Patent ID: 6585884
Filing Date: 2003-07-01
Classification: B01J,C10G,C10J,Y02P

Abstract:
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 1150Â° F. to about 1400Â° 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 proportion 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; 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 1500Â° F. to about 1800Â° F. and maintained in a partial oxidation mode, said second regeneration zone temperature and partial oxidation mode of operation resulting in 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 introducing said spent cracking catalyst from said second regeneration zone into a third regeneration zone in a presence of a third oxygen and carbon dioxide atmosphere, wherein said third regeneration zone is operated at a temperature of greater than about 1400Â° F. and maintained in an oxidation mode to produce a flue gas by-product rich in carbon dioxide.