Apparatus and process for injecting catalysts into a counter-current downer for fluidized catalytic cracking

A method for processing hydrocarbons, the method comprising:

• introducing a hydrocarbon feed stream into a reactor vessel through a hydrocarbon feed inlet proximate a bottom end of the reactor vessel;
• introducing a catalyst into the reactor vessel through a catalyst injection system proximate a top end of the reactor vessel, wherein the catalyst injection system comprises a plurality of injector nozzles, and wherein one or more injector nozzles of the plurality of injector nozzles comprises:
• a nozzle axis AN;
• a nozzle tip defining a nozzle end plane PE that is normal to the nozzle axis AN;
• a first inner diameter ID1 at a first distance D1 from the nozzle end plane PE along the nozzle axis AN;
• a second inner diameter ID2 at a second distance D2 from the nozzle end plane PE along the nozzle axis AN, wherein the second distance D2 is greater than the first distance D1, and wherein the second inner diameter ID2 is greater than the first inner diameter ID1;
• and
• a downwards elevation angle Φ of at most 60 degrees between the nozzle axis AN and a longitudinal axis AL of the reactor vessel;
• and
• contacting the hydrocarbon feed stream with the catalyst in a reaction zone of the reactor vessel to produce a cracked hydrocarbon stream and a spent catalyst, wherein the hydrocarbon feed stream has a net upward superficial velocity through the reaction zone and the catalyst has a net downward superficial velocity through the reaction zone.