Ashland Oil, Inc.

Lloyd E Busch

Paul W Walters

George D Myers

Oliver J Zandona

George D Myers, Deceased

H Anthony Raiche

Gerald O Henderson

William M Rice

Bill E McKay, Jr

Charles W Palmeter

Virginia K Myers

A process for upgrading topped crude oils and residual portions comprising material boiling above 552.degree. C. (1025.degree. F.) by the combination of partial demetallizing and decarbonizing of the residual oil before effecting zeolite catalytic cracking thereof is described in conjunction with a product separation process, a combined hydrocarbon gas product concentration section and the use of parallel arranged CO boilers to produce sulfur free flue gas and steam. Steam generated by the combination operation effectively reduces the energy requirement of the combustion process.

Combination process for upgrading residual oils

A process for upgrading residual portions of crude oils comprising metal contaminants and Conradson Carbon contributing components by the combination of thermal visbreaking with fluid inert solids and catalytic upgrading of naphtha and higher boiling components of thermal visbreaking in separate systems of riser conversion and solids regeneration is discussed. Heat management of the regeneration systems is restricted in substantial measure by a novel external solids heat exchange apparatus arrangement utilized to partially cool hot regenerated solids utilized in the solids regeneration systems.

Method and apparatus for cooling fluid solid particles used in a

An apparatus for upgrading residual portions of crude oils comprising metal contaminants and Conradson Carbon contributing components by the combination of thermal visbreaking with fluid inert solids and catalytic upgrading of naphtha and higher boiling components of thermal visbreaking in separate systems of riser conversion and solids regeneration includes an external solids heat exchange apparatus arrangement utilized to partially cool hot regenerated solids utilized in the solids regeneration systems.

The present invention is concerned with the method of regenerating the fluidizable, catalytic, particulate solids in the regenerator section of an FCC process, and RCC process or a metals removal system or 'ART' type process. It is directed to the use of a conduit means for charging fluidizing gaseous material to a vertical cylindrical vessel for cooling fluidizable particulate solids flowing through said vertical cylindrical vessel, which conduit means comprises a horizontal header means having suspended therefrom a plurality of vertical and horizontally spaced apart conduits, each conduit having near its open end a restriction orifice. The header means is located near the top of the cylindrical cooling vessel. One portion of the vertical conduits has lower ends located in the upper half of the vessel and a second portion of the vertical conduits has lower ends located in a lower half of the vessel.

Apparatus for cooling fluid solid particles in a regeneration system

The present invention is concerned with the cooling of the fluidizable particulate solids, either catalytic or inert, in the regenerator section of an FCC process, an RCC process or a metals removal systems or 'ART' type process. It is directed to the use of a conduit means for charging fluidizing gaseous material to a vertical cylindrical vessel for cooling fluidizable particulate solids flowing through said vertical cylindrical vessel, which conduits means comprises a horizontal header means having suspended therefrom a plurality of vertical and horizontally spaced apart conduits, each conduit having near its open end a restriction orifice. The header means can be located near the top of the cylindrical cooling vessel. While the example of a specific embodiment discloses one portion of the vertical conduits with lower ends located in a lower cross-sectional area of the vessel other arrangements sufficient to ensure proper fluidization are also possible.

A combination process is described for upgrading residual oils and high boiling portions thereof comprising metal contaminants and high boiling Conradson carbon forming compounds comprising a thermal visbreaking operation with fluidizable inert solids followed by a fluidized zeolite catalytic cracking operation processing demetallized products of the visbreaking operation, regenerating solid particulate of each operation under conditions to provide CO rich flue gases relied upon to generate steam used in each of the fluidized solids conversion operation and downstream product separation arrangements, separating the wet gas product stream of each operation in a common product recovery arrangement and processing the high boiling feed product of visbreaking comprising up to 100 ppm Ni+V metal contaminant over a recycled crystalline zeolite cracking catalyst distributed in a sorbent matrix material comprising a high level of Ni+V metal contaminant.

Oil upgrading by thermal and catalytic cracking

A process for economically converting carbo-metallic oils to lighter products. The carbo-metallic oils contain 650.degree. F. and material which is characterized by a carbon residue on pyrolysis of at least about 1 and a Nickel Equivalents of heavy metals content of at least about 4 parts per million. This process comprises flowing the carbo-metallic oil together with particulate cracking catalyst through a progressive flow type reactor having an elongated reaction chamber, which is at least in part vertical or inclined, for a predetermined vapor riser residence time in the range of about 0.5 to about 10 seconds, at a temperature of about 900.degree. to about 1400.degree. F., and under a pressure of about 10 to about 50 pounds per square inch absolute sufficient for causing a conversion per pass in the range of about 50% to 90% while producing coke in amounts in the range of about 6 to about 14% by weight based on fresh feed, and laying down coke on the catalyst in amounts in the range of about 0.3 to about 3% by weight. The spent, coke-laden catalyst from the stream of hydrocarbons formed by vaporized feed and resultant cracking products is separated, the sorbed hydrocarbons are stripped from the catalyst particles by contacting them in one or more fluidized beds with hot combustion gases. The stripped catalyst is regenerated in one or more regeneration beds in one or more regeneration zones by burning the coke on the spent catalyst with oxygen. The catalyst particles are retained in the regeneration zone or zones in contact with the combustion-supporting gas for an average total residence time in said zone or zones of about 5 to about 30 minutes to reduce the level of carbon on the catalyst to about 0.25% by weight or less. The regenerated catalyst is recycled to the reactor and contacted with fresh carbo-metallic oil.

Stripping hydrocarbons from catalyst with combustion gases

A process is disclosed for cracking a carbo-metallic oil feed containing 650.degree. F. material which is characterized by a carbon residue on pyrolysis of at least about 1 and by a level of heavy metal(s) of at least about 4.0 ppm by weight of Nickel Equivalents. The process includes contacting the feed with cracking catalyst bearing an accumulation of substantially more than 600 ppm by weight of Nickel Equivalents of heavy metal(s). The resultant stream flows through a progressive flow type reactor for a vapor residence time of about 0.5 to about 10 seconds at conditions sufficient for causing a conversion per pass of about 50% to about 90% while producing coke in amounts of at least about 6% by weight based on fresh feed and laying down coke on the catalyst in amounts of at least about 0.3% by weight based on catalyst. After such contact, catalyst is separated from product vapors, stripped, and thereafter regenerated in at least a first regeneration zone and a second regeneration zone separate from the first regeneration zone. The amount of oxygen-containing gas in the first regeneration zone is sufficient to convert a major portion of the coke on the catalyst to carbon oxides. The amount of oxygen-containing gas in the second regeneration zone is sufficient to reduce the weight of residual coke on the catalyst to about 0.25% or less. The total amount of oxygen-containing gas supplied to all regeneration zones is less than the stoichiometric amount which would be required to burn all of the carbon in the coke to CO.sub.2, to burn all of the hydrogen in the coke to water, and to burn any other combustibles which may be present in the coke to their respective combustion products. After such regeneration, the regenerated catalyst is recycled to the reactor for contact with fresh feed.

Carbo-metallic oil conversion with controlled CO:CO.sub.2 ratio in

Novel riser reactor design with associated multiple feed inlet means for contacting regenerated catalyst particles with low quality naphtha, C.sub.5 minus wet gas product of hydrocarbon conversion and a residual oil feed comprising components boiling above about 1025.degree. F. and comprising metal contaminants. Low quality naphtha from thermal cracking is charged either separately or in admixture with C.sub.5 and lower boiling wet gas product of hydrocarbon conversion to the bottom portion of the riser conversion zone for contact with freshly regenerated zeolite cracking catalyst. The vaporous material thus charged conveys the regenerated catalyst at an acceptable velocity to an expanded section of the riser wherein residual oil is charged by a plurality of nozzle means penetrating the wall of the riser in the transition section to the expander user section. A suspension of hydrocarbon vapors and catalyst particles is then passed through the riser discharge for a desired contact time before separation by ballistic separation with a cup about the riser upper to the riser end.

Method and apparatus for converting oil feeds

Method for recovering sulfur oxides from CO-rich flue gas

A method is disclosed for cracking a carbo-metallic oil feed containing high amounts of coke forming carbonaceous materials as characterized by a Conradson carbon value of more than 1 and containing a level of nickel and/or vanadium of greater than 5 ppm. The method includes contacting the feed with catalyst particles and liquid water containing hydrogen sulfide. At least a portion of the water may be recycled water from prior catalytic cracking of an oil feed containing sulfur.

Carbo-metallic oil conversion with liquid water containing H.sub.2 S

A process for the production of high octane gasoline and/or valuable lower molecular weight products from carbometallic oils comprising contacting hydrogen and a carbometallic feed in a progressive flow reaction zone with hot conversion catalysts capable of activating hydrogen. The hydrogen gas may be introduced into the feed prior to or simultaneous with contacting the feed with catalysts. Alternately, the hydrogen gas may be introduced to the catalysts prior to or simultaneously with its contact with the carbometallic feed.

Carbometallic oil conversion with hydrogen in a riser using a high

The method and means for effecting selective visbreaking of residual oil feeds comprising metallo-organic compounds with a fluid solid sorbent particle material in the presence of process sour water and wet gas recycle material is described to provide a gas oil rich product more suitable for crystalline zeolite fluid catalytic cracking operations.

Demetallizing and decarbonizing heavy residual oil feeds

A method is disclosed for cracking a carbo-metallic oil feed containing high amounts of coke forming carbonaceous materials as characterized by a carbon residue on pyrolysis of at least about 1 and by a level of heavy metal(s) of at least about 5.5 ppm by weight of Nickel Equivalents. The method includes contacting the feed with cracking catalyst bearing an accumulation of at least about 3,000 ppm by weight of Nickel Equivalents of heavy metal(s) and with additional material including water. The resultant stream flows through a progressive flow type reactor for a vapor residence time of about 0.5 to about 6 seconds at conditions sufficient for causing a conversion per pass of about 60% to about 90%. The additional material is added in a weight ratio relative to feed of up to about 0.4 and includes water in a weight ratio relative to feed of at least about 0.04. The water may be introduced as steam and/or liquid water. After such contact, catalyst is separated from product vapors and thereafter regenerated with oxygen-containing gas under conditions sufficient to reduce carbon on catalyst to about 0.25 percent by weight or less while maintaining a CO:CO.sub.2 molar ratio of at least about 0.25 in combustion gases in heat exchange contact with the catalyst.

Carbo-metallic oil conversion with water

A process for economically converting carbo-metallic oils to lighter products. This process comprises flowing the carbo-metallic oil together with particulate cracking catalyst through a progressive flow type reactor having an elongated reaction chamber, which is at least in part vertical or inclined, for a predetermined vapor riser residence time in the range of about 0.5 to about 10 seconds, at a temperature of about 900 to about 1400.degree. F., and under a pressure of about 10 to about 50 pounds per square inch absolute sufficient for causing a conversion per pass in the range of about 50% to about 90% while producing coke in amounts in the range of about 6 to about 14% by weight based on fresh feed, and laying down coke on the catalyst in amounts in the range of about 0.3 to about 3% by weight. The spent, coke-laden catalyst from the stream of hydrocarbons formed by vaporized feed and resultant cracking products is separated and regenerated in one or more regeneration beds in one or more regeneration zones by burning the coke on the spent catalyst with oxygen. The bed density is in the range of about 25 to about 50 pounds per cubic foot and the bed or beds are sustained by fluidization gas containing combustion-supporting gas having a linear velocity in the range of about 0.2 to about 4 feet per second. Liquid water is added to the bed or beds in a weight ratio of water to converter feed from about 0.01 to about 0.5 to at least partly absorb the heat produced by the burning coke.

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Ashland, KY, United States of America

Lloyd E Busch