US 6,491,810 B1Granted

Method of producing synthesis gas from a regeneration of spent cracking catalyst

OwnerWarden W. Mayes, Jr.inventor

Life of this patent

Estimating the term…

Loading patent…

Abstract

The present invention provides a method of producing a synthesis gas from a regeneration of spent cracking catalyst. The method includes introducing a spent cracking catalyst into a first regeneration zone in a presence of a first oxygen and carbon dioxide atmosphere and at a first regeneration temperature. For example, a temperature that does not exceed about 1400° F., and more preferable a temperature that ranges from about 1150° F. to about 1400° F., may be used as the first regeneration temperature. The method further includes introducing the spent cracking catalyst from the first regeneration zone into a second regeneration zone in a presence of a second oxygen and carbon dioxide atmosphere, and producing a synthesis gas from cracking deposits located on the spent cracking catalyst within the second regeneration zone at a second regeneration temperature substantially greater than said first regeneration temperature. In a preferred embodiment, the second regeneration temperature ranges from about 1500° F. to about 1800°, and in a related embodiment is about 1800° F.

Claims22

Dependent claims

A method of producing a synthesis gas product from a regeneration of spent cracking catalyst, comprising:

introducing a spent cracking catalyst into a first regeneration zone in a presence of a first oxygen and carbon dioxide atmosphere, wherein said first regeneration zone is operated at a temperature ranging from about 1150° F. to about 1400° F. so as to reduce cracking catalyst damage resulting from high temperature regeneration with a high moisture content atmosphere, and so as to oxidize a greater amount of a hydrogen content than carbon content of coke associated with said spent cracking catalyst, thereby substantially reducing a water content of a subsequent regeneration zone, and wherein said carbon dioxide of said first oxygen and carbon dioxide atmosphere is a diluent for said oxygen of said first oxygen and carbon dioxide atmosphere;
and
introducing said spent cracking catalyst from said first regeneration zone into a second regeneration zone in a presence of a second oxygen and carbon dioxide atmosphere, wherein said second regeneration zone is operated at a temperature ranging from about 1500° F. to about 1800° F. and maintained in a partial oxidation mode, said second regeneration zone temperature and partial oxidation mode of operation causing a substantial portion of said carbon dioxide of said second oxygen and carbon dioxide atmosphere to function as a reactant with carbon remaining associated with said spent cracking catalyst to form two moles of carbon monoxide per mole of carbon dioxide reacted, and thus result in a synthesis gas product rich in carbon monoxide.

A catalytic cracking process, comprising:

introducing a feed stock and a catalyst into a catalytic cracker reaction zone;
cracking said feed stock into a cracked product and a spent cracking catalyst;
regenerating said spent cracking catalyst obtained from said catalytic cracker reaction zone, including;
introducing said spent cracking catalyst from said catalytic cracker reaction zone into a first regeneration zone in a presence of a first oxygen and carbon dioxide atmosphere, wherein said first regeneration zone is operated at a temperature ranging from about 1110° F. to about 1400° F. so as to reduce cracking catalyst damage resulting from high temperature regeneration with a high moisture content atmosphere, and so as to oxidize a greater amount of a hydrogen content than carbon content of coke associated with said spent cracking catalyst, thereby substantially reducing a water content of a subsequent regeneration zone, and wherein said carbon dioxide of said first oxygen and carbon dioxide atmosphere is a diluent for said oxygen of said first oxygen and carbon dioxide atmosphere;
and
introducing said spent cracking catalyst from said first regeneration zone into a second regeneration zone in a presence of a second oxygen and carbon dioxide atmosphere, wherein said second regeneration zone is operated at a temperature ranging from about 1100° F. to about 1800° F. and maintained in a partial oxidation mode, said second regeneration zone temperature and partial oxidation mode of operation causing a substantial portion of said carbon dioxide of said second oxygen and carbon dioxide atmosphere to function as a reactant with carbon remaining associated with said spent cracking catalyst to form two moles of carbon monoxide per mole of carbon dioxide reacted, and thus result in a synthesis gas product rich in carbon monoxide;
and
recycling a regenerated catalyst from said second regeneration zone to said catalytic cracker reaction zone.

5 more elements

Dependencies are inferred from the claim text.