Mobil Oil Corporation

Mobil Oil Co

Lillian A Rankel

Nai Y Chen

Costandi A Audeh

Ernest W Valyocsik

Leslie R Rudnick

John Scott Buchanan

Paul Shu

Tsoung-Yuan Yan

Darrell D Whitehurst

Randall D Partridge

Roland H Heck

Use of a carbon-based catalyst composition, particularly activated-carbon, optionally containing at least one metal selected from Ni, Co, Mo, W, Fe, or mixtures thereof, for heavy oil hydroprocessing. Recovery and partial gasification of the catalyst to produce a synthesis gas and a partially gasified catalyst residue. Use of the synthesis gas in a process to produce synthetic hydrocarbons and use of the catalyst residue in steel or alloy production. Catalysts used for heavy oil hydrocarbon hydroprocessing frequently become contaminated with metals which increase the cost of disposal of the spent catalysts, e.g. landfills. This invention uses a specific catalyst for hydroprocessing which can then be partially gasified to produce a catalyst residue which can be further used in steel or alloy production, thereby reducing the need for expensive disposal.

Integrated process for hydrotreating heavy oil, then manufacturing an

Heavy oil is hydrotreated by processing with hydrogen in the presence of a catalyst composition comprising an activated carbon component having a specified range of pore volume distribution and average pore diameter, a molybdenum or tungsten component and a cobalt or nickel component to reduce the content of nickel and vanadium therein and to achieve demetallation and conversion of the carbon residue for producing a lighter oil.

Process for treating heavy oil

A process for treating heavy oil by contacting the oil with hydrogen in a reactor containing an activated carbon catalyst having a specified range of Alpha value, and average pore diameter, and pore distribution, to reduce the content of nickel and vanadium in the feedstock and to achieve conversion of the carbon residue for producing a lighter oil. Demetallation capacity of the carbon catalyst is enhanced by the addition of a carbon-reactive oxidant, e.g., steam, under conditions sufficient to form additional carbon surface.

A process for treating heavy oil by contacting the oil with hydrogen in a reactor containing an activated carbon catalyst having a specified range of Alpha value, and average pore diameter, and pore distribution, to reduce the content of nickel and vanadium in the feedstock and to achieve conversion of the carbon residue for producing a lighter oil.

Deasphalting heavy, asphaltic crudes before significant thermal treatment, even mild treatment which is inherent in, e.g., vacuum distillation, produces deasphalted whole crude with a reduced soluble metal content. This process is especially effective for preparing feedstocks for catalytic cracking units from heavy crudes containing large amounts of Ni and V which are porphyrin coordinated, and which are thermally unstable.

Integrated process for whole crude deasphalting and asphaltene upgrading

A catalytic cracking process for heavy metals and asphaltene containing feed is disclosed. A reactive sulfur compound, preferably H.sub.2 S, is dissolved in the heavy feed and then kept at a temperature and for a time sufficient to at least partially decompose the metal containing compounds and also to reduce the molecular weight of the asphaltenes. Preferably a metal scavenging additive is added to the equilibrium catalyst. The additive will rapidly remove the thermal- and sulfur-treated metal containing compounds and prevent or minimize metals poisoning of the cracking catalyst. Sulfur induced cracking of heavy oil components reduces the viscosity of the heavy feed, and permits lower temperature to be used in the cracking reactor.

Catalytic cracking with sulfur compound added to the feed

A process for preparing a pipelineable oil from a heavy crude oil by thermally treating the oil in the absence of added hydrogen, and under sufficiently severe conditions to induce the formation of an upgraded, low viscosity oil phase and a liquid asphalt phase that contains dispersed coke. The reaction is conducted under pressure sufficient to retain in the reactor most of the normally liquid hydrocarbons, under which conditions the two phases are readily separated and recovered solely by gravity settling. The process is readily adapted to oil field use with skid mounted units. The severity is adjusted to provide sufficient asphalt which, when burned, furnishes the steam required for production of the heavy crude oil.

Pipelineable syncrude (synthetic crude) from heavy oil

A process is provided for preparing pipelineable syncrude and asphalt from a heavy crude oil. The syncrude has substantially less metals content and Conradson Carbon Residue than the precursor crude oil, and may be used as feed for catalytic cracking or as fuel oil. The asphalt is adaptable for paving. The process consists of air-blowing the crude, deasphalting the air-blown product, and thermally cracking the deasphalted oil to reduce its viscosity, in that order. The process is adaptable to on-site use in or near a heavy oil field, using skid-mounted equipment.

This invention provides a method for extending the catalytic dewaxing cycle time of a refined waxy lube stock. The method, in its broadest aspect, requires the additional refining step of thermally treating the refined waxy stock or precursor thereof for about 0.1 to about 2.0 hours at elevated temperature and at a pressure of 0 to 3000 psig (pounds per square inch gauge), and recovering an upgraded waxy stock having a reduced content of trace compounds that contain metals, nitrogen, sulfur and oxygen. In a specific embodiment of this invention, a vacuum residuum is thermally treated at a temperature of about 700.degree. F. to 950.degree. F. prior to solvent deasphalting and solvent extraction, and the waxy bright stock so formed is catalytically dewaxed with extended cycle time.

Manufacture of lube base stocks

Disclosed is a method for accelerating the exchange of hydrogen between a hydrogen donor and a petroleum resid to be subjected to cracking, visbreaking, or coking. Acceleration is effected by incorporating an aqueous solution of ammoniun sulfide into the mixture of donor and resid and subjecting the mixture to a period of heat-soaking at an elevated temperature.

Accelerated cracking of residual oils and hydrogen donation utilizing

Hydrocarbon oils, particularly petroleum residua, are demetallized by contacting the oil first with an aqueous solution of a hypochlorite such as sodium hypochlorite or calcium hypochlorite and subsequently subjecting at least the oil fraction thereof to a solvent deasphalting step.

Upgrading heavy hydrocarbon oils using sodium hypochlorite

A combination process of oxidation/mild coking and in-situ deasphalting provides a process wherein upgraded crude with high levels of demetalation and low solids rejection is produced.

Process for upgrading heavy crude oils

A series of transition metal complexes, having stability at relatively high pH, have been utilized as templates for the synthesis of mordenite type zeolites.

Process for the preparation of mordenite utilizing transition metal

An improved process for upgrading vacuum resids to premium liquid products which comprises mild hydrotreating of the vacuum resids followed by fractionating and short contact time thermal cracking of the fraction boiling above 850.degree. F.+, such as by short contact time thermal cracking or rapid pyrolysis.

Process for upgrading vacuum resids to premium liquid products

A combined process for treating heavy hydrocarbon feedstocks, such as resids that minimizes coke production and maximizes naphtha production, comprising the steps of thermally treating the feedstocks, in the absence of an added catalyst and either with or without hydrogen and steam, at a temperature of at least about 750.degree. F. (399.degree. C.) and under a pressure greater than about 400 psig to create significant chemical transformations without causing phase separation and consequent formation of sludge or a coke deposit; topping the thermally treated product to produce a distillate fraction and a bottoms fraction; coking the bottom fraction to produce gas, liquid products, and coke; and finally catalytically cracking the combined distillate fraction and liquid products to recover gas, gasoline, and light distillate products.

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Princeton, NJ, United States of America

Lillian A Rankel