Combination process for upgrading reduced crude

Claim 2

In a reduced crude conversion process for heavy oil feeds having Conradson carbon numbers above 2, which process comprises contacting such heavy oil feeds with catalysts to form products comprising lower molecular weight hydrocarbons and coke on catalyst, said coke containing minor amounts of hydrogen and thereafter regenerating said catalyst by removing at least a portion of said coke; the improvement which comprises: (a) converting said heavy oil feed in a progressive flow riser conversion zone in the presence of water condensation product separated from hydrocarbon products of said conversion operation and regenerating said catalyst in the presence of steam and C0 2 and gas containing substantial amounts of oxygen so as to produce a CO-rich flue gas, (b) recovering hydrogen produced from said hydrocarbon conversion operation, separately from the hydrocarbon products of said hydrocarbon conversion operation, and (c) subjecting said hydrogen to purification and removing sulfur from said CO-rich flue gas, then combining said hydrogen and said flue gas to produce a fuel gas or a synthesis gas suitable for production of methane, methanol or suitable as a feedstock for Fischer-Tropsch synthesis or high octane gasoline.

Claim 3

In a catalytic cracking process for heavy oil feeds containing relatively high amounts of Conradson- carbon-contributing materials comprising contacting such heavy oil feeds with a catalyst to form products comprising lower molecular weight hydrocarbons and coke on catalyst, said coke containing minor amounts of hydrogen and thereafter regenerating said catalyst by removing at least a portion of said coke; the improvement which comprises: (a) converting said heavy oil feed in a progressive flow riser conversion zone in the presence of H 2 0 and in the further presence of a flue gas product from said catalyst regeneration step, said flue gas product comprising primarily CO, minor amounts of C0 2 and excess steam from said regeneration operation, regenerating said catalyst in the presence of steam and C0 2 and gas containing substantial amounts of oxygen, (b) recovering a C- 2 product of said hydrocarbon conversion operation separate from higher boiling hydrocarbon products of said hydrocarbon conversion operation said higher boiling hydrocarbon products comprising hydrogen and CO, and (c) subjecting at least a part of said C- 2 product to water gas shift reaction to produce hydrogen and C0 2'

Claim 4

In a catalytic cracking process for heavy oil feeds containing relatively high amounts of Conradson- carbon-contributing materials comprising contacting such heavy oil feeds with a catalyst to form products comprising lower molecular weight hydrocarbons and coke on catalyst, said coke containing minor amounts of hydrogen and thereafter regenerating said catalyst by removing at least a portion of said coke; the improvement which comprises: (a) converting said heavy oil feed in a progressive flow riser conversion zone in the presence of H 2 0 and in the further presence of a flue gas product from said catalyst regeneration step, said flue gas product comprising primarily CO, minor amounts of C0 2 and excess steam from said regeneration operation, regenerating said catalyst in the presence of steam and C0 2 and gas containing substantial amounts of oxygen, (b) recovering a C- 2 product of said hydrocarbon conversion operation separate from higher boiling hydrocarbon products of said hydrocarbon conversion operation said higher boiling hydrocarbon products comprising hydrogen and CO, and (c) subjecting at least a part of said C- 2 product to water gas shift reaction to produce hydrogen and C0 2'

Claim 5

In a process for riser cracking of carbo-metallic oil feeds in the presence of catalyst to produce products comprising lower molecular weight hydrocarbons and catalyst comprising coke with subsequent regeneration of said catalyst by removing said coke at high temperatures in a regeneration zone, the improvement comprising feeding H 2 0 and a gas comprising at least about fifty percent by volume of oxygen whereby the products of said regeneration zone consists essentially of catalysts reduced in coke content, hydrogen content, and carbon monoxide with minor amounts of carbon dioxide, nitrogen and other gases.

Claim 6

In a process for riser cracking of carbo-metallic oil feeds in the presence of catalyst to produce products comprising lower molecular weight hydrocarbons and catalyst comprising coke with subsequent regeneration of said catalyst by removing said coke at high temperatures in a regeneration zone, the improvement comprising feeding H 2 0 and a gas comprising at least about fifty percent by volume of oxygen whereby the products of said regeneration zone consists essentially of catalysts reduced in coke content, hydrogen content, and carbon monoxide with minor amounts of carbon dioxide, nitrogen and other gases.

Claim 7

The process according to Claim 3 wherein said regeneration zone consists of a first regeneration stage and a second regeneration stage and wherein said coke catalyst enters said first stage and is contacted with H 2 0 and minor amounts of oxygen and wherein said temperature is controlled to be just sufficient to support the endothermic removal of coke and wherein said catalyst subsequently enters said second stage of said regeneration zone and in said second stage is contacted with substantial additional quantities of oxygen to produce catalyst substantially reduced in coke and substantial quantities of C0 2 and wherein the products from said first stage, consisting essentially of hydrogen, CO, minor amounts of C0 2 , minor amounts nitrogen and minor amounts of other gases are kept separate from the gaseous products from said second regeneration stage.

Claim 8

In a catalytic process for cracking heavy oil feeds of relatively high Conradson carbon-contributing materials in combination with a catalyst regeneration operation for removing deposited hydrocarbonaceous products of heavy oil feed conversion, the improvement which comprises: (a) converting heavy oil feed in a riser conversion zone in the presence of water condensation product separated from hydrocarbon products of said riser conversion in combination with a flue gas product of catalyst regeneration comprising primarily CO, very little C0 2 and excess steam used in the regeneration operation to achieve endothermic conversion removal of hydrocarbonaceous deposits from the catalyst in the presence of C0 2 and high purity oxygen containing gas, (b) recovering a C 2 minus product of said hydrocarbon conversion operation separate from higher boiling hydrocarbon products comprising hydrogen and CO, subjecting said C 2 minus product of water gas shift reaction to produce hydrogen and C0 2 , and (c) passing the product of said water gas shift reaction to said riser conversion zone.

Claim 9

In a catalytic process for cracking heavy oil feeds of relatively high Conradson carbon-contributing materials in combination with a catalyst regeneration operation for removing deposited hydrocarbonaceous products of heavy oil feed conversion, the improvement which comprises: (a) converting heavy oil feed in a riser conversion zone in the presence of water condensation product separated from hydrocarbon products of said riser conversion in combination with a flue gas product of catalyst regeneration comprising primarily CO, very little C0 2 and excess steam used in the regeneration operation to achieve endothermic conversion removal of hydrocarbonaceous deposits from the catalyst in the presence of C0 2 and high purity oxygen containing gas, (b) recovering a C 2 minus product of said hydrocarbon conversion operation separate from higher boiling hydrocarbon products comprising hydrogen and CO, subjecting said C 2 minus product of water gas shift reaction to produce hydrogen and C0 2 , and (c) passing the product of said water gas shift reaction to said riser conversion zone.

Claim 12

The method of Claim 6 wherein the water condensation product is separated from the product of hydrocarbon conversion comprises absorbed sulfur and nitrogen compounds, and said sulfur and nitrogen compounds are separated from said water condensation product before recycling the water to the riser conversion zone, and wherein the separated light gaseous phase comprising hydrogen and CO is subjected to catalytic methanation and the methane product thereof is used as a fuel support for the process, and wherein the separated light gaseous phase is subjected to water gas shift to increase the hydrogen to CO ratio of the stream before effecting methanation thereof, and wherein catalyst particles comprising carbonaceous deposits separated from hydrocarbon product vapors is subjected to a high temperature stripping operation in admixture with hot freshly regenerated catalyst before subjecting said catalyst mixture to regeneration in the presence of C0 2 rich flue gas comprising steam and oxygen.

Claim 13

The method of Claim 7 wherein the high temperature steam operation is at least 593°C (1100°F) and stripping is accomplished with one of steam, CO 2 , or a mixture thereof, and wherein the catalyst recovered from said second regeneration operation is at a temperature not substantially above about 760°C (1400°F) and is stripped with an inert non-reducing gas to remove high purity absorbed oxygen therefrom before transfer to said riser conversion zone, and wherein the oxygen purity of the regeneration gas stream exceeds that provided by air to reduce the nitrogen content of flue gas obtained in the regeneration operation and the oxygen requirements of the combination regeneration operation is initially charged to the second stage of catalyst regeneration reserved for removing residual carbon from partially regenerated catalyst, and wherein the first stage of regeneration effected with hot flue gases comprising C0 2 , steam and high purity oxygen rely upon a combination of endothermic and exothermic reactions between C0 2 and C, CO and H 2 0, C and H 2 0 and oxygen and carbon to achieve up to 80 weight percent removal of deposited carbonaceous material and produce a CO rich flue gas free of combustion supporting amounts of oxygen.

Claim 16

The method of Claim 9 wherein the separated catalyst phase comprises hydrocarbonaceous deposits and said hydrocarbonaceous deposits are partially removed with a regeneration gas mixture comprising C0 2 , steam and oxygen rich gas to produce a CO rich flue gas product comprising substantial steam in the absence of a combustion supporting amount of oxygen passed to said riser reaction zone, and wherein the separated catalyst phase is stripped at a temperature of at least 593°C (1100°F) in admixture with hot regenerated catalyst particles before passage to the catalyst regeneration operation and wherein the partially regenerated catalyst is further regenerated to provide a high temperature regenerated catalyst of low residual coke in a separate zone with a steam-high purity oxygen containing regeneration gas steam under conditions to produce a C0 2 rich flue gas comprising steam and oxygen, which flue gas is relied upon to effect said partial regeneration of said separated catalyst phase, and wherein the high temperature regenerated catalyst product of said further regeneration is recycled to each of said high temperature stripping operation and said riser reaction zone.