Patent Description:
Generally, a fluid catalytic reactor system may include a reactor unit and a regeneration unit. The reactor unit converts the feedstock chemical into the product chemical by contact with the catalyst. During the reaction, the catalyst may become "spent," and have reduced activity in reactions thereafter. Therefore, the spent catalyst may be transferred to the regeneration unit to be regenerated, thus increasing its activity from its spent state and making it available for further catalytic processes. Following regeneration in the regeneration unit, the regenerated catalyst is transferred back into the reactor unit for continued reactions with feedstock chemicals.

However, mechanical problems in fluid catalytic reactor systems may be present due to the large loads of catalyst placed in the system and the relatively high temperatures at which the reactions take place. For example, conventional fluid catalytic reactor systems may utilize a design where the reactor and separator of the main reactor section and regeneration section, respectively, are in direct contact with one another, and the reactor and separator may be contained in a unitary structure. For example, in conventional examples, the top walls of the reactor may be the bottom walls of the separator. However, intense thermal conditions in the reactor may demand complex designs at the intersection of the reactor and separator. Accordingly, improved system components for fluid catalytic cracking units may be beneficial. <CIT> describes apparatuses and methods for separating regenerated catalyst. In one embodiment, an apparatus for separating regenerated catalyst includes a regeneration vessel including a catalyst bed section. The apparatus includes a catalyst settler physically separated from the catalyst bed section by a wall extending within the regeneration vessel. The catalyst overflowing the catalyst bed section flows over the wall and enters the catalyst settler. The apparatus further includes a pipe in fluid communication with the catalyst settler and configured to deliver regenerated catalyst from the regeneration vessel to another vessel. <CIT> discloses a fluid catalytic cracking process for simultaneously cracking a gas oil feed and upgrading a gasoline-range feed to produce motor fuel. <CIT> discloses a gas-solids reaction system for improving product recovery in a multiple reactor reaction system. <CIT> discloses a fluidized bed reactor and its use for producing olefins from oxygenates. <CIT> discloses an arrangement for the controlled production of an essentially linear array of hydrocarbon feed injection jets. <CIT> discloses a method and system for cracking hydrocarbons and regeneration of catalyst. <CIT> discloses a hydrocarbon conversion-catalyst regeneration operation. <CIT> discloses a design and operation of a short contact time Fluid Catalytic Cracking Reactor wherein an upper internal riser and a lower internal riser are in fluid connection with one another and provide a disengaging zone for entraining vapors from a dilute phase area of the Fluid Catalytic Cracking Reactor. <CIT> discloses a process for fluid catalytic cracking. <CIT> discloses an apparatus suitable for solids-fluid (e.g. cracking catalyst/ hydrocarbon vapour) separation. <CIT> discloses a process and apparatus for mixing streams of regenerated and carbonized catalyst involving passing a catalyst stream into and out of a chamber in a lower section of a riser. <CIT> discloses a fluid catalytic cracking apparatus and process comprising a reactor riser zone, a primary and a secondary cyclones, connected in series to the riser zone, and a stripping zone. <CIT> discloses an apparatus for separating fluidized solids (e.g. catalytic particles) suspended in a gaseous phase comprising a riser which is generally vertically positioned within a catalyst disengaging zone and which has a plurality of openings around a circumference of the riser at its discharge end. <CIT> discloses an apparatus for the fluidized catalytic cracking of a hydrocarbon feed comprising: a riser which is generally vertically positioned within a catalyst disengaging zone and which has a plurality of openings around a circumference of the riser at its discharge end.

The present disclosure relates to designs for system components of catalytic reactor systems, such as reactor sections or regeneration sections of fluid catalytic reactor systems. According to one embodiment, each of the presently disclosed components of the fluid catalytic reactor systems (such as a reactor section or a regeneration section) comprise a separate reactor vessel and catalyst separation section. For example, the reactor vessel and catalyst separation section may be spaced apart from one another and connected with a riser. In such a design, thermal transport in the system may be better controlled, especially at sensitive portions of the system such as at the catalyst outlet ports of the reactor section and/or the regeneration section, which may be prone to mechanical failure of the vessel or refractory portions of the system when subjected to heat from the reactor section.

Generally, a catalytic reactor system may include a main reactor section utilized for converting the chemical feedstock, sometimes referred to herein as the "reactor section," and a regeneration section for regenerating the catalyst. Each of the main reactor section and the regeneration section include a reactor vessel and a separation device located in a catalyst separation section, which is utilized to separate the catalyst from other materials present in the system. For example, a main reactor section generally includes a reactor vessel, where a reaction such as catalytic cracking or dehydrogenation may take place, and a catalyst separation section utilized to separate the spent catalyst utilized in the cracking reaction. Similarly, the regeneration section includes a reactor vessel (such as a combustion vessel), where spent catalyst may be, for example, de-coked and/or supplemental fuel may be combusted, and a catalyst separator utilized to separate the regenerated catalyst from the process gases of the combustion reaction. Generally, the respective reactors (e.g., the main process reactor and the combustor) may be positioned below the separators, and a riser may be utilized to move the catalyst upward from each the reactor to each catalyst separator. As the basic scheme of movement and reaction may be similar in the reactor section and the regenerator section, their designs may be similar, or at least incorporate similar design principles, as will be disclosed herein.

According to the present disclosure, a system component of a fluid catalytic reactor system, such as a reactor section or a regeneration section of a fluid catalytic reactor system, is provided according to claim <NUM>.

In accordance with the present disclosure, a fluid catalytic reactor system comprising a reactor section and a regeneration section is provided according to claim <NUM>.

It is to be understood that both the foregoing brief summary and the following detailed description present embodiments of the technology, and are intended to provide an overview or framework for understanding the nature and character of the technology as it is claimed. The accompanying drawings are included to provide a further understanding of the technology, and are incorporated into and constitute a part of this specification. The drawings illustrate various embodiments and, together with the description, serve to explain the principles and operations of the technology. Additionally, the drawings and descriptions are meant to be merely illustrative, and are not intended to limit the scope of the claims in any manner.

Additional features and advantages of the technology disclosed herein will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the technology as described herein, including the detailed description which follows, the claims, as well as the appended drawings.

It should be understood that the drawings are schematic in nature, and do not include some components of a fluid catalytic reactor system commonly employed in the art, such as, without limitation, temperature transmitters, pressure transmitters, flow meters, pumps, valves, and the like. It would be known that these components are within the spirit and scope of the present embodiments disclosed. However, operational components, such as those described in the present disclosure, may be added to the embodiments described in this disclosure.

Reference will now be made in greater detail to various embodiments of system components of fluid catalytic reactor systems, some embodiments of which are illustrated in the accompanying drawings. Referring now to <FIG>, a fluid catalytic reactor system <NUM> is schematically depicted. The fluid catalytic reactor system <NUM> generally comprises multiple system components, such as a reactor section <NUM> and/or a regeneration section <NUM>. As used herein, a "reactor section" generally refers to the portion of a fluid catalytic reactor system in which the major process reaction takes place, and catalyst (sometimes spent, meaning it is at least partially deactivated) is separated from the product stream of the reaction. Also, as used herein, a "regeneration section" generally refers to the portion of a fluid catalytic reactor system where the catalyst is regenerated, such as through combustion, and the regenerated catalyst is separated from the other process materials, such as evolved gases from the combusted material previously on the de-activated catalyst or from supplemental fuel. The reactor section <NUM> generally includes a reactor vessel <NUM>, a riser <NUM> including an external riser section <NUM> and an internal riser section <NUM>, and a catalyst separation section <NUM>. The regeneration section <NUM> generally includes a reactor vessel <NUM>, a riser <NUM> including an external riser section <NUM> and an internal riser section <NUM>, and a catalyst separation section <NUM>. Generally, the catalyst separation section <NUM> may be in fluid communication with the reactor vessel <NUM> (e.g., via standpipe <NUM>) and the catalyst separation section <NUM> may be in fluid communication with the reactor vessel <NUM> (e.g., via standpipe <NUM> and transport riser <NUM>).

As used herein, an "external riser section" refers to the portion of the riser that is outside of the catalyst separation section, and an "internal riser section" refers to the portion of the riser that is within the catalyst separation section.

For example, the internal riser section <NUM> of the reactor section <NUM> may be positioned within the catalyst separation section <NUM>, while the external riser section <NUM> is positioned outside of the catalyst separation section <NUM>. Similarly, the internal riser section <NUM> of the regeneration section <NUM> may be positioned within the catalyst separation section <NUM>, while the external riser section <NUM> is positioned outside of the catalyst separation section <NUM>.

According to one or more embodiments described herein, the external riser section <NUM> of the riser <NUM> of the reactor section <NUM> and/or the external riser section <NUM> of the riser <NUM> of the regeneration section <NUM> may have a length which is greater than its maximum diameter. That is, for the external riser section <NUM> of the riser <NUM> of the reactor section <NUM>, the distance between the riser port <NUM> and the reactor vessel outlet port <NUM> (i.e., measured in <FIG> in the vertical direction) may be greater than the maximum diameter of the external riser section <NUM>, where the "maximum diameter" refers to the greatest diameter in any portion of the external riser section <NUM> (i.e., measured in <FIG> in the horizontal direction). Similarly, for the external riser section <NUM> of the riser <NUM> of the regeneration section <NUM>, the distance between the riser port <NUM> and the reactor vessel outlet port <NUM> (i.e., measured in <FIG> in the vertical direction) may be greater than the maximum diameter of the external riser section <NUM>, where the "maximum diameter" refers to the greatest diameter in any portion of the external riser section <NUM> (i.e., measured in <FIG> in the horizontal direction). The diameter of the external riser section <NUM> and/or external riser section <NUM> may be substantially constant (i.e., not vary by more than about <NUM>%), and may be tubular in shape.

Generally, the fluid catalytic reactor system <NUM> may be operated by feeding a chemical feed and a fluidized catalyst into the reactor vessel <NUM>, and reacting the chemical feed by contact with a fluidized catalyst to produce a chemical product in the reactor vessel <NUM> of the reactor section <NUM>. The chemical product and the catalyst may be passed out of the reactor vessel <NUM> and through the riser <NUM> to a separation device <NUM> in the catalyst separation section <NUM>, where the catalyst is separated from the chemical product, which is transported out of the catalyst separation section <NUM>. The separated catalyst is passed from the catalyst separation section <NUM> to the reactor vessel <NUM>. In the reactor vessel <NUM>, the catalyst may be regenerated by a chemical process such as combustion. For example, without limitation, the spent catalyst may be de-coked and/or supplemental fuel may be catalytically combusted. The catalyst is then passed out of the reactor vessel <NUM> and through the riser <NUM> to a riser termination separator <NUM>, where the gas and solid components from the riser <NUM> are partially separated. The vapor and remaining solids are transported to a secondary separation device <NUM> in the catalyst separation section <NUM> where the remaining catalyst is separated from the gases from the regeneration reaction (e.g., gases emitted by combustion of spent catalyst). The separated catalyst is then passed from the catalyst separation section <NUM> to the reactor vessel <NUM>, where it is further utilized in a catalytic reaction. Thus, the catalyst, in operation, may cycle between the reactor section <NUM> and the regeneration section <NUM>. In general, the processed chemical streams, including the feed streams and product streams may be gaseous, and the catalyst may be fluidized particulate solid.

It should be understood that as used herein, a "system component" may refer to either of a reactor section <NUM> or a regeneration section <NUM> in a fluid catalytic reactor system <NUM>, and that, in some embodiments, the fluid catalytic reactor system <NUM> may include either a reactor section <NUM> or a regeneration section <NUM>, and not both. In other embodiments, the fluid catalytic reactor system <NUM> may include a single regeneration section <NUM> and multiple reactor sections <NUM> in fluid communication with the regeneration section <NUM>. Additionally, as described herein, the structural features of the reactor section <NUM> and regeneration section <NUM> may be similar or identical in some respects. For example, each of the reactor section <NUM> and regeneration section <NUM> include a reactor vessel (i.e., reactor vessel <NUM> of the reactor section <NUM> and reactor vessel <NUM> of the regeneration section <NUM>), a riser (i.e., riser <NUM> of the reactor section <NUM> and riser <NUM> of the regeneration section <NUM>), and a catalyst separation section (i.e., catalyst separation section <NUM> of the reactor section <NUM> and catalyst separation section <NUM> of the regeneration section <NUM>). It should be appreciated that since many of the structural features of the reactor section <NUM> and the regeneration section <NUM> may be similar or identical in some respects, similar or identical portions of the reactor section <NUM> and the regeneration section <NUM> have been provided reference numbers throughout this disclosure with the same final two digits, and disclosures related to one portion of the reactor section <NUM> may be applicable to the similar or identical portion of the regeneration section <NUM>, and vice versa.

As depicted in <FIG>, the reactor vessel <NUM> may include a reactor vessel catalyst inlet port <NUM> defining the connection of transport riser <NUM> to the reactor vessel <NUM>, and may additionally include a reactor vessel outlet port <NUM> in fluid communication with (such as directly connected to) the external riser section <NUM> of the riser <NUM>. As used herein, a "reactor vessel" refers to a drum, barrel, vat, or other container suitable for a given chemical reaction. A reactor vessel may be generally cylindrical in shaped (i.e., having a substantially circular diameter), or may alternately be non-cylindrically shaped, such as prism shaped with cross-sectional shaped of triangles, rectangles, pentagons, hexagons, octagons, ovals, or other polygons or curved closed shapes, or combinations thereof. Reactor vessels, as used throughout this disclosure, may generally include a metallic frame, and may additionally include refractory linings or other materials utilized to protect the metallic frame and/or control process conditions.

As described, the reactor vessel <NUM> may include a reactor vessel catalyst inlet port <NUM> and a reactor vessel outlet port <NUM>. Generally, "inlet ports" and "outlet ports" of any system unit of the fluid catalytic reactor system <NUM> described herein refer to openings, holes, channels, apertures, gaps, or other like mechanical features in the system unit. For example, inlet ports allow for the entrance of materials to the particular system unit and outlet ports allow for the exit of materials from the particular system unit. Generally, an outlet port or inlet port will define the area of a system unit of the fluid catalytic reactor system <NUM> to which a pipe, conduit, tube, hose, transport line, or like mechanical feature is attached, or to a portion of the system unit to which another system unit is directly attached. While inlet ports and outlet ports may sometimes be described herein functionally in operation, they may have similar or identical physical characteristics, and their respective functions in an operational system should not be construed as limiting on their physical structures. Other ports, such as the riser port <NUM>, may comprise an opening in the given system unit where other system units are directly attached, such as where the riser <NUM> extends into the catalyst separation section <NUM> at the riser port <NUM>.

The reactor vessel <NUM> may be connected to a transport riser <NUM>, which, in operation, may provide regenerated catalyst and/or reactant chemicals to the reactor section <NUM>. The regenerated catalyst and/or reactant chemicals may be mixed with a distributor <NUM> housed in the reactor vessel <NUM>. The catalyst entering the reactor vessel <NUM> via transport riser <NUM> may be passed through standpipe <NUM> to a transport riser <NUM>, thus arriving from the regeneration section <NUM>. In some embodiments, catalyst may come directly from the catalyst separation section <NUM> via standpipe <NUM> and into a transport riser <NUM>, where it enters the reactor vessel <NUM>. This catalyst may be slightly deactivated, but may still, in some embodiments, be suitable for reaction in the reactor vessel <NUM>.

As depicted in <FIG>, the reactor vessel <NUM> may be directly connected to the external riser section <NUM> of the riser <NUM>. In one embodiment, the reactor vessel <NUM> may include a reactor vessel body section <NUM> and a reactor vessel transition section <NUM>. The reactor vessel body section <NUM> may generally comprise a greater diameter than the reactor vessel transition section <NUM>, and the reactor vessel transition section <NUM> may be tapered from the size of the diameter of the reactor vessel body section <NUM> to the size of the diameter of the external riser section <NUM> such that the reactor vessel transition section <NUM> projects inwardly from the reactor vessel body section <NUM> to the external riser section <NUM>. It should be understood that, as used herein, the diameter of a portion of a system unit refers to its general width, as shown in the horizontal direction in <FIG>.

As described herein, the riser <NUM> includes an external riser section <NUM> and an internal riser section <NUM> contained within the catalyst separation section <NUM>. Still referring to <FIG>, the catalyst separation section <NUM> includes separation section walls <NUM> defining an interior region <NUM> of the catalyst separation section <NUM>. The riser <NUM> extends into the interior region <NUM> of the catalyst separation section <NUM> through the riser port <NUM>. The riser port <NUM> may be any opening in the catalyst separation section <NUM> through which at least the internal riser section <NUM> of the riser <NUM> protrudes into the interior region <NUM> of the catalyst separation section <NUM>.

In embodiments described herein, the reactor vessel transition section <NUM> may be outside of the catalyst separation section. In some conventional reactor and regeneration units, the portion of the reactor analogous to the reactor vessel transition section <NUM> may also be the bottom portion of the separation section. Thus, in conventional setups, the heat from the reactor may be conducted through the transition section and directly into the separation section. Instability in the materials of the reactor and/or separator may result from these high thermal loads, particularly at or near attachment points of standpipes.

In one or more embodiments, the catalyst separation section <NUM> may include several segments. For example, as depicted in <FIG>, the catalyst separation section <NUM> may include an upper segment <NUM>, a middle segment <NUM>, and a lower segment <NUM>. The internal riser section <NUM> of the riser <NUM> may extend through the riser port <NUM> of the catalyst separation section <NUM> and through the lower segment <NUM>, the middle segment <NUM>, and into the upper segment <NUM>. Generally, at least the majority of the internal riser section <NUM> may have a substantially constant diameter, and may be similar in diameter to the external riser section <NUM> (relative to the other units in the system, such as within <NUM>% of one another), but slightly smaller in diameter than the majority of the external riser section. At the upper segment <NUM> of the catalyst separation section <NUM>, the internal riser section <NUM> may be in fluid communication with the separation device <NUM>. The separation device <NUM> may be any mechanical or chemical separation devices which may be operable to separate solid particles from gas or liquid phases, such as a cyclone or plurality of cyclones.

According to one or more embodiments, the separation device <NUM> may be a cyclonic separation system, which may include two or more stages of cyclonic separation. In embodiments where the separation device <NUM> comprises more than one cyclonic separation stages, the first separation device into which the fluidized stream enters is referred to a primary cyclonic separation device. The fluidized effluent from the primary cyclonic separation device may enter into a secondary cyclonic separation device for further separation. Primary cyclonic separation devices may include, for example, primary cyclones, and systems commercially available under the names VSS (commercially available from UOP) , LD<NUM> (commercially available from Stone and Webster), and RS<NUM> (commercially available from Stone and Webster). Primary cyclones are described, for example, in <CIT>; <CIT>; and <CIT>. In some separation systems utilizing primary cyclones as the primary cyclonic separation device, one or more set of additional cyclones, e.g. secondary cyclones and tertiary cyclones, are employed for further separation of the catalyst from the product gas. It should be understood that any primary cyclonic separation device may be used in embodiments of the invention.

The catalyst may move upward through the riser <NUM> (from the reactor vessel <NUM>), and into the separation device <NUM>. The separation device <NUM> may be operable to deposit separated catalyst into the bottom of the upper segment <NUM> or into the middle segment <NUM> or lower segment <NUM>. The separated vapors may be removed from the fluid catalytic reactor system <NUM> via a pipe <NUM> at a gas outlet port <NUM> of the catalyst separation section <NUM>.

As depicted in <FIG>, in one or more embodiments, the upper segment <NUM> of the catalyst separation section <NUM> may have a greater diameter than the middle segment <NUM>, and the lower segment <NUM> may have a greater maximum diameter than the middle segment <NUM>. The upper segment <NUM> of the catalyst separation section <NUM> may be connected to the middle segment <NUM> via a transition segment <NUM> which projects inwardly from the upper segment <NUM> to the middle segment <NUM>. The upper segment <NUM> and/or the middle segment <NUM> may, respectively, have a relatively constant diameter (i.e., the diameter does not vary by more than about <NUM>% in a particular section). The separation section walls <NUM> at the middle segment <NUM> and the internal riser section <NUM> may define a coaxial channel that houses a stripper <NUM>. The stripper <NUM> may be utilized to remove product vapors from the catalyst prior to sending it regeneration section <NUM> for regeneration. As product vapors transported to the regeneration section <NUM> will be combusted, it is desirable to remove those product vapors with the stripper <NUM> and which utilizes less expensive gases for combustion than product gases.

Following separation from vapors in the separation device <NUM>, the catalyst may generally move through the stripper <NUM> in the middle segment <NUM> and into the lower segment <NUM>. The lower segment <NUM> may include the catalyst outlet port <NUM> where the catalyst is transferred out of the reactor section <NUM> via standpipe <NUM> and into the regeneration section <NUM>. Optionally, the catalyst may also be transferred directly back into the reactor vessel <NUM> via standpipe <NUM>. Alternatively, the catalyst may be premixed with regenerated catalyst in the transport riser <NUM>.

Now referring to <FIG>, a detailed view of the area around the lower segment <NUM> of the catalyst separation section <NUM> is depicted. Among other features, <FIG> depicts the main interior (or internal) riser wall segment <NUM>, the main exterior (or external) riser wall segment <NUM>, as well as various refractory materials and other wall segments of the system. Generally, the main interior riser wall segment <NUM> and the main exterior wall segment <NUM> may be tubular and substantially parallel with one another (i.e., forming an angle of less than <NUM>° with one another). The main interior riser wall segment <NUM> may be connected to the main external riser wall segment <NUM> via a riser transition wall segment <NUM>.

In some embodiments, the lower segment <NUM> of the catalyst separation section <NUM> may have a greater maximum diameter than the middle segment <NUM> of the catalyst separation section <NUM>. For example, the lower segment <NUM> of the catalyst separation section <NUM> may protrude outwardly from the middle segment <NUM> of the catalyst separation section <NUM> in a bulb-like shape. The bottom section of the lower segment <NUM> may sometimes be referred to as a "hemispherical" shape. This widening may accommodate a frustum <NUM> through which catalyst is passed and enters standpipe <NUM> through the catalyst outlet port <NUM>. As such, the channel through which the catalyst may travel (i.e., the space between the internal riser section <NUM> and the separation section walls <NUM>) is widened. For example, the distance between the separation section walls <NUM> at the middle segment <NUM> of the catalyst separation section <NUM> and the internal riser section <NUM> may be less than the distance between the separation section walls <NUM> at the lower segment <NUM> of the catalyst separation section <NUM> and the internal riser section <NUM>. Without being bound by theory, it is believed that the widening of the channel (such as by providing a bulb shaped lower segment <NUM>) may be beneficial because the velocity at which the bubbles in the stream are moving downward may be reduced, which may allow them to disengage from the flowing solids prior to introduction to the standpipe <NUM>, allowing for smooth passage of the catalyst through the catalyst outlet port <NUM> and out of the reactor section <NUM>. For example, the presently disclosed design may mitigate the risk of creating local areas of high catalyst velocities in the stripper <NUM>, which can lead to operational problems as the bubbles accelerate downward and then do not disengage just prior to entry into the standpipe <NUM>. Additionally, the design may reduce bubbles being entrained into the standpipe <NUM>, which can negatively impact the pressure build.

According to another embodiment, a bulb-like shaped lower segment <NUM> of the catalyst separation section <NUM> may provide enhanced mechanical support because it may allow for a wider joint ligament <NUM>. As used herein, a "joint ligament" refers to the distance between the riser port <NUM>, usually positioned at or near the axial center of the catalyst separation section <NUM>, and the one or more catalyst outlet ports <NUM> positioned nearer the sides of the catalyst separation section <NUM>. In general, the greater the distance of the joint ligament <NUM>, the more mechanically stable the lower segment <NUM> may be. Moreover, in various embodiments, it should be understood that any curved shape is contemplated as a suitable shape for the lower segment <NUM> of the catalyst separation section <NUM> because it may provide for a wider joint ligament <NUM>.

Now referring to <FIG> and <FIG>, according to one or more embodiments, the riser <NUM> may comprise a main interior riser wall segment <NUM>, a riser transition wall segment <NUM>, and a main external riser wall segment <NUM>. Generally, the majority (e.g., at least <NUM>%) of the main external riser wall segment <NUM> may be outside of the catalyst separation section <NUM> (i.e., part of the external riser section <NUM>), and the majority (e.g., at least <NUM>%) of the main interior riser wall segment <NUM> may be within the catalyst separation section <NUM> (i.e., part of the internal riser section <NUM>). The main external riser wall segment <NUM> may have a relatively constant diameter (e.g., not varying by more than about <NUM>%) and the main interior riser wall segment <NUM> may have a relatively constant diameter (e.g., not varying by more than about <NUM>%).

The riser transition wall segment <NUM> may connect the main interior riser wall segment <NUM> with the main external riser wall segment <NUM>, either directly or via the lower segment <NUM> of the catalyst separation section <NUM>. As depicted in <FIG>, the riser transition wall segment <NUM> may be attached to the main interior riser wall segment <NUM> at attachment point <NUM> and to the main external riser wall segment <NUM> at attachment point <NUM>. The riser transition wall segment <NUM> may project inwardly from the main external riser wall segment <NUM> of the external riser section <NUM> to the main interior riser wall segment <NUM> of the internal riser section <NUM>.

As described herein, portions of system units such as reaction vessel walls, separation section walls, or riser walls, may comprise a metallic material, such as carbon or stainless steel. In addition, the walls of various system units may have portions which are attached with other portions of the same system unit or to another system unit. Sometimes, the points of attachment or connection are referred to herein as "attachment points" and may incorporate any known bonding medium such as, without limitation, a weld, an adhesive, a solder, etc. It should be understood that components of the system may be "directly connected" at an attachment point, such as a weld.

Still referring to <FIG>, the an internal riser lip segment <NUM> may be connected to the main interior riser wall segment <NUM>, the riser transition wall segment <NUM>, or both. The internal riser lip segment <NUM> may generally be disposed in a direction generally parallel to one or more of the main interior riser wall segment <NUM> and the main external riser wall segment <NUM>. As shown in <FIG>, in some embodiments, the main external riser wall segment <NUM> may coaxially surround at least a portion of the internal riser lip segment <NUM>. For example, the main external riser wall segment <NUM> may coaxially surround the internal riser lip segment <NUM> along a length of the external riser section <NUM> that is at or near the riser transition wall segment <NUM>.

According to some embodiments, the internal riser lip segment <NUM> may be about aligned with the main interior riser wall segment <NUM>, and an angle of about <NUM> degrees (such as from about <NUM> degrees to about <NUM> degrees, or from about <NUM> degrees to about <NUM> degrees) may be formed between the riser transition wall segment <NUM> and the main interior riser wall segment <NUM> and/or the internal riser lip segment <NUM>.

Still referring to <FIG> and <FIG>, refractory materials may be included in the riser <NUM> as well as the catalyst separation section <NUM>. It should be understood that while embodiments are provided of specific refractory material arrangements and materials, they should not be considered limiting regarding the physical structure of the disclosed system. For example, refractory liner <NUM> may be attached to and act as an erosion protectant or thermal liner for the main interior riser wall segment <NUM> and internal riser lip segment <NUM> within the internal riser section <NUM>. The refractory liner <NUM> may extend in the riser <NUM> into the middle segment <NUM> and upper segment <NUM> of the catalyst separation section <NUM>. The refractory liner <NUM> may end at or near the bottom of the internal riser lip segment <NUM>. The refractory liner <NUM> may include hex mesh or other suitable refractory materials. Refractory liner <NUM> may be attached to and act as a thermal liner for the riser transition wall segment <NUM> and the main interior riser wall segment <NUM>. For example, the refractory liner <NUM> may run from the separation section walls <NUM> at the joint ligament <NUM> to the middle segment <NUM> of the catalyst separation section <NUM> on the outer surface of the internal riser section <NUM>. In certain embodiments, the refractory liner <NUM> may be a ceramic fiber blanket or refractory material, or a combination of both.

In additional embodiments, separation section walls <NUM> in the lower segment <NUM> of the catalyst separation section <NUM> may include a refractory liner <NUM> which coats, at least partially, its interior surface. Refractory material <NUM> may be positioned adjacent the frustum <NUM>. Additionally, refractory material <NUM> may be positioned between the main external riser wall segment <NUM> and the internal riser lip segment <NUM>, in contact with the riser transition wall segment <NUM>. Refractory material <NUM> may be positioned between the main external riser wall segment <NUM> and the main interior riser wall segment <NUM>, and may hang over and extend past the internal riser lip segment <NUM>. The refractory material <NUM> may define a gap <NUM> of void space between itself and the main interior riser wall segment <NUM> and refractory liner <NUM>. In embodiments, the refractory material <NUM> may extend into the external riser section <NUM>, coating the walls of the external riser section <NUM>.

As depicted in <FIG>, the main interior riser wall segment <NUM> may be connected to the riser transition wall segment <NUM>, and the riser transition wall segment <NUM> may be connected to the main external riser wall segment <NUM>. In the embodiment of <FIG>, the lower segment <NUM> of the catalyst separation section <NUM> is attached to the main external riser wall segment <NUM> at attachment point <NUM>. However, other embodiments, such as those depicted in <FIG> may be suitable arrangements for connection between the main interior riser wall segment <NUM>, the riser transition wall segment <NUM>, and the main external riser wall segment <NUM>. It should be understood that <FIG> are have been simplified to only illustrate the main interior riser wall segment <NUM>, riser transition wall segment <NUM>, main external riser wall segment <NUM>, and lower segment <NUM> of the catalyst separation section <NUM>. Thus, it should be understood that the embodiments of <FIG> may additionally include various refractory materials and other components such as a internal riser lip segment <NUM>, which are not depicted in <FIG>.

Referring to <FIG>, according to various embodiments, the lower segment <NUM> of the catalyst separation section <NUM> may be attached to the riser transition wall segment <NUM>, the main external riser wall segment <NUM>, or both. For example, referring to <FIG>, the lower segment <NUM> of the catalyst separation section <NUM> may be directly connected with the main external riser wall segment <NUM>, and the main external riser wall segment <NUM> may be directly connected to the riser transition wall segment <NUM>, which is also directly connected to the main interior riser wall segment <NUM>. The distance between the area of direct connection of the lower segment <NUM> with the main external riser wall segment <NUM> and the riser transition wall segment <NUM> with the main external riser wall segment <NUM> may be about <NUM> to <NUM> inches (<NUM> centimetres to <NUM> centimetres), such as <NUM> to <NUM> inches (<NUM> centimetres to <NUM> centimetres). In such an embodiment, a portion of the main external riser wall segment <NUM> is within the catalyst separation section <NUM> and a portion of the main external riser wall segment <NUM> is positioned within the catalyst separation section <NUM>. However, the majority of the main external riser wall segment <NUM> is outside of the catalyst separation section <NUM>.

According to the embodiment depicted in <FIG>, the lower segment <NUM> may be directly connected to the riser transition wall segment <NUM> and the main external riser wall segment <NUM>. In such an embodiment, the riser transition wall segment <NUM> may be indirectly connected with the main external riser wall segment <NUM> via the lower segment <NUM>. In such an embodiment, the entirety of the riser transition wall segment <NUM> is within the catalyst separation section <NUM>.

According to the embodiment depicted in <FIG>, the main interior riser wall segment <NUM> is directly connected with the riser transition wall segment <NUM>, which is directly connected with the main external riser wall segment <NUM>. The lower segment <NUM> is directly connected with the riser transition wall segment <NUM>, between the point of connection between the riser transition wall segment <NUM> and the main external riser wall segment <NUM>, and the point of connection between the riser transition wall segment <NUM> and the main interior riser wall segment <NUM>. In such an embodiment, a portion of the riser transition wall segment <NUM> is within the catalyst separation section <NUM>, and a portion of the riser transition wall segment <NUM> is outside of the catalyst separation section <NUM>.

According to embodiments, the riser transition wall segment <NUM> may have a length that is less than or equal to about <NUM>% of the maximum diameter of the internal riser section <NUM> (such as less than or equal to about <NUM>%, less than or equal to about <NUM>%, less than or equal to about <NUM>%, less than or equal to about <NUM>%, less than or equal to about <NUM>%, less than or equal to about <NUM>%). The relatively small length of the riser transition wall segment <NUM> may accommodate a main interior riser wall segment <NUM> and a main external riser wall segment <NUM> which have maximum diameters that are within <NUM>%, <NUM>%, <NUM>%, <NUM>%, or even <NUM>% of one another. For example, the maximum diameter of the main internal riser wall segment <NUM> may be at least <NUM>%, <NUM>%, <NUM>%, <NUM>%, or even <NUM>% of the maximum diameter of the main external riser wall segment <NUM>.

Mechanical loads applied onto the reactor vessel <NUM> from the weight of the catalyst and other parts of the reactor section <NUM> may be high, and springs may be utilized to apply pressure upwardly on the reactor vessel <NUM>. For example, the reactor vessel <NUM> may be hung from springs, or springs may be positioned below the reactor vessel <NUM> to support its weight. For example, <FIG> spring supports <NUM> mechanically attached to the reactor section <NUM> at the reactor vessel <NUM>, wherein the reactor section <NUM> is suspended from a support structure by the spring supports <NUM>.

After separation in the catalyst separation section <NUM>, the spent catalyst is transferred to the regeneration section <NUM>. The regeneration section <NUM>, as described herein, may share many structural similarities with the reactor section <NUM>. As such, the reference numbers assigned to the portions of the regeneration section <NUM> are analogous to those used with reference to the reactor section <NUM>, where if the final two digits of the reference number are the same the given portions of the reactor section <NUM> and regeneration section <NUM> may serve similar functions and have similar physical structure. Thus, many of the present disclosures related to the reactor section <NUM> may be equally applied to the regeneration section <NUM>, and distinctions between the reactor section <NUM> and the regeneration section <NUM> will be highlighted hereinbelow.

Referring now to the regeneration section <NUM>, as depicted in <FIG>, the reactor vessel <NUM> (such as a combustor) of the regeneration section <NUM> may include one or more reactor vessel inlet ports <NUM> and a reactor vessel outlet port <NUM> in fluid communication with (such as directly connected to) the external riser section <NUM> of the riser <NUM>. The reactor vessel <NUM> may be in fluid communication with the catalyst separation section <NUM> via standpipe <NUM>, which may supply spent catalyst from the reactor section <NUM> to the regeneration section <NUM> for regeneration. The reactor vessel <NUM> may include an additional reactor vessel inlet port <NUM> where air inlet <NUM> connects to the reactor vessel <NUM>. The air inlet <NUM> may supply reactive gases which may react with the spent catalyst to at least partially regenerate the catalyst. For example, the catalyst may be coked following the reactions in the reactor vessel <NUM>, and the coke may be removed from the catalyst (i.e., regenerating the catalyst) by a combustion reaction. For example, oxygen (such as air) may be fed into the reactor vessel <NUM> via the air inlet <NUM>.

As depicted in <FIG>, the reactor vessel <NUM> may be directly connected to the external riser section <NUM> of the riser <NUM>. In one embodiment, the reactor vessel <NUM> may include a reactor vessel body section <NUM> and a reactor vessel transition section <NUM>. The reactor vessel body section <NUM> may generally comprise a greater diameter than the reactor vessel transition section <NUM>, and the reactor vessel transition section <NUM> may be tapered from the size of the diameter of the reactor vessel body section <NUM> to the size of the diameter of the external riser section <NUM> such that the reactor vessel transition section <NUM> projects inwardly from the reactor vessel body section <NUM> to the external riser section <NUM>.

Still referring to <FIG>, the catalyst separation section <NUM> includes separation section walls <NUM> defining an interior region <NUM> of the catalyst separation section <NUM>. The riser <NUM> extends into the interior region <NUM> of the regeneration section <NUM> via a riser port <NUM>. The riser port <NUM> may be any opening in the catalyst separation section <NUM> through which at least the internal riser section <NUM> of the riser <NUM> protrudes into the interior region <NUM> of the catalyst separation section <NUM>.

Similar to the reactor section <NUM>, conventional examples of the regeneration section <NUM> may incorporate a unitary reactor/separator design where the reactor and separator are separated by a wall. Utilizing an external riser between the catalyst separation section and the reactor vessel may allow for better thermal control of the catalyst separation section <NUM> since it is not directly connected to the heat-generating reactor vessel <NUM>.

In one or more embodiments, the catalyst separation section <NUM> may include several segments. For example, as depicted in <FIG>, the catalyst separation section <NUM> may include an upper segment <NUM> and a lower segment <NUM>. The internal riser section <NUM> may extend through the riser port <NUM> of the catalyst separation section <NUM> and through the lower segment <NUM> and into the upper segment <NUM>. At the upper segment <NUM>, the internal riser section <NUM> may be in fluid communication with the riser termination separator. The fluid stream may then pass to the secondary separation device <NUM>, which may be any mechanical separation devices which may be operable to separate solid particles from gas phases, such as a cyclone or plurality of cyclones, such as multiple cyclones in series. The secondary separation device <NUM> may be operable to deposit separated catalyst into the bottom of the upper segment <NUM> or into the lower segment <NUM>. The lower segment <NUM> may include the catalyst outlet port <NUM>.

Now referring to <FIG> and <FIG>, in one embodiment, the lower segment <NUM> of the catalyst separation section <NUM> may include an ellipsoidal shape at or near the riser port <NUM>. For example, as depicted in <FIG> and <FIG>, the lower segment <NUM> may include a cylinder geometry with a ellipsoidal bottom to the cylinder. The ellipsoidal shape may contribute to an increased length of the joint ligament <NUM>. Other curved shapes may also be suitable, such as the bulb shaped disclosed in reference to the reactor section <NUM>. Likewise, the ellipsoidal shaped lower segment <NUM> may be suitable for the reactor section <NUM>.

It should be understood that the regeneration section <NUM> may include a riser transition sidewall <NUM>, similar to the riser transition wall segment <NUM> described with regards to the reactor section. For example, the embodiments depicted in FIGS. 3A-3C may be applicable to the riser <NUM> of the regeneration section. Additionally, spring supports <NUM> may be utilized to support mechanical loads applied on the reactor vessel <NUM>.

The systems described herein may be utilized as processing equipment for various fluidized catalyst reactions. For example, hydrocarbons, as well as other chemical feedstocks, can be converted into desirable products through use of fluidized bed reactors. Fluidized bed reactors serve many purposes in industry, including dehydrogenation of paraffins and/or alkyl aromatics, cracking of hydrocarbons (i.e., fluid catalytic cracking), chlorination of olefins, oxidations of naphthalene to phthalic anhydride, production of acrylonitrile from propylene, ammonia, and oxygen, Fischer-Tropsch synthesis, and polymerization of ethylene.

Claim 1:
A system component (<NUM>, <NUM>) of a fluid catalytic reactor system (<NUM>), the system component (<NUM>, <NUM>) comprising:
a catalyst separation section (<NUM>, <NUM>) comprising separation section walls (<NUM>, <NUM>) defining an interior region (<NUM>, <NUM>) of the catalyst separation section (<NUM>, <NUM>), a gas outlet port (<NUM>, <NUM>), a riser port (<NUM>, <NUM>), a separation device (<NUM>, <NUM>), and a catalyst outlet port (<NUM>, <NUM>);
a riser (<NUM>, <NUM>) extending through the riser port (<NUM>, <NUM>) of the catalyst separation section (<NUM>, <NUM>), the riser (<NUM>, <NUM>) comprising a main interior riser wall segment (<NUM>, <NUM>), a main exterior riser wall segment (<NUM>, <NUM>), and a riser transition wall segment (<NUM>, <NUM>), at least <NUM>% of the main interior riser wall segment (<NUM>, <NUM>) positioned within the interior region (<NUM>, <NUM>) of the catalyst separation section (<NUM>, <NUM>) and connected with at least the riser transition wall segment (<NUM>, <NUM>), and the main exterior riser wall segment (<NUM>, <NUM>) positioned at least partially outside of the catalyst separation section (<NUM>, <NUM>); and
a reactor vessel (<NUM>, <NUM>) comprising a reactor vessel inlet port (<NUM>, <NUM>), and a reactor vessel outlet port (<NUM>, <NUM>) in fluid communication with the main exterior riser wall segment (<NUM>, <NUM>),
wherein the main interior riser wall segment (<NUM>, <NUM>) and the main exterior riser wall segment (<NUM>, <NUM>) are substantially parallel, and the maximum diameter of the main interior riser wall segment (<NUM>, <NUM>) is less than the maximum diameter of the main exterior riser wall segment (<NUM>, <NUM>).