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US 2023/0416615 A1Published application
Methods and systems for enhancing processing of hydrocarbons in a fluid catalytic cracking unit using a renewable additive
AssigneeMarathon Petroleum Company LP
InventorsNikolas A. Larsen, Jeffrey A. Sexton, Ray Brooks
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Abstract
Systems and methods for enhancing the processing of hydrocarbons in a FCC unit by introduction of the coked FCC catalyst from the FCC reactor and a renewable feedstock to the FCC regenerator to facilitate regeneration of the coked FCC catalyst. The renewable feedstock can contain biomass-derived pyrolysis oil. The biomass-derived pyrolysis oil and coke from the coked FCC catalyst are oxidized by oxygen to provide a regenerated catalyst that is recycled to the FCC reactor.
Claims30
A system to process a gas oil in a fluid catalytic cracking (FCC) unit, the system comprising:
- a reactor having (i) a reactor inlet, (ii) an FCC reaction zone operable to crack a gas oil stream received via the reactor inlet in presence of steam and an FCC catalyst, thereby to form a plurality of FCC products and coked FCC catalyst when in operation, (iii) a separation zone to separate the plurality of FCC products from the coked FCC catalyst, and (iii) one or more outlet to remove the plurality of FCC products from the reactor;
- a regenerator in fluid communication with the reactor, the regenerator having a first regenerator inlet to receive at least oxygen, a second regenerator inlet in fluid communication with a biomass-derived pyrolysis oil, a first regenerator outlet in fluid communication with the reactor to supply a regenerated FCC catalyst to the reactor, and a second regenerator outlet positioned to discharge a flue gas from the regenerator, the regenerator being operable to oxidize coke and the biomass-derived pyrolysis oil, thereby to produce the regenerated FCC catalyst and the flue gas;
- and
- a controller configured to adjust an amount of the biomass-derived pyrolysis oil supplied to the regenerator based on an indication of a temperature within the system, thereby to maintain sufficient temperatures within the system to crack the gas oil stream in the FCC reaction zone and to oxidize the coke in the regenerator.
1 more element
A method of processing a gas oil in a fluid catalytic cracking (FCC) system, the method comprising:
- mixing the gas oil and steam with an FCC catalyst;
- cracking the gas oil into one or more FCC hydrocarbon products in a reactor of the FCC system, thereby to cause one or more surfaces of the FCC catalyst to be at least partially covered by coke so as to define a coked FCC catalyst;
- separating the coked FCC catalyst from the one or more FCC hydrocarbon products within the reactor;
- supplying the coked FCC catalyst to a regenerator of the FCC system;
- supplying a biomass-derived pyrolysis oil into the regenerator;
- combusting a combination of the biomass-derived pyrolysis oil and the coke of the coked FCC catalyst in the regenerator, thereby to produce a regenerated FCC catalyst and a flue gas;
- supplying the regenerated FCC catalyst to the reactor;
- and
- controlling an amount of the biomass-derived pyrolysis oil supplied to the regenerator based on a temperature within the FCC system, thereby to maintain sufficient temperatures within the FCC system to crack the gas oil in the reactor and to combust the coke in the regenerator.
6 more elements
A method of processing a gas oil in a fluid catalytic cracking (FCC) system, the method comprising:
- cracking the gas oil into one or more hydrocarbon products in the presence of a catalyst in a reactor of the FCC system, thereby to cause one or more surfaces of the catalyst to be at least partially covered by coke so as to define a coked catalyst;
- separating the coked catalyst from the one or more hydrocarbon products;
- introducing a biomass-derived pyrolysis oil into one or more of:
- (a) a stripping zone of the reactor, or (b) one or more fluid pathways in fluid communication between the reactor and a regenerator, thereby to supply the biomass-derived pyrolysis oil to the regenerator;
- combusting the biomass-derived pyrolysis oil and the coke of the coked catalyst when in the regenerator, thereby to produce a regenerated catalyst and a flue gas;
- returning the regenerated catalyst to the reactor;
- and
- controlling an amount of the biomass-derived pyrolysis oil supplied to the regenerator based on one or more temperatures within the FCC system, thereby to maintain sufficient the one or more temperatures within the FCC system to crack the gas oil in the reactor and to combust the coke in the regenerator.
5 more elements
A method of processing a gas oil, the method comprising:
- cracking the gas oil into one or more hydrocarbon products in the presence of a catalyst in a reactor, thereby to cause one or more surfaces of the catalyst to be at least partially covered by coke so as to define a coked catalyst;
- separating the coked catalyst from the one or more hydrocarbon products;
- supplying a biomass-derived pyrolysis oil and the coked catalyst to a regenerator;
- combusting the biomass-derived pyrolysis oil and coke of the coked catalyst in the regenerator, thereby to produce a regenerated catalyst and a flue gas;
- and
- controlling an amount of the biomass-derived pyrolysis oil supplied to the regenerator based on one or more temperatures within one or more of:
- (a) the regenerator or (b) the reactor, thereby to maintain sufficient temperatures within the reactor to crack the gas oil and within the regenerator to combust the coke.
4 more elements
Dependencies are inferred from the claim text.