High efficiency process for separating fillers from catalyst and gases in a fluid bed catalytic pyrolysis process

A method for producing olefins and aromatics comprising:

• passing a feed stream comprising plastics, at least one of which contains filler material, to a fluidized bed reactor comprising a catalyst;
• wherein the filler material has a particle size that is smaller than a particle size of the fluid bed catalyst;
• catalytically reacting the feed stream with the catalyst in the fluidized bed reactor to form a product mixture comprising a first mass ratio of catalyst to filler material;
• recovering a vapor effluent from the product mixture, wherein the vapor effluent comprises catalyst particles and filler material;
• passing the vapor effluent through a solids separation system comprising passing the vapor effluent into a first cyclone and separating a first bottoms fraction and a first overflow fraction;
• wherein the first cyclone is a classifier cyclone;
• wherein the first bottoms fraction has a second mass ratio that is greater than the first mass ratio;
• passing the overflow fraction from the first cyclone into a second cyclone and separating a second bottoms fraction and a second overflow fraction;
• wherein the first cyclone has a first separation efficiency for the catalyst particles and the second cyclone has a second separation efficiency for the particles that is greater than the first separation efficiency;
• wherein the second bottoms fraction has a third mass ratio that is less than the first mass ratio;
• discarding the second bottoms fraction and
• recovering olefins, aromatics, or some combination thereof from the second overflow fraction exiting the second cyclone.