the biofeed directly into the riser reactor. In some embodiments, the biofeed nozzle may be designed using the same principles as a nozzle designed for hydrocarbon feedstock. Fuel gas may be used as the dispersion medium in the biofeed nozzle to aid atomization of the biofeed. Fuel gas may be generally supplied as a dispersion medium at the necessary pressure but with a much lower temperature than steam and with the necessary superheat to prevent condensation. In some embodiments fuel gas prevents raising the temperature of the biofeed within the biofeed nozzle. The fuel gas dispersion medium may be introduced in exactly the same way as it would for the hydrocarbon feed nozzle, using disclosed nozzles. Disclosed systems use natural gas as a dispersion medium for at least one of the biofeed and hydrocarbon feed stock. The use of natural gas as the dispersion medium prevents heat transfer to the biofeed that occurs with steam at higher temperatures and equivalent pressures.

[0052] In some embodiments, the dispersion medium used in disclosed catalytic cracking units may be supplied from any one of a refinery fuel gas header, a recycled dry gas from the catalytic cracking unit, a natural gas from mains, nitrogen, or any other suitable source. In someAttorney Docket No. 23-22 PCTembodiments, gas compression may be required if the refiner header supply pressure is not sufficient. The dispersion medium amount provided to the biofeed nozzle may be dependent on properties of the biofeed, which may vary from about 1 wt. % to about 25 wt. %, or more, by weight of the fresh biofeed. For example, the dispersion medium amount may include about 1 wt. %, or about 5 wt. %. or about 10 wt. %, or about 15 wt. %, or about 20 wt. %, or about 25 wt. %, or more, where about includes plus or minus 2.5 wt. %. In some embodiments, additional cracked product may pass through a riser reactor and into a separation section of the catalytic cracking unit. Additional cracked product, such as a light gas, may have to be accounted for in downstream equipment, such as in a wet gas compressor.

[0053] Disclosed catalytic cracking units may advantageously control a biofeed preheat temperature to below a maximum temperature limit to substantially avoid formation of degradation products. In some embodiments, to control the biofeed preheat temperature, the biofeed may be separated from a hydrocarbon feedstock having a higher preheat temperature, such as one above a temperature that may cause degradation of the biofeed. A biofeed preheater may be required to heat the biofeed from storage temperature to the maximum temperature limit. By limiting the maximum temperature limit of the biofeed, decomposition of the biofeed may be prevented. The system may be designed to handle different types of biofeed.

[0054] Additionally, in some embodiments, a disclosed system or method may have a benefit of not requiring an active cooling system to keep a biofeed preheat temperature below a maximum temperature limit, thereby substantially preventing production of decomposition products. Meanwhile, hydrocarbon feedstock may be kept at a higher desired preheat temperature for maintaining an overall heat balance and to ensure the hydrocarbon feedstock may be hot enough to reduce the viscosity of the hydrocarbon feedstock for desired operations.Attorney Docket No. 23-22 PCT

[0055] In the case of pyrolysis-based biofeeds used in disclosed catalytic cracking units, immiscible flow may be avoided in some embodiments of this disclosure. Avoidance of immiscible flow may be avoided since a disclosed hydrocarbon feedstock pre-heat system may be not the same as a disclosed biofeed pre-heat system. Equipment, piping and nozzles interacting with only the biofeed may be constructed from metallurgy that may be suitable for the biofeed ensuring target life of the system may be met. A lower operating temperature may also help with metallurgy selection, as a higher temperature or even a more acidic system may require more expensive metallurgy than a lower temperature, less acidic system, or even less oxidation prone system. The corrosive properties of the feed may determine the required type of metal for construction, such as carbon steel, stainless steel, and high or low alloys.

[0056] Viscosity of feeds may be controlled in disclosed catalytic cracking units by cofeeding hydrocarbon liquids with biofeed. Cycle oil, distillate, and naphtha co-feed may reduce the viscosity of biofeed (e.g., biomass pyrolysis oil) and serve as an alternative to raising the temperature of the biofeed. The hydrocarbon co-feed can originate from fossils or bioderived sources. In some embodiments, co-feed may be premixed with the biofeed downstream of a biofeed nozzle and the mixture may be fed to the biofeed nozzle. Depending on biofeed properties, it may be possible to use heavier materials for viscosity reduction.

[0057] Other disclosed catalytic cracking unit component arrangements may be considered for feeding a biofeed to a riser reactor of a catalytic cracking unit. The biofeed may be introduced at either at a same level as an existing hydrocarbon feed nozzle, above the existing hydrocarbon feed nozzle, or below the existing hydrocarbon feed nozzle. In some embodiments, the biofeed may also be introduced into a dedicated second riser reactor. The first riser reactor may be fedAttorney Docket No. 23-22 PCTwith only the hydrocarbon feedstock and the second riser reactor may be fed with only the biofeed or a combination of hydrocarbon feedstock and biofeed.

[0058] A disclosed catalytic cracking unit may provide a working solution that allows refiners operating the catalytic cracking unit to increase renewable content of fuels produced from the catalytic cracking unit by increasing production of fuels from biogenic, non-fossil origin. The carbon in biofeed may be sourced from the environment as part of a biogenic carbon cycle. Compared to carbon from traditional fossil-based hydrocarbon feedstocks, carbon from biofeed may not add to global atmospheric carbon inventories. This way, when fuels based on biofeed are produced and consumed, global atmospheric CO2 inventories are not significantly increased. Overall, Scope 3 emissions would be reduced. In some embodiments, the disclosed invention also ensures biofeeds may be supplied to the catalytic cracking unit with reduced degradation / operation issues / etc. Scope 3 emissions are proportionally reduced as biofeed is proportionally increased relative to fossil-based feedstocks, and in the case of complete replacement of fossil-based feedstocks, Scope 3 emissions will be eliminated.

[0059] In some embodiments, Scope 1 CO2 emissions from a refinery with a disclosed catalytic cracking unit may also be reduced from the implementation of the disclosed invention. A portion of the biofeed will form coke that will lay down on the catalyst and be combusted in a catalyst regenerator. The portion of the coke from the biofeed combusted in the catalyst regenerator does not add to global atmospheric carbon CO2 inventories. Similarly, a portion of the biofeed will form dry gas or fuel gas (C2 minus product gas) that may be typically sent to the refinery fuel gas system where it may be combusted to supply heat energy. The portion of the dry gas from the biofeed that may be combusted as a fuel gas does not add to global atmospheric carbon CO2 inventories. The catalytic cracking unit according to some embodiments of thisAttorney Docket No. 23-22 PCTdisclosure may be reduced from about 1.0 kilograms to about 0.0 kilograms of CO2 per kilogram of feed, if biofeed completely displaces fossil-based material.

[0060] A disclosed catalytic cracking unit may include disclosed biofeed and hydrocarbon nozzles. The biofeed and hydrocarbon feed nozzle arrangement / metallurgy may differ depending on application. In some embodiments, active cooling of a biofeed pre-feed system may not be required to keep a temperature of the biofeed below a maximum temperature limit to prevent formation of degradation products. The CO2 footprint may be further reduced by replacing steambased dispersion mediums with fuel gas. Other alternative biofeeds, such as pyrolysis oil from a synthetic waste recycling technology (e.g., plastics, tires, etc.), may be incorporated as feedstocks into disclosed catalytic cracking units.

[0061] One relevant property of bio-derived pyrolysis oil is its lack of stability. Two phases (aqueous and organic phase) appear when such oil is left at rest. As a stream of this material is transported, the flow can stratify within the pipe to form core-annular or otherwise stratified flow. If stratified flow of the two liquids enters a catalytic cracking unit feed nozzle, the aqueous phase will preferentially occupy the annulus around the wall if denser than the oil phase. When oil is brought in contact with a nozzle wall (which itself is in contact with the hot environment of the FCC), flashing of the aqueous phase can occur. This will lead to thermal degradation of the non-aqueous pyrolysis oil fraction and associated nozzle fouling and plugging. Use of mechanical features can promote turbulent flow by mixing to prevent flashing of the aqueous phase.Catalytic Cracking Units

[0062] FIG. 1 depicts a unit schematic drawing of a disclosed catalytic cracking unit 100 in accordance with some embodiments of this disclosure. According to some embodiments, theAttorney Docket No. 23-22 PCTcatalytic cracking unit 100 may be equipped with a pseudo-adiabatic riser reactor 116, 118 and a continuous catalyst regenerator 104, operating under steady state conditions. The riser reactor may be separated into a riser 118 and a reactor 116. A hydrocarbon feedstock 120 and a biofeed 122 may be introduced at two different axial positions in the riser 118, which includes a cylindrical tube. The riser 118 and the reactor 116 may be combined into one riser reactor. The combined riser reactor may perform both the functions of the riser 118 and the reactor 116. The introduction of the biofeed through a separate biofeed feed nozzle from the hydrocarbon feedstock may permit the heating of the hydrocarbon feedstock from a temperature of about 10 °C to a temperature of about 280 °C depending on heat balance requirements of the catalytic cracking unit. For example, the hydrocarbon feedstock may be preheated to a temperature of about , or about 10 °C, or about 20 °C, or about 30 °C, or about 40 °C, or about 50 °C. or about 60 °C, or about 70 °C , or about 80 °C, or about 90 °C, or about 100 °C, or about 110 °C, or about 120 °C, or about 130 °C, or about 140 °C, or about 150 °C, or about 160 °C, or about 170 °C, or about 180 °C, or about 190 °C, or about 200 °C, or about 210 °C, or about 220 °C, or about 230 °C, or about 240 °C, or about 250 °C, or about 260 °C, or about 270 °C, or about 280 °C, where about includes plus or minus 5 °C. The hydrocarbon feedstock may include a gas oil (e.g., Brazilian vacuum gasoil). In some embodiments, the biofeed may include a fast pyrolysis liquid. Within the riser 118, dispersion mediums 124 (e.g., natural gas) and catalysts 112 may combine with the hydrocarbon feedstock 120 and biofeed 122. The dispersion mediums may include a natural gas. The catalysts may include a metal, a metal oxide, a crystalline zeolite, a silica, an alumina, a silica-alumina, an aluminosilicate zeolite, a zeolite, and combinations thereof. T he mixture may result in the cracking of heavier and longer hydrocarbon chains from the hydrocarbon feedstock to form shorter, lighter, and more refined hydrocarbons, also referred to as cracked hydrocarbon productsAttorney Docket No. 23-22 PCTor cracked products. The mixture may then enter the reactor 116, wherein the cracked product would proceed with further processing in the main fractionator and gas concentration sections. Meanwhile the catalysts and coke may mix with stripper steam 114 in the reactor 116 and the spent catalyst 110 may transfer to a catalyst regenerator 104 to produce regenerated catalyst 112 and flue gas 102. In some embodiments, coke is burned off the catalyst surface when mixed with injected air 108.

[0063] FIG. 2A illustrates a disclosed system diagram 200 of biofeed pre-heat systems and hydrocarbon feedstock pre-heat systems for co-feeding biofeed and hydrocarbon feedstock into catalytic cracking units in accordance with some embodiments of this disclosure. Independent biofeed pre-heat systems include having entirely separate lines and biofeed nozzles into the riser reactor to ensure the temperature of the biofeed may be kept below certain temperatures. The biofeeds may include triglyceride oils, such as palm oil, or biomass derived pyrolysis oil. Having separate biofeed pre-heat systems also aids the movement of immiscible biofeeds, such as pyrolysis oil, since they cannot be mixed with hydrocarbon feedstock. The low temperatures required for the separate biofeed pre-heat systems prevent expensive metallurgy upgrades. The hydrocarbon feedstock pre-heat system may comprise a feed pump 202 and a fire heater 204 for the hydrocarbon feedstock 206 to pre-heat before entering the riser reactor 230. Hydrocarbon feeds may be preheated in a heat exchanger against hot streams from the main fractionator products (e.g., slurry). The spent catalyst 234 would transfer from the riser reactor 230 to the catalyst regenerator 236. Flue gas 240 and regenerated catalyst 232 may leave the regenerator 236. Low pressure steam 224 will interact with biofeed 212 in an exchanger 214 for the biofeed 212 to reach its desired preheated temperature. The low pressure steam 224 leaves the exchanger as low pressure condensate 216. The exchanger 214 heats the biofeed 212 using other heating mediums.Attorney Docket No. 23-22 PCTThe preheated biofeed 228 then mixes with fuel gas 208 and enters the reactor 230. There may be a temperature control loop 226 that controls the temperature of the preheated biofeed 228, but is not required. A steam condensate drum 218 ensures no moisture from the low pressure condensate 216 reaches downstream components by removing moisture through a condensate outlet 220. The steam condensate drum 218 is connected to a pressure equalizing line 222.

[0064] A disclosed catalytic cracking unit 200 may include a riser reactor 230 configured to combine a hydrocarbon feedstock 206 with the preheated biofeed 228 and a catalyst 232 to form a cracked product and a spent catalyst 234. The catalytic cracking unit 200 may include a catalyst regenerator 236 connected to the riser reactor 230, the catalyst regenerator 236 comprising a cyclonic separation system. The catalyst regenerator 236 may be configured to receive the spent catalyst 234 from the riser reactor 230. The catalyst regenerator 236 may be configured to burn coke off of the spent catalyst 234 with heat created as a byproduct of the exothermic combustion of coke on catalyst and air. The catalyst regenerator 236 may be configured to separate, in the catalyst regenerator 236, the hot catalyst mixture into the regenerated catalyst 232 and the combustion gases. The catalyst regenerator 236 may be configured to convey the regenerated catalyst 232 to the riser reactor 230. The biofeed 212 comprises at least one of a plastic pyrolysis oil, a biomass pyrolysis oil, a triglyceride-based oil, and a fuel gas as a dispersion medium. The biofeed 212 comprises alternative feedstock. The triglyceride-based oil comprises a palm oil, an olive oil, a sunflower oil. a canola oil, a coconut oil, a safflower oil, a com oil, a peanut oil, a cottonseed oil, a palm-kernel oil, a soybean oil, a used cooking oil, an animal fat, a tallow, a rapeseed oil, an algae oil, and combinations thereof. The pyrolysis oil may be generated from a thermal decomposition of a lignocellulosic biomass in the absence of oxygen. The pyrolysis oil may be generated from a plastic recycling technology.Attorney Docket No. 23-22 PCT

[0065] FIG. 2B illustrates a disclosed system diagram, of biofeed and hydrocarbon feedstock pre-heat systems for co-feeding biofeed to disclosed catalytic cracking units in accordance with some embodiments of this disclosure. The disclosed system diagram 250 illustrates embodiments for feeding biofeed 212 from plastics -derived pyrolysis oil. The biofeed 212 may be co-fed with the hydrocarbon feedstock 202 at 252. This embodiment may require a metallurgy upgrade depending upon the metallurgy of the existing feed preheat system. Plastic pyrolysis-based biofeed may be miscible with hydrocarbon feedstock. Some embodiments include an independent feed system 242 for biofeed. In these embodiments, there may be an entirely separate line and feed nozzle(s) in the riser reactor 230 to ensure temperature of the biofeed is kept low enough to prevent expensive metallurgy upgrades.

[0066] Other arrangements may be considered for feeding the biofeed or alternate feeds to the riser reactor. One such arrangement may introduce biofeed either at the same level as the existing hydrocarbon feed nozzles or above the existing hydrocarbon feed nozzles or below the existing hydrocarbon feed nozzles. Another such arrangement may introduce biofeed into a dedicated second riser. In this arrangement, the first riser may be fed with only hydrocarbon feedstock and the second riser may be fed with only biofeed or the second riser may be fed with a combination of hydrocarbon feedstock and biofeed. A third arrangement would be to introduce the biofeed into the stripper.

[0067] As shown in FIG. 2B, a feed preheat system may include a feed pump 202 and a fire heater 204 for a hydrocarbon feedstock 206 to preheat before entering a riser reactor 230. A spent catalyst 234 may transfer from the riser reactor to 230 to a catalyst regenerator 236. Flue gas 240 and regenerated catalyst 232 may be transferred from a catalyst regenerator 236 to a riser reactor 230. In some embodiments, low pressure steam 224 may interact with biofeed 212 beforeAttorney Docket No. 23-22 PCTmixing with fuel gas 208 and entering the riser reactor 230. The exchanger 214 heats the biofeed 212 using heating mediums other than low pressure steam 224. Each component shown in FIGS.2A and 2B may be fluidly connected to any number of conduits.

[0068] FIG. 3 illustrates a disclosed unit schematic drawing for a catalytic cracking unit 300, in accordance with some embodiments of this disclosure. For the purpose of discussing the disclosure, a unit schematic drawing may be divided into five main sections with continuous catalyst circulation occurring from section to section: the riser reactor 302, disengager 310, spent catalyst stripper 304, catalyst cooler 308, and catalyst regenerator 306. The riser reactor 302 design may employ a catalyst standpipe and catalyst slide valve to move regenerated catalyst from the regenerator vessel 306 to the riser reactor 302. In some embodiments, catalyst may flow up the vertical dense phase transfer line from the slide valve toward the oil injection pickup point. The catalyst flowing through this line may be fluidized with a distribution medium. Biofeed and hydrocarbon feedstock may be injected into a lower part of the riser reactor 302 through biofeed and hydrocarbon feed nozzles 326 located around the circumference of the riser reactor 302. A distribution medium, such as a natural gas or fuel gas, may be used to aid oil atomization in the biofeed and hydrocarbon feed nozzles 326. The hot regenerated catalyst vaporizes the biofeed and hydrocarbon feedstock, raises it to reaction temperature, and supplies the necessary heat for cracking. The cracking reaction may proceed as the catalyst and vapor mixture flows up the riser reactor 302. The riser reactor 302 uses an outlet temperature controller that adjusts the catalyst slide valve position to regulate the amount of regenerated catalyst admitted into the riser reactor 302.

[0069] In some embodiments, as shown in FIG. 3, a riser quench system 332 may be configured to inject vaporized heavy catalytic naphtha, or other hydrocarbon liquid, from the mainAttorney Docket No. 23-22 PCTfractionator, into the riser reactor 302 above the biofeed and hydrocarbon feed nozzles 326.Recycled material may act as a heat sink as it may be vaporized by the catalyst. At constant riser outlet temperature, quench may increase a catalyst-to-oil ratio because the riser outlet temperature control point may be located downstream of the quench location. Introduction of quench oil may also increase the temperature in the mix zone and the lower section of the riser reactor 302.

[0070] In some embodiments, having a higher initial cracking temperature and a higher catalyst-to-oil ratio may increase gasoline yield, olefin production, and gasoline octane, of a disclosed catalytic cracking unit. Rapidly lowering the temperature at the optimally located quench point prevents secondary reactions such as saturation of olefins and over cracking to form dry gas may be especially useful for residue hydrocarbon feedstocks with high boiling ranges. With an elevated mix zone temperature, the fresh biofeed and hydrocarbon feedstock vaporization efficiency may be improved. Since the desirable catalytic reactions occur in the vapor phase, vaporization of the fresh feed at the mix zone may be beneficial.

[0071] In some embodiments, as shown in FIG. 3, once selective cracking reactions have been completed, it may be advantageous to minimize product vapor residence time in the disengager 310 to prevent unwanted thermal or catalytic cracking reactions that produce dry gas and coke from more valuable products. A catalyst and cracked oil products from a riser reactor 302 may pass into riser cyclones 314 through a bend (e.g., 90° bend) at a top of the riser reactor 302. Product vapors from the riser cyclones 314 may flow directly into an intermediate plenum chamber 316, through dedicated ductwork. Stripped hydrocarbon feedstock and dispersion medium from the spent catalyst stripper 304 may also enter the intermediate plenum chamber 316.In some embodiments, the intermediate plenum chamber 316 increases the robustness of closedAttorney Docket No. 23-22 PCTcyclone system by redistributing the hydrocarbons and steam into upper cyclones. The reaction vapors leave the disengager 310 and flow to the main fractionator.

[0072] In some embodiments, catalyst separated in a riser cyclone 314 of a disclosed catalytic cracking unit, may flow through respective diplegs and discharges into a spent catalyst stripper 304. The diplegs of a riser (primary) and upper cyclones may be submerged in a stripper bed. The diplegs of the upper cyclones may discharge through trickle valves. The spent catalyst entering the spent catalyst stripper 304 may be contacted by up flowing steam introduced through two steam distributors. The steam displaces most of the hydrocarbon vapors that were entrained with the spent catalyst. The spent catalyst then flows down through a packed section 318 in the spent catalyst stripper 304. In the packed section 318, a combination of residence time, steam partial pressure and intimate contact between the spent catalyst and steam may be used to cause the hydrocarbons to diffuse out of the catalyst pores into the steam introduced via the lower distributor. Stripped catalyst, with essentially all strippable hydrocarbons removed, passes into a standpipe, which may be aerated with steam to maintain smooth flow. At the base of the standpipe, a plug valve regulates the flow of spent catalyst to maintain the spent catalyst level in the spent catalyst stripper 304. The spent catalyst then flows into the spent catalyst distributor 322 and into the catalyst regenerator 306.

[0073] In some embodiments, coke may be burned off the spent catalyst to supply the heat requirements of the process and restore the spent catalyst's activity in a catalyst regenerator 306. The catalyst regenerator 306 may be operated in either a full or partial carbon monoxide combustion mode as process requirements dictate. Combustion air may be supplied to the catalyst regenerator 306 via an air blower. The combustion products from the burning of the coke may include CO, CO2, H2O, SOx and NOx. The combustion gases are separated from the spent catalystAttorney Docket No. 23-22 PCTin regenerator cyclones 320. The gases then flow into the flue gas system and the regenerated catalyst may be returned to the dense bed through the cyclone diplegs. The catalyst regenerator 306 may be equipped with technology which will allow good catalyst regeneration. The technology will also reduce catalyst deactivation and hence minimize catalyst addition rate. The catalyst inventory within the catalyst regenerator 306 may be not under direct level control, but rather depends on the entire catalytic cracking unit inventory. The regenerator pressure control may be maintained by throttling a flue gas slide valve. The valve position may be controlled by a differential pressure controller system provided between the catalyst regenerator 306 and disengager vessels.

[0074] In some embodiments, converter heat removal requirements may be provided by a catalyst cooler 308. Such an advanced design operates with steam and water inside the tubes and hot catalyst flowing at low velocity in the shell. The single tube sheet with free hanging tubes makes this a simple, mechanically reliable design.

[0075] According to some embodiments, a catalyst cooler 308 may have the flexibility to change duty over a broad range; varying the catalyst flow through the slide valve controls the amount of heat removal. A unique vent line in the design allows turndown to near zero heat removal duty by preventing catalyst back mixing between the catalyst regenerator 306 and catalyst cooler 308 when the slide valve may be closed. This may be important during heat-up of components of a disclosed catalytic cracking unit during start-up or when processing a biofeed and hydrocarbon feedstocks not requiring regenerator heat removal. The catalyst cooler 308 may be able to control regenerator temperature as feed quality changes. The tubes are double pipe, bayonet design with boiler feed water flowing downward in the inner tube, and steam and water flowing upward in the annulus. The length and number of bayonet tubes determines the heat transfer duty,Attorney Docket No. 23-22 PCTwhich may be achieved in the unit. The tubes are free hanging from a tube sheet at the top of the unit and are guided at two locations to avoid vibration. Because of this, when the unit may be started up or when catalyst temperature changes due to varying heat load, tube expansion does not produce thermal stresses. The fluidization air in the cooler shell may be located well below the tubes, so disclosed tube erosion from aeration air jet may be eliminated.

[0076] In some embodiments, a catalyst may enter a shell of a catalyst cooler 308. as shown in FIG. 3, through a short conduit between a regenerator wall and the catalyst cooler 308. Bubbles bursting at the top of the bed inside the catalyst cooler 308 may aid lateral catalyst mixing, equalizing the radial temperature distribution over the tube field. Catalyst may flow down the length of the catalyst cooler 308 and may be then withdrawn into a short standpipe containing a slide valve at its base. Catalyst may be transported back to the catalyst regenerator bed from the discharge of the slide valve via a vertical dilute phase earner line. High pressure saturated steam generated from catalyst cooler 308 may be sent to flue gas cooler for superheating.

[0077] Numerous system variables may be directly controlled within a disclosed catalytic cracking unit 300. These variable may include riser outlet temperatures, spent catalyst stripper bed level, catalyst regenerator air rate, disengager - catalyst regenerator differential pressure, catalyst regenerator pressure, feed rate and temperature. The main control loop may be the riser outlet temperature, which may be controlled by the amount of hot regenerated catalyst admitted into the riser reactor 302. By setting a desired reaction temperature, the controller will adjust the regenerated catalyst slide valve position to pass enough hot catalyst to reach the desired riser outlet temperature.

[0078] A disclosed catalytic cracking unit may be configured to control a differential pressure between a catalyst regenerator 306 and a disengager 310, which may effectively set anAttorney Docket No. 23-22 PCTavailable pressure differential for two catalyst control valves. The disengager or reaction side pressure floats on the wet gas compressor suction pressure plus the pressure consumed in the main fractionator system. A constant pressure differential between a catalyst regenerator 306 and disengager 310 may advantageously allow for a smooth movement of spent catalyst from the spent catalyst stripper 304 and into the catalyst regenerator 306 and then back to a riser reactor 302.

[0079] A disclosed catalytic cracking unit 300 may include a spent catalyst stripper. A level of catalyst contained in the spent catalyst stripper may be controlled by a spent catalyst plug valve. In some embodiments, maintaining a constant level of catalyst may be important to sealing the closed cyclone diplegs in the dense phase catalyst bed. Level controllers may be used to set the plug valve position and therefore control the catalyst level. The catalyst regenerator bed may be allowed to float as catalyst may be added and withdrawn from the converter system. The range of catalyst level fluctuation allowed in the catalyst regenerator 306 may be about 1.25 meters, where about may be plus or minus 1 meter. The converter system has numerous safety systems to prevent unsafe operation. In some embodiments, should either very high or low reaction temperatures occur, the disclosed system may be designed to alert operators of the problem and in some cases automatically stop fresh hydrocarbon feedstock, biofeed, and riser quench flow to the riser reactor 302. Other safety controllers include automatic overrides to the catalyst control valves should the valve differential pressure drop below a pre-set value. The system may be designed to maintain catalyst flow in the positive direction and avoid dangerous catalyst flow reversals. The catalytic cracking unit 300 may also comprise one or more baffles 330, one or more disengager cyclone transition chambers 312, one or more air distributors 324, and one or more wye 328. In some embodiments, as shown in FIG. 3, the catalytic cracking unit may include a baffle 330 (e.g.,Attorney Docket No. 23-22 PCTRegenMax baffle), a disengager cyclone transition chamber 312, air distributors 324, and wyes 328.

[0080] According to some embodiments, a disclosed catalytic cracking unit 300 may include a distillation column fluidly connected to a riser reactor 302, the distillation column comprising a heat source and a distillation plate. The distillation column may be configured to receive the cracked product. The distillation column may be configured to separate the cracked product into at least one of a product gas, a naphtha, a light cycle oil, and a heavy cycle oil. The catalytic cracking unit 300 comprises a disengager 310 connected to a top outlet located at a top portion of the riser reactor 302, wherein the disengager 310 receives the cracked product and the spent catalyst from the riser reactor 302 to prevent unwanted cracking reactions of the cracked product that produce a dry gas and a coke. The catalytic cracking unit 300 comprises a spent catalyst stripper 304 wherein the spent catalyst stripper 304 may be connected to the disengager 310 through a cyclone and connected to the catalyst regenerator 306 through a spent catalyst distributor 322. The catalytic cracking unit 300 comprises a spent catalyst stripper 304, wherein the spent catalyst stripper 304 receives the spent catalyst from the disengager 310 through the cyclone and separates all strippable hydrocarbons away from the spent catalyst before transferring the spent catalyst to the catalyst regenerator 306 through the spent catalyst distributor 322. The catalytic cracking unit 300 may include a catalyst cooler 308 connected to the catalyst regenerator 306 through a short conduit and a slide valve. The catalyst cooler 308 may be configured to receive a portion of the regenerated catalyst from the catalyst regenerator 306 through a short conduit. In some embodiments, the catalyst cooler 308 may be configured to cool the regenerated catalyst to form a cooled catalyst. The catalyst cooler 308 may be configured to transfer the cooled catalyst back to the catalyst regenerator 306 through the slide valve.Attorney Docket No. 23-22 PCT

[0081] Illustrated in FIG.4A may be an embodiment of a disclosed catalytic cracking unit 400 of a biofeed nozzle 450 for injecting biofeed into a reactor body at a reactor body or container 406. The reactor body may include an outer reactor wall 402, a reactor refractory wall 404, and a reactor body 406. The biofeed nozzle 450 may penetrate through the outer reactor wall 402 and reactor refractory wall 404. The biofeed nozzle may inject a mixture of biofeed and hydrocarbon feedstock into the reactor body 406. In some embodiments, the biofeed nozzle may not transfer any hydrocarbon feedstock into the reactor body 406. The hydrocarbon feedstock and biofeed may be injected into a reactor body 406 at a ratio ranging from about 10:90 to about 90:10. For example, the ratio of hydrocarbon feedstock to biofeed may be about 10:90, or about 20:80, or about 30:70, or about 40:60, or about 50:50, or about 60:40, or about 70:30, or about 80:20, or about 90: 10, where about includes plus or minus 5:5. Besides, hydrocarbon feedstock and biofeed, a natural gas dispersion medium may account for the remaining component of what is injected into the reactor body 406. For example, the dispersion medium (e.g., natural gas) amount provided to reactor body 406 may vary from about 1 wt. % to about 25 wt. %, or more, by weight of the combined hydrocarbon feedstock and biofeed. For example, the dispersion medium amount may include about 1 wt. %, or about 5 wt. %, or about 10 wt. %, or about 15 wt. %, or about 20 wt. %, or about 25 wt. %, or more, of the combined hydrocarbon feedstock and biofeed, where about includes plus or minus 2.5 wt. %.

[0082] In some embodiments, a riser reactor may include a reactor body 406 designed to receive a hydrocarbon feedstock, the biofeed and a catalyst during the cracking. In some embodiments, the reactor body 406 is designed to allow flow of a hydrocarbon feedstock, the biofeed and a catalyst during the cracking. In examples, the reactor body 406 is designed to contain or house the hydrocarbon feedstock, the biofeed and the catalyst as they flow through it during theAttorney Docket No. 23-22 PCTcracking. The riser reactor may include a hydrocarbon feed nozzle connected to the reactor body and feeding the hydrocarbon feedstock to the reactor body. The riser reactor may include a biofeed nozzle connected to the reactor body and feeding the biofeed to the reactor body.

[0083] Illustrated in FIG. 4B, is a close-up view of a disclosed embodiment of a biofeed nozzle 450 for injecting biofeed 464 into a riser reactor of a catalytic cracking unit. The biofeed 464 may enter the biofeed nozzle 450 via the biofeed inlet 464. A dispersion medium (e.g., natural gas) may enter the biofeed nozzle 450 through the dispersion medium inlet 462. The dispersion medium and biofeed may combine to form a mixture in the mixing zone 456 before exiting through the open slot 454 in the nozzle cap 452. In some embodiments, the mixing process may be facilitated by a mixer 460, designed to maximize feed dispersion and mixing within the mixing zone 456. The mixing zone 456 may be equipped with components that maximize turbulent flow. This promotes small atomized feed droplets and a consistent temperature profile within the zone. The biofeed nozzle 450 may include a substantially hollow body with at least one curved edge. In some embodiments, the biofeed nozzle may include an open slot 454 located in the body and having a plurality of teeth. A disclosed catalytic cracking unit containing a disclosed biofeed nozzle 450 may advantageously feed the biofeed into a reactor riser without raising the biofeed to a temperature of above about 100 “C within a portion of the catalytic cracking unit. For example, the temperature of the biofeed may be maintained at a temperature of about 0 °C, or about 10 °C, or about 20 °C, or about 30 °C. or about 40 °C, or about 50 °C, or about 60 °C. or about 70 °C, or about 80 °C, or about 90 °C, or about 100 °C, where about includes plus or minus 5 °C. The biofeed nozzle may include a metal including a carbon steel, a 9 Cr-1 Mo steel, a chromium, a nickel, a molybdenum, a titanium, alloys thereof, and combinations thereof. The biofeed nozzleAttorney Docket No. 23-22 PCT450 may inject hydrocarbon feedstock or a combination of biofeed and hydrocarbon feedstock into a riser reactor of a disclosed catalytic cracking unit.

[0084] Illustrated in FIG.5A, may be a disclosed embodiment of a feed nozzle cap 500 of a disclosed catalytic cracking unit, for injecting biofeed or hydrocarbon feedstock into a riser reactor from a biofeed nozzle or hydrocarbon feed nozzle. The feed injection system of a catalytic cracking unit plays a key role in the yield performance of the unit. In some embodiments, a well-designed feed injection system must provide both rapid vaporization and intimate contact between the oil and catalyst. The feed nozzle cap 500 in FIG. 5A fulfills the key issues of performance and reliability. In some embodiments, the feed nozzle cap 500 includes a hollow, hemisphericalshaped body. The body may feature an open slot 504 for lower erosion disclosed with a plurality of teeth 506 for improved atomization, solid cobalt-6 tip 502 for better reliability, and fits within the existing riser sleeves for low costs. The solid cobalt-6 tip 502 may be made of any known polymer, metal, or composite thereof. For example, the solid cobalt-6 tip 502 may include a metal such as titanium, tungsten, chromium, nickel, cobalt, cobalt-6, 9 Cr-1 Mo steel, molybdenum, alloys thereof, and combinations thereof. The biofeed nozzle cap 500, in conjunction with the biofeed nozzle, has the benefits of excellent atomization and optimal dispersion of the feed, increased gasoline yield, which may be the building block for higher olefins yield, intimate mixing of the oil and catalyst across the entire rise cross section, and mechanical reliability for longer run lengths. The open slot 504 may include one or more shapes including at least one rectangle, square, circle, triangle, polygon, oval, parallelogram, cross, star, flat profile, curved profile, or combinations thereof. The open slot 504 further comprises from about two to about 30 teeth 506.For example, the open slot 504 may comprise about two teeth, or about four teeth, or about six teeth, or about eight teeth, or about ten teeth, or about 12 teeth, or about 14 teeth, or about 16 teeth,Attorney Docket No. 23-22 PCTor about 18 teeth, or about 20 teeth, or about 22 teeth, or about 24 teeth, or about 26 teeth, or about 28 teeth, or about 30 teeth, where about includes plus or minus 1 tooth. The open slot 504 protrudes outward from the hollow hemispherical-shaped body.

[0085] As shown in FIG. 5B, a disclosed nozzle may include a fan nozzle cap 550 of a disclosed catalytic cracking unit, for injecting biofeed, hydrocarbon feedstock, or a combination of biofeed with hydrocarbon feedstock. The fan nozzle cap 550 comprises a hollow, hemispherical- shaped body connected to a single slotted "fan" spray tip 558. The fan nozzle tip 552 has a saw tooth pattern comprising one or more teeth 556 on the inside edge of the fan nozzle tip 552. The fan nozzle tip 552 expands to form a proprietary single slotted "fan" spray tip 558 for increased riser reactor cross-sectional coverage. The fan nozzle cap 550 features a fan open slot 554 for lower erosion disclosed. The fan nozzle cap 550 exhibits exceptional reliability due to its single open slot design, however, the single slotted "fan" spray tip 558 may require a larger riser sleeve diameter than other nozzles. The fan nozzle cap 550 may replace the feed nozzle cap 500 for injecting biofeed or hydrocarbon feedstock into a riser reactor from a biofeed nozzle or hydrocarbon feed nozzle. The fan open slot 554 may have a shape including a rectangle, a square, a circle, a triangle, a polygon, an oval, a parallelogram, a cross, a star, a flat profile, or a curved profile. The fan open slot 554 may include from about two to about 30 teeth 556. For example, the open slot 554 may comprise about two teeth, or about four teeth, or about six teeth, or about eight teeth, or about ten teeth, or about 12 teeth, or about 14 teeth, or about 16 teeth, or about 18 teeth, or about 20 teeth, or about 22 teeth, or about 24 teeth, or about 26 teeth, or about 28 teeth, or about 30 teeth, where about includes plus or minus 1 tooth. The open slot 554 protrudes outward from the hollow hemispherical-shaped body.Attorney Docket No. 23-22 PCT

[0086] In examples, a biofeed nozzle may include one or more structural reliefs at an inner surface or walls of the nozzle feed tub and / or mixing zone. The structural reliefs may include one or more annular structures such as rings. In examples, annual structures may include concentric rings as described further below. In examples, the annular rings may include discontinuous step rings as described in more detail below. In examples, the biofeed nozzle may be configured for static mixing as described in more detail below. In examples, the biofeed nozzle may be configured for swirl mixing as also further described below. In examples, a biofeed nozzle may include any one or more of these features.

[0087] Illustrated in FIG. 6A is a side profile of an embodiment of a rotated ring biofeed nozzle 600 for injecting biofeed while preventing preferential flashing of the aqueous phase and degradation of the pyrolysis oil fraction, in accordance with some embodiments of this disclosure. Disclosed rotated ring biofeed nozzles 600 advantageously permit feed for at least one of a biofeed, a hydrocarbon feedstock, and a fluidization dispersion medium (e.g., natural gas) without overheating the biofeed and forming degradation products. Use of mechanical features may promote turbulent flow by mixing to prevent flashing of the aqueous phase. The liquid feed and atomization medium may fully mix in a mixing zone 610 and prevent preferential flashing of the aqueous phase and degradation of the pyrolysis oil fraction. As shown in FIG.6B, concentric rings 604 are installed in the feed tube 612 and mixing zone 610. The rotated ring biofeed nozzle 600 may include a hollow cylindrical body including a mixing zone 610 forming a top end, a fluid receiver port 615 forming a bottom end, a steam side tube 606, a nozzle tip 602 and a plurality of concentric rings 604 located within the inside surface of the body of the ring biofeed nozzle 600.Separating each of the concentric rings 604 may include a mixing zone 610. In some embodiments, the ring biofeed nozzle 600 may include from 2-20 concentric rings 604, or more. In someAttorney Docket No. 23-22 PCTembodiments, the ring biofeed nozzle 600 may include from 1-19 areas to mix within a mixing zone 610. For example, as shown in FIG. 6B, the ring biofeed nozzle 600 may include between one and ten concentric rings 604 located in the nozzle tip 602, between 1 and 10 areas to mix within a mixing zone 610, four concentric rings 604 located in the fluid receiver port 615, and between 1 and 10 areas to mix components within the mixing zone 610 located in the fluid receiver port 615. The receiver port 615 may include more than one inlet for receiving a fluid or a gas into the receiver port 615. As shown in FIGS 6 A and 6B, the receiver port 615 may include two inlets for receiving a fluid or a gas into the receiver port 615. The rotated ring biofeed nozzle 600 may also comprise a baffle 614 and plug 616 for directing flow of fluids.

[0088] In some embodiments, concentric rings 604 of the ring biofeed nozzle 600 may be spaced apart by from about 1 inch to about 10 inches. For example, the concentric rings 604 of the ring biofeed nozzle 600 may be spaced apart by about 1 inch, or about 2 inches, or about 4 inches, or about 6 inches, or about 8 inches or about 10 inches, where about includes plus or minus 1 inch. For example, the concentric rings 604 may have a height of about 0.1 inch, or about 0.2 inches, or about 0.4 inches, or about 0.6 inches, or about 0.8 inches, or about 1.0 inch, or about 1.2 inches, or about 1.4 inches, or about 1.6 inches, or about 1.8 inches, or about 2 inches, where about includes 0.1 inches. In some embodiments, the concentric rings 604 may be spaced apart by a distance that is proportional to from about 1 % to about 50 % of a total length of the biofeed nozzle. For example, the concentric rings 604 may be spaced apart by a distance that is proportional to about 1 %, or about 10 %, about 20 %, or about 30 %, or about 40 %, or about 50 %, or more, of a total length of the biofeed nozzle, where about includes plus or minus 5 %. The concentric rings 604 may have a height ranging from about 0.1 inch to about 10 inches. For example, the concentric rings 604 may have a height of about 0.1 inch, or about 1 inch, or about 2 inches, or about 3 inches,Attorney Docket No. 23-22 PCTor about 4 inches, or about 5 inches, or about 6 inches, or about 7 inches, or about 8 inches, or about 9 inches, or about 10 inches, where about includes 0.5 inches. In some embodiments, the concentric rings 604 may have a height that is proportional to from about 1 % to about 25 % of a tube diameter of the biofeed nozzle. For example, the concentric rings 604 may have a height that is proportional to about 1 %, or about 5 %, or about 10 %, or about 15 %. or about 20 %, or about 25 %. or more, of a tube diameter of the biofeed nozzle, where about includes plus or minus 2.5 %. The concentric rings 604 may have a width ranging from about 0.1 inch to about 10 inches. For example, the concentric rings 604 may have a width of about 0.1 inch, or about 1 inch, or about 2 inches, or about 3 inches, or about 4 inches, or about 5 inches, or about 6 inches, or about 7 inches, or about 8 inches, or about 9 inches, or about 10 inches, where about includes 0.5 inches. In some embodiments, the concentric rings 604 may have a width that is proportional to from about 1 % to about 10 % of a total length of the biofeed nozzle. For example, the concentric rings 604 may have a width that is proportional to about 1 %, or about 2 %, or about 4 %, or about 6 %, or about 8 %, or about 10 %, or more, of a total length of the biofeed nozzle, where about includes plus or minus 1 %. These concentric rings 604 prevent stratification by forcing the heavier fractions of the mixture away from the steam side tube 606 and mixing zone walls 608.

[0089] FIG. 6C illustrates an embodiment of a disclosed nozzle. As shown in FIG. 6C, a disclosed nozzle may include a discontinuous stepped-ring biofeed nozzle 620 for injecting biofeed while preventing preferential flashing of the aqueous phase and degradation of the pyrolysis oil fraction, in accordance with some embodiments of this disclosure. Instead of the concentric rings shown in FIGS. 6A and 6B, the discontinuous stepped ring biofeed nozzle 620 includes a plurality of discontinuous stepped rings 624 located within the mixing zone. In some embodiments, the discontinuous stepped ring biofeed nozzle 620 may include from 2-20Attorney Docket No. 23-22 PCTdiscontinuous stepped rings 624, or more, within the mixing zone. For example, as shown in FIG.6C, the discontinuous stepped ring biofeed nozzle 620 may include four discontinuous stepped rings 624 located in the mixing zone 610. The receiver port 615 may include more than one inlet for receiving a fluid or a gas into the receiver port 615. As shown in FIGS 6C, the receiver port 615 may include two inlets for receiving a fluid or a gas into the receiver port 615. In some embodiments, each discontinuous stepped ring 624 may be made up of a plurality of teeth that protrude from an inside surface of the mixing zone 610. Each of the teeth, as shown in FIG. 6C may be positioned in a parallel row. However, in some embodiments, each of the teeth may be staggered so that they are not positioned in a parallel row, but instead are broken up and not aligned (not shown).

[0090] In some embodiments, discontinuous stepped rings 624 of the discontinuous stepped ring biofeed nozzle 620 may be axially spaced apart by from about 0.1 inch to about 10 inches. For example, the discontinuous stepped rings 624 of the discontinuous stepped ring biofeed nozzle 620 may be spaced apart by about 0.1 inch, or about 1 inch, or about 2 inches, or about 4 inches, or about 6 inches, or about 8 inches or about 10 inches, where about includes plus or minus 1 inch. In some embodiments, the discontinuous stepped rings 624 may be spaced apart by a distance that is proportional to from about 1 % to about 50 % of a total length of the discontinuous stepped ring biofeed nozzle. For example, the discontinuous stepped rings 624 may be spaced apart by a distance that is proportional to about 1 %, or about 10 %, or about 20 %, or about 30 %, or about 40 %, or about 50 %, or more, of a total length of the discontinuous stepped ring biofeed nozzle, where about includes plus or minus 0.5 %. As another example, the discontinuous stepped rings 624 may have a height of about 0.1 inch, or about 0.2 inches, or about 0.4 inches, or about 0.6 inches, or about 0.8 inches, or about 1.0 inch, or about 1.2 inches, or aboutAttorney Docket No. 23-22 PCT1.4 inches, or about 1.6 inches, or about 1.8 inches, or about 2 inches, where about includes 0.1 inches. The discontinuous stepped rings 624 may have a height ranging from about 0.1 inch to about 10 inches. For example, the discontinuous stepped rings 624 may have a height of about 0.1 inch, or about 1 inch, or about 2 inches, or about 3 inches, or about 4 inches, or about 5 inches, or about 6 inches, or about 7 inches, or about 8 inches, or about 9 inches, or about 10 inches, where about includes 0.5 inches. In some embodiments, the discontinuous stepped rings 624 may have a height that is proportional to from about 1 % to about 25 % of a tube diameter of the discontinuous stepped ring biofeed nozzle. For example, the discontinuous stepped rings 624 may have a height that is proportional to about 1 %, or about 5 %, or about 10 %, or about 15 %, or about 20 %, or about 25 %, or more, of a tube diameter of the discontinuous stepped ring biofeed nozzle, where about includes plus or minus 2.5 %. The discontinuous stepped rings 624 may have a width ranging from about 0.1 inch to about 10 inches. For example, the discontinuous stepped rings 624 may have a width of about 0.1 inch, or about 1 inch, or about 2 inches, or about 3 inches, or about 4 inches, or about 5 inches, or about 6 inches, or about 7 inches, or about 8 inches, or about 9 inches, or about 10 inches, where about includes 0.5 inches. In some embodiments, the discontinuous stepped rings 624 may have a width that is proportional to from about 1 % to about 10 % of a total length of the discontinuous stepped ring biofeed nozzle. For example, the discontinuous stepped rings 624 may have a width that is proportional to about 1 %, or about 2 %, or about 4 %, or about 6 %, or about 8 %. or about 10 %, or more, of a total length of the discontinuous stepped ring biofeed nozzle, where about includes plus or minus 1 %. These discontinuous stepped rings 624 prevent stratification by forcing the heavier fractions of the mixture away from the feed tube 612 and mixing zone walls. In some embodiments, the liquid feed and atomization medium may fully or at least substantially mix in the discontinuous stepped-Attorney Docket No. 23-22 PCTring mixing zone 622 and prevent preferential flashing of the aqueous phase and degradation of the pyrolysis oil fraction. Discontinuous stepped rings 624 may be installed in the discontinuous stepped-ring feed side tube 626 and discontinuous stepped-ring mixing zone 622. In some embodiments, these discontinuous stepped rings 624 are offset relative to adjacent discontinuous stepped-rings, and each discontinuous ring in the mixing zone can have a unique number of stepped members. These members within the same ring can be tangentially spaced apart equally or not and can be staggered or aligned with adjacent discontinuous rings.

[0091] FIG. 6D illustrates a disclosed nozzle including a static mixing biofeed nozzle 640 for injecting biofeed while preventing preferential flashing of the aqueous phase and degradation of the pyrolysis oil fraction, in accordance with some embodiments of this disclosure. Static mixing allows the two biofeed phases, aqueous and organic, that would otherwise be stratified, to form a single continuous phase before contacting the baffle plug 642 and entering the mixing chamber 644 in a fully turbulent state. This mixing prevents stratification which may result in flashing of the aqueous phase and degradation of the organic phase. In the static mixing biofeed nozzle 640, a static mixer 646 is located in the static mixing feed tube 648 (of the fluid receiver port 615) to mix the two phases. In some embodiments, static mixers can be individual or can comprise multiple helical ribbons. Static mixers include packing or other internal structures that can induce mixing. The placement of one or more static mixers in the feed tube can occupy between one unit cell (or single turn) of the mixer. The placement of one or more static mixers in the feed tube can occupy the full feed tube. In some embodiments, the one or more static mixers are made of corrosion resistant materials such as stainless steel or ceramics.

[0092] FIG. 6E illustrates an embodiment of a swirling biofeed nozzle 660 for preventing preferential flashing of the biofeed aqueous phase and degradation of the biofeed oil phase, inAttorney Docket No. 23-22 PCTaccordance with some embodiments of this disclosure. Use of static mixing inside the swirling feed tube 662 creates a layer of organic high-boiling oil compounds (lipidic or fossil) at the swirling feed tube wall 664 to minimize or prevent the contact of the aqueous phase with the swirling feed tube wall 664. Another benefit of static mixing in a feed tube can be attributed to the shear- thinning nature of feedstocks. Imparting rotational or helical components to the flow field creates a high-shear environment that promotes mixing inside a feed tube as well as decreases pressure drop in a feed tube. As shown in FIG. 6E, atomization medium may be injected in such a way as to induce a swirling effect. In examples, the injection of the atomization medium may be by offset injections. The baffle 666 may have a baffle plug 668 equipped with vanes that promote swirling in the opposite direction to induce mixing. Baffle arms 670 are designed with a gradient 672 that promotes flow once again in the opposite direction of the baffle 666, to force agitation and turbulent flow. In some embodiments, at the exit of the swirling feed tube 662, the flow of liquid feed meets atomization steam at the feed steam amount ranging between 0.1 % and 30 %. For example, the flow of liquid feed may meet the atomization steam at the feed steam amount of about 0.1 %, or about 5 %, or about 10 %, or about 15 %, or about 20 %, or about 25 %, or about 30 %, where about includes plus or minus 2.5 %. In some embodiments, other atomizing mediums, such as naphtha or fuel gas, can be used at the same or different ratios. Use of other atomizing mediums may help atomize the liquid by separating a continuous body of liquid into droplets in the mixing chamber. After having passed through the mixing chamber 674, the flow of the atomizing medium and liquid feed droplets exits the biofeed nozzle 660 into a riser through a biofeed nozzle slotted tip 676.

[0093] Illustrated in FIGS. 7A - 7C are embodiments of alternative methods for injecting a dispersion medium (e.g.. natural gas, fuel gas, steam) into a biofeed nozzle feed tube forAttorney Docket No. 23-22 PCTpreventing preferential flashing of the biofeed aqueous phase and degradation of the biofeed oil fraction, in accordance with some embodiments of this disclosure. In FIG. 7A, multi-stage injections 702 are perpendicular inside the feed tube to induce turbulent flow and prevent stratification of feed liquid phases. In FIG. 7B, multi-stage injections 702 are counter-current inside the feed tube to induce turbulent flow and prevent stratification of feed liquid phases. In FIG. 7C. multi-stage injections 702 are co-current inside the feed tube to induce turbulent flow and prevent stratification of feed liquid phases. The number of injection points of each of these mediums is at least one. The injection points can form a discontinuous ring, and each ring can have a unique number of injection points. Spacing between adjacent discontinuous rings can be between 0.1 and 10 inches. For example, the spacing between adjacent discontinuous rings can be about 0.1 inch, or about 1 inch, or about 2 inches, or about 3 inches, or about 4 inches, or about 5 inches, or about 6 inches, or about 7 inches, or about 8 inches, or about 9 inches, or about 10 inches, where about includes 0.5 inches. These injection ports within the same ring can be tangentially spaced apart equally or not and can be staggered or aligned with adjacent discontinuous rings.

[0094] The figures and descriptions provided herein may have been simplified to illustrate aspects that are relevant for a clear understanding of the herein described devices, systems, and methods, while eliminating, for the purpose of clarity, other aspects that may be found in typical similar devices, systems, and methods. Those of ordinary skill may recognize that other elements and / or operations may be desirable and / or necessary to implement the devices, systems, and methods described herein. But because such elements and operations are well known in the art, and because they do not facilitate a better understanding of the present disclosure, a discussion of such elements and operations may not be provided herein. However, the present disclosure may be deemed to inherently include all such elements, variations, and modifications to the describedAttorney Docket No. 23-22 PCTaspects that would be known to those of ordinary skill in the art. Any other variation of fabrication, use, or application should be considered apparent as an alternative embodiment of the present disclosure.

[0095] The terminology used herein may be for the purpose of describing particular example embodiments only and may not be intended to be limiting. For example, as used herein, the singular forms "a", "an" and "the" may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms "comprises," "comprising," "including," and "having," are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It may be also to be understood that additional or alternative steps may be employed.

[0096] As used herein, the term “if’ may be construed to mean “when” or “upon” or “in response to determining” or “in response to detecting,” depending on the context. As used herein, the terms "catalytic cracking unit" may be used interchangeably with "residue fluid catalytic cracking unit", "RFCC", "fluid catalytic cracking unit", and "FCC".

[0097] Although the terms first, second, third, etc., may be used herein to describe various elements, components, regions, layers and / or sections, these elements, components, regions, layers and / or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another element, component, region, layer or section. That is, terms such as "first," "second," and other numerical terms, when used herein,Attorney Docket No. 23-22 PCTdo not imply a sequence or order unless clearly indicated by the context. These terms are used to distinguish one element from another. For example, a first object or step may be termed a second object or step, and, similarly, a second object or step may be termed a first object or step, without departing from the scope of the disclosure. The first object or step, and the second object or step, are both objects or steps, respectively, but they are not to be considered the same object or step.

[0098] Those with skill in the art will appreciate that while some terms in this disclosure may refer to absolutes, e.g., all biofeed, each of a plurality of objects, etc., the methods and techniques disclosed herein may also be performed on fewer than all of a given thing, e.g., performed on one or more components and / or performed on one or more biofeed. Accordingly, in instances in the disclosure where an absolute may be used, the disclosure may also be interpreted to be referring to a subset.

[0099] The above descriptions of the implementations of the present disclosure have been presented for the purposes of illustration and description. It may be not intended to be exhaustive or to limit the present disclosure to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to explain the principles of the disclosed subject-matter and its practical applications, to thereby enable others skilled in the art to use the technology disclosed and various embodiments with various modifications as are suited to the particular use contemplated. It may be intended that the scope of the present disclosure be limited not by this detailed description, but rather by the claims of this application. As will be understood by those familiar with the art, the present disclosure may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. It may be appreciated that the term optimize / optimal and its variants (e.g., efficient or optimally) may simply indicate improving, rather than the ultimate form of 'perfection'Attorney Docket No. 23-22 PCTor the like. Accordingly, the present disclosure may be intended to be illustrative, but not limiting, of the scope of the present disclosure, which may be set forth in the following claims.

Claims

Attorney Docket No. 23-22 PCTWHAT MAY BE CLAIMED IS:

1. A catalytic cracking unit for cracking a feedstock, the catalytic cracking unit comprising: a riser reactor configured to combine a hydrocarbon feedstock with a biofeed and a catalyst to form a cracked product and a spent catalyst, the riser reactor comprising:(a) a reactor body comprising a reactor configured to receive the hydrocarbon feedstock, the biofeed, and the catalyst during the cracking process;(b) a hydrocarbon feed nozzle connected to the reactor body, the hydrocarbon feed nozzle configured to feed the hydrocarbon feedstock to the reactor body; and(c) a biofeed nozzle connected to the reactor body, the biofeed nozzle configured to feed the biofeed to the reactor body, the biofeed nozzle comprising a hollow cylindrical body comprising a mixing zone forming a top end, at least one fluid receiver port forming a bottom end, an outside surface, and an inside surface, wherein at least one of the mixing zone or the at least one fluid receiver port is configured to induce turbulent flow.

2. The catalytic cracking unit according to claim 1, further comprising:a catalyst regenerator connected to the riser reactor, the catalyst regenerator comprising a heater and a regenerator cyclone, and configured to:(i) receive the spent catalyst from the riser reactor;(ii) burn coke off of the spent catalyst with heat provided by the heater and combustion gases to form a hot catalyst mixture; and(iii) separate, in the catalyst regenerator, the hot catalyst mixture into the regenerated catalyst and the combustion gases; and(iv) convey the regenerated catalyst to the riser reactor.

3. The catalytic cracking unit according to claim 1, further comprising:a distillation column connected to the riser reactor, the distillation column comprising a heat source and a distillation plate, the distillation column configured to:i.receive the cracked product; andii. separate the cracked product into at least one of a product gas, a naphtha, a light cycle oil, and a heavy cycle oil.Attorney Docket No. 23-22 PCT4. The catalytic cracking unit according to claim 1 , wherein the biofeed nozzle further comprises one or more reliefs in the mixing zone to induce the turbulent flow.

5. The catalytic cracking unit according to claim 4, wherein the one or more reliefs comprise at least one concentric ring.

6. The catalytic cracking unit according to claim 5, wherein the at least one concentric ring comprises eight concentric rings.

7. The catalytic cracking unit according to claim 5, wherein the at least one concentric ring comprises at least two concentric rings,wherein each of the concentric rings is spaced apart by a distance that is proportional to from about 1 % to about 50 % of a total length of the biofeed nozzle.

8. The catalytic cracking unit according to claim 5, wherein each concentric ring has a width that is proportional to from about 1 % to about 10 % of a total length ofthe biofeed nozzle.

9. The catalytic cracking unit according to claim 5, wherein each concentric ring has a height that is proportional to from about 1 % to about 25 % of a tube diameter ofthe biofeed nozzle.

10. The catalytic cracking unit according to claim 4, wherein the one or more reliefs comprise at least one discontinuous stepped ring.

11. The catalytic cracking unit according to claim 10, further comprising at least two discontinuous stepped rings,wherein each of the discontinuous stepped rings is spaced apart by a distance that is proportional to from about 1 % to about 50 % of a total length of the discontinuous steppedring biofeed nozzle.Attorney Docket No. 23-22 PCT12. The catalytic cracking unit according to claim 10, wherein each of the discontinuous stepped rings has a width that is proportional to from about 1 % to about 10 % of a total length of the discontinuous stepped-ring biofeed nozzle.

13. The catalytic cracking unit according to claim 10, wherein each of the discontinuous stepped rings has a height that is proportional to from about 1 % to about 25 % of a tube diameter of the discontinuous stepped-ring biofeed nozzle.

14. The catalytic cracking unit according to claim 1, wherein the biofeed nozzle comprises a metal comprised of carbon steel, a 9 Cr- 1 Mo steel, a chromium, a nickel, a molybdenum, a titanium, alloys thereof, and combinations thereof.

15. The catalytic cracking unit according to claim 1, further comprising a natural gas dispersion medium tank configured to provide the catalytic cracking unit with natural gas for dispersing at least one of the hydrocarbon feedstock and the biofeed.

16. The catalytic cracking unit according to claim 1, wherein the biofeed nozzle further comprises a static mixer in the at least one fluid receiver port to induce the turbulent flow.

17. The catalytic cracking unit of claim 16, wherein the static mixer comprises one or more helical ribbons.

18. The catalytic cracking unit according to claim 1, wherein the at least one fluid receiver port comprises multi-stage injection points to introduce a dispersion medium.

19. The catalytic cracking unit according to claim 18, wherein the multi-stage injection points are arranged offset from each other or perpendicular to each other.

20. The catalytic cracking unit according to claim 19, wherein the multi-stage injection points are arranged offset from each to induce a swirling effect.Attorney Docket No. 23-22 PCT21. The catalytic cracking unit according to claim 18, wherein the multi-stage injection points are arranged to inject the dispersion medium counter-current to a flow of the biofeed or co-current with the flow of the biofeed.

22. The catalytic cracking unit according to claim 18, wherein the biofeed nozzle further comprises a baffle plug comprising a plurality of vanes.

23. The catalytic cracking unit according to claim 18, the biorf eed nozzle further comprising a nozzle slotted tip.

24. The catalytic cracking unit according to claim 18, further comprising a natural gas dispersion medium tank configured to provide the catalytic cracking unit with natural gas for dispersing at least one of the hydrocarbon feedstock and the biofeed.

25. A biofeed nozzle connected to a reactor body and configured to feed the biofeed to the reactor body, the biofeed nozzle comprising:a hollow cylindrical body comprising a mixing zone forming a top end;at least one fluid receiver port forming a bottom end;an outside surface; andan inside surface,wherein at least one of the mixing zone or the at least one fluid receiver port is configured to induce turbulent flow.

26. The biofeed nozzle according to claim 25, further comprising one or more reliefs in the mixing zone to induce the turbulent flow.

27. The biofeed nozzle according to claim 26, wherein the one or more reliefs comprise at least one concentric ring.

28. The biofeed nozzle according to claim 26. wherein the at least one concentric ring comprises eight concentric rings.Attorney Docket No. 23-22 PCT29. The biofeed nozzle according to claim 26, wherein the one or more reliefs comprise at least one discontinuous stepped ring.

30. The biofeed nozzle according to claim 26, further comprising at least two reliefs, wherein each relief is spaced apart by a distance that is proportional to from about 1 % to about 50 % of a total length of the biofeed nozzle.

31. The biofeed nozzle according to claim 26, wherein each of the reliefs has a width that is proportional to from about 1 % to about 10 % of a total length of the biofeed nozzle.

32. The biofeed nozzle according to claim 26, wherein each of the reliefs has a height that is proportional to from about 1 % to about 25 % of a tube diameter of the biofeed nozzle.

33. The biofeed nozzle according to claim 25, wherein the biofeed nozzle comprises a metal comprised of carbon steel, a 9 Cr- 1 Mo steel, a chromium, a nickel, a molybdenum, a titanium, alloys thereof, and combinations thereof.

34. The biofeed nozzle according to claim 25, further comprising a static mixer in the at least one fluid receiver port to induce the turbulent flow.

35. The biofeed nozzle according to claim 34, wherein the static mixer comprises one or more helical ribbons.

36. The biofeed nozzle according to claim 25. wherein the at least one fluid receiver port comprises multi-stage injection points to introduce a dispersion medium.

37. The biofeed nozzle according to claim 36, wherein the multi-stage injection points are arranged offset from each other or perpendicular to each other.Attorney Docket No. 23-22 PCT38. The biofeed nozzle according to claim 37, wherein the multi-stage injection points are arranged offset from each to induce a swirling effect.

39. The biofeed nozzle according to claim 36, wherein the multi-stage injection points are arranged to inject the dispersion medium counter-current to a flow of the biofeed or co-current with the flow of the biofeed.

40. The biofeed nozzle according to claim 36, wherein the biofeed nozzle further comprises a baffle plug comprising a plurality of vanes.

41. The biofeed nozzle according to claim 36. the biorfeed nozzle further comprising a nozzle slotted tip.

42. A method of feeding biofeed to a catalytic cracking unit comprising a riser reactor configured to combine a hydrocarbon feedstock with a biofeed and a catalyst to form a cracked product and a spent catalyst, the method comprising:injecting a biofeed and a dispersion medium into the riser reactor using a feed nozzle in accordance with any of the preceding claims, wherein the dispersion medium is a natural gas.

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