Staged fluid catalytic cracking processes incorporating a solids separation device for upgrading naphtha range material

A system for performing chemical reactions, comprising:

• a separator configured to separate a reactor effluent comprising a reaction product, a first particulate catalyst, and a second particulate catalyst, wherein the first particulate catalyst has a smaller average particle size and/or is less dense than the second particulate catalyst, to recover a first stream, comprising the reaction product and the first particulate catalyst, and a second stream, comprising the second particulate catalyst;
• a mixing device configured to intimately contact the second stream comprising the second particulate catalyst with a catalyst stream, the catalyst stream comprising first particulate catalyst and second particulate catalyst at an elevated temperature, wherein the intimately contacting produces a mixed catalyst at a uniform temperature intermediate the elevated temperature and the reactor outlet temperature, wherein the mixing devise comprises a standpipe comprising:
• a first inlet to receive the second stream from the separator;
• a second inlet to receive the catalyst stream from a catalyst regenerator;
• and
• an outlet to supply the mixed catalyst to the moving bed reactor;
• a moving bed reactor configured to:
• contact the mixed catalyst with a first reactant at the intermediate temperature, reducing a temperature of the mixed catalyst to a second intermediate temperature;
• contact the mixed catalyst at the second intermediate temperature with a second reactant;
• a flow stream configured to recover the reactor effluent from the moving bed reactor.

A system for performing chemical reactions, comprising:

• a separator configured to separate a reactor effluent comprising a reaction product, a first particulate catalyst, and a second particulate catalyst, wherein the first particulate catalyst has a smaller average particle size and/or is less dense than the second particulate catalyst, to recover a first stream, comprising the reaction product and the first particulate catalyst, and a second stream, comprising the second particulate catalyst;
• a mixing device configured to intimately contact the second stream comprising the second particulate catalyst with a catalyst stream, the catalyst stream comprising first particulate catalyst and second particulate catalyst at an elevated temperature, wherein the intimately contacting produces a mixed catalyst at a uniform temperature intermediate the elevated temperature and the reactor outlet temperature, wherein the mixing device comprises:
• a first catalyst distributor disposed in a lower portion of the moving bed reactor, the catalyst distributor configured to receive the second stream from the separator and to disperse the second catalyst contained in the second stream into the moving bed reactor;
• a second catalyst distributor disposed proximate the first catalyst distributor configured to receive the catalyst stream from the catalyst regenerator and to disperse the first and second catalysts contained in the catalyst stream into the moving bed reactor and into contact with the second catalyst from the first catalyst distributor;
• a moving bed reactor configured to:
• contact the mixed catalyst with a first reactant at the intermediate temperature, reducing a temperature of the mixed catalyst to a second intermediate temperature;
• contact the mixed catalyst at the second intermediate temperature with a second reactant;
• a flow stream configured to recover the reactor effluent from the moving bed reactor.

A process for the conversion of hydrocarbons, comprising:

• feeding a catalyst stream comprising a first particulate catalyst and a second particulate catalyst to a reactor, wherein the first particulate catalyst has a smaller average particle size and/or is less dense than the second particulate catalyst and admixing the catalyst stream with a second catalyst stream, comprising second particulate catalyst, to provide a mixed catalyst having a uniform temperature in the range from about 900° F. to about 1250° F.;
• feeding a light naphtha feedstock and a heavy naphtha feedstock to the reactor, wherein the light naphtha feedstock is introduced to the reactor at a lower elevation than the heavy naphtha feedstock;
• contacting the light and heavy naphtha feedstocks with the mixed catalysts to react hydrocarbons contained therein;
• recovering an overhead product from the reactor comprising a converted hydrocarbon effluent, the second particulate catalyst, and the first particulate catalyst;
• separating the second particulate catalyst from the overhead product to provide a first stream comprising the first particulate catalyst and the converted hydrocarbon effluent and the second catalyst stream, comprising the separated second particulate catalyst;
• returning the separated second particulate catalyst in the second stream to the reactor.

A system for cracking hydrocarbons, comprising:

• a mixing zone comprising:
• a first inlet configured to receive a catalyst mixture comprising a first particulate catalyst and a second particulate catalyst at a first elevated temperature;
• a second inlet configured to receive a catalyst stream comprising second particulate catalyst at a second lower temperature;
• and
• an outlet configured to supply an admixture of the catalysts in the catalyst mixture and the catalyst stream to provide a mixed catalyst having a uniform intermediate temperature;
• a reaction zone configured to:
• contact the catalyst mixture having a uniform intermediate temperature with a light naphtha feed to produce a hydrocarbon-catalyst mixture at a second intermediate temperature;
• contact the hydrocarbon-catalyst mixture at a second intermediate temperature with a light naphtha feed to produce a reactor effluent comprising first particulate catalyst, second particulate catalyst, and hydrocarbons;
• a particle separator for separating second particulate catalyst from the reactor effluent to recover a hydrocarbon effluent stream comprising hydrocarbons and the first particles and the catalyst stream comprising second particulate catalyst,
• a feed line for returning separated second particles from the particle separator to the mixing zone.