Two-stage process for the conversion of liquid hydrocarbon to a methane rich gas stream

Claim 2

A PROCESS FOR PRODUCING A METHANE-RICH STREAM BY TREATING A HYDROCARBON FEEDSTRE M CON BOND, WHICH COMPRISES A. TREATING SAID FEEDSTREAM IN A FIRST REACTION ZONE MAINTAINED AT A PRESSURE BETWEEN ABOUT 250 AND 1,450*F AND AT A TEMPERATURE BETWEEN ABOUT 1,200* AND 1,450*F IN THE PRESENCE OF PARTICULATE CATALYST COMPOSITION COMPRISING AN ALKALI METAL COMPOUND AND A SOLID PARTICULATE MATERIAL TO PRODUCE A VAPOROUS PRODUCT COMPRISING CH4 AND OTHER LIGHT HYDROCARBON PARDUCTS, AND A SOLID HYDROCARBON MATERIAL WHICH DEPOSITS ON SAID PARTICULATE COMPOSITION; B. REMOVING SAID VAPOROUS PRODUCT FROM SAID FIRST REACTION ZONE; C. PASSING AT LEAST A PORTION OF SAID PARTICULATE CATALYST COMPOSITION WITH THE SOLID HYDROCARBON MATERIAL DEPOSITION TO A SECOND REACTION ZONE MAINTAINED AT A PRESSURE BETWEEN ABOUT 250 AND 1,500 PSIG AND AT A TEMPERATURE

Claim 3

The process of claim 1, wherein an oxygen-containing gas is introduced into said second reaction zone.

Claim 4

The process of claim 1, wherein steam is introduced into said first reaction zone.

Claim 5

The process of claim 1, wherein said catalyst composition comprises K2CO3 or Cs2CO3 deposited on said solid particulate material.

Claim 6

The process of claim 1, wherein said catalyst composition comprises K2CO3 or Cs2CO3 mixed with said solid particulate material.

Claim 7

The process of claim 1, wherein said solid particulate material is selected from the group consisting of alumina, silica-alumina, crude or partially purified bauxite or mixtures thereof.

Claim 8

The process of claim 1, wherein carbon is deposited on said solid particulate material.

Claim 9

The process of claim 1, wherein said solid particulate material is activated carbon and said alkali meTal compound is mixed therewith.

Claim 10

The process of claim 1, wherein said feedstream contains at least 10 weight percent liquid hydrocarbons having a boiling point above about 900*F at atmospheric pressure.

Claim 11

The process of claim 1, wherein said alkali metal (calculated as the metal) comprises between 0.5 and 35 weight percent of the solids in said first reaction zone.

Claim 12

The process of claim 1, wherein said feedstream comprises a petroleum residuum.

Claim 13

The process of claim 1, wherein said first and second reaction zones are maintained at pressures between about 400 and 1,000 psig.

Claim 14

The process of claim 1, wherein said second reaction zone is maintained at a temperature between about 1,100* and 1,500*F.

Claim 15

The process of claim 1, wherein said second reaction zone is maintained at a temperature between about 1,200* and 1,450*F.

Claim 16

A process for producing a methane-rich stream by treating a hydrocarbon feedstream containing a liquid hydrocarbon, which comprises: a. treating said feedstream in a first reaction zone maintained at a pressure between about 250 and 1500 psig and at a temperature between about 1,000*F and 1,600*F in the presence of a particulate catalyst composition comprising an alkali metal compound and a solid particulate material to produce a vaporous product comprising CH4 and other light hydrocarbon products, and a solid hydrocarbon material which deposits on said particulate catalyst composition; b. removing said vaporous product from said first reaction zone; c. passing at least a portion of said particulate catalyst composition with the solid hydrocarbon material deposition to a second reaction zone maintained at a pressure between about 250 and 1,500 psig and at a temperature between about 1,000* and 1, 600*F to contact steam introduced into said second reaction zone at a steam-to-carbon in solid hydrocarbon material of the second reaction zone mole ratio between 1 and 10, whereby at least a portion of the solid hydrocarbon material deposition is converted into a gaseous product comprising CH4, H2, CO and CO2; d. removing said gaseous product from the second reaction zone; e. combining the gaseous product of step (d) with the vaporous product of step (b) to produce a combined stream rich in methane content; f. treating the methane-rich stream of step (e) to separate normally gaseous products from normally liquid products; and g. recycling at least a portion of the normally liquid products to said second reaction zone.

Claim 17

A process for producing a methane-rich stream by treating a hydrocarbon feedstream containing a liquid hydrocarbon, which comprises: a. treating said feedstream in a first reaction zone maintained at a pressure between about 250 and 1500 psig and at a temperature between about 1,000*F and 1,600*F in the presence of a particulate catalyst composition comprising an alkali metal compound and a solid particulate material to produce a vaporous product comprising CH4 and other light hydrocarbon products, and a solid hydrocarbon material which deposits on said particulate catalyst composition; b. removing said vaporous product from said first reaction zone; c. passing at least a portion of said particulate catalyst composition with the solid hydrocarbon material deposition to a second reaction zone maintained at a pressure between about 250 and 1,500 psig and at a temperature between about 1,000* and 1, 600*F to contact steam introduced into said second reaction zone at a steam-to-carbon in solid hydrocarbon material of the second reaction zone mole ratio between 1 and 10, whereby at least a portion of the solid hydrocarbon material deposition is converted into a gaseous product comprising CH4, H2, CO and CO2; d. removing said gaseous product from the second reaction zone; e. combining the gaseous product of step (d) with the vaporous product of step (b) to produce a combined stream rich in methane content; f. treating the methane-rich stream of step (e) to separate normally gaseous products from normally liquid products; and g. recycling at least a portion of the normally liquid products to said second reaction zone.

Claim 18

A process for producing a methane-rich stream by treating a hydrocarbon feedstream containing a liquid hydrocarbon, which comprises: a. treating said feedstream in a first reaction zone maintained at a pressure between about 250 and 1,500 psig, and at a temperature between about 1,000* and 1,600*F in the presence of a particulate catalyst composition comprising an alkali metal compound and a solid particulate material to produce a vaporous product comprising CH4 and other light hydrocarbon products, and a solid hydrocarbon material which deposits on such particulate catalyst composition; b. removing said vaporous product from said first reaction zone; c. passing at a portion of said particulate catalyst composition with the solid hydrocarbon material deposition to a second reaction zone maintained at a pressure between about 250 and 1,500 psig and at a temperature between about 1,000*F and 1,600*F to contact steam introduced into said second reaction zone at a steam-to-carbon in solid hydrocarbon material of the second reaction zone mole ratio between 1 and 10, whereby at least a portion of the solid hydrocarbon material deposition is converted into a gaseous product comprising CH4, H2, CO and CO2; d. removing said gaseous product from said second reaction zone; e. treating said vaporous product of step (b) to separate the normally liquid hydrocarbons from the normally gaseous product; and f. recycling at least a portion of said normally liquid hydrocarbons to the second reaction zone.

Claim 19

A process for producing a methane-rich stream by treating a hydrocarbon feedstream containing a liquid hydrocarbon, which comprises: a. treating said feedstream in a first reaction zone maintained at a pressure between about 250 and 1,500 psig, and at a temperature between about 1,000* and 1,600*F in the presence of a particulate catalyst composition comprising an alkali metal compound and a solid particulate material to produce a vaporous product comprising CH4 and other light hydrocarbon products, and a solid hydrocarbon material which deposits on such particulate catalyst composition; b. removing said vaporous product from said first reaction zone; c. passing at a portion of said particulate catalyst composition with the solid hydrocarbon material deposition to a second reaction zone maintained at a pressure between about 250 and 1,500 psig and at a temperature between about 1,000*F and 1,600*F to contact steam introduced into said second reaction zone at a steam-to-carbon in solid hydrocarbon material of the second reaction zone mole ratio between 1 and 10, whereby at least a portion of the solid hydrocarbon material deposition is converted into a gaseous product comprising CH4, H2, CO and CO2; d. removing said gaseous product from said second reaction zone; e. treating said vaporous product of step (b) to separate the normally liquid hydrocarbons from the normally gaseous product; and f. recycling at least a portion of said normally liquid hydrocarbons to the second reaction zone.

Claim 20

A process for producing a methane-rich stream by treating a hydrocarbon feedstream containing a liquid hydrocarbon, which comprises: a. treating such feedstream with an oxygen-containing gas in a first reaction zone maintained at a pressure between about 250 and 1,500 psig, and at a temperature between about 1,000*F and 1,600*F in the presence of a particulate catalyst composition comprising an alkali metal compound and a solid particulate material to produce a vaporous product comprising CH4 and other light hydrocarbon products, and a solid hydrocarbon material which deposits on said particulate catalyst composition; b. removing said vaporous product from said first reaction zone; c. passing at least a portion of said particulate catalyst composition with the solid hydrocarbon material deposition to a second reaction zone maintained at a pressure between about 250 and 1,500 psig and at a temperature between about 1,000*F and 1,600*F to contact steam introduced into said second reaction zone at a steam-to-carbon in solid hydrocarbon material of the second reaction zone mole ratio between 1 and 10, whereby at least a portion of the solid hydrocarbon material deposition is converted into a gaseous product comprising CH4, H2, CO and CO2; and d. removing said gaseous product from said second reaction zone.

Claim 21

A process for producing a methane-rich stream by treating a hydrocarbon feedstream containing a liquid hydrocarbon, which comprises: a. treating such feedstream with an oxygen-containing gas in a first reaction zone maintained at a pressure between about 250 and 1,500 psig, and at a temperature between about 1,000*F and 1,600*F in the presence of a particulate catalyst composition comprising an alkali metal compound and a solid particulate material to produce a vaporous product comprising CH4 and other light hydrocarbon products, and a solid hydrocarbon material which deposits on said particulate catalyst composition; b. removing said vaporous product from said first reaction zone; c. passing at least a portion of said particulate catalyst composition with the solid hydrocarbon material deposition to a second reaction zone maintained at a pressure between about 250 and 1,500 psig and at a temperature between about 1,000*F and 1,600*F to contact steam introduced into said second reaction zone at a steam-to-carbon in solid hydrocarbon material of the second reaction zone mole ratio between 1 and 10, whereby at least a portion of the solid hydrocarbon material deposition is converted into a gaseous product comprising CH4, H2, CO and CO2; and d. removing said gaseous product from said second reaction zone.

Claim 22

A process for producing a methane-rich stream by treating the hydrocarbon feedstream containing a liquid hydrocarbon, which comprises: a. treating said feedstream in a first reaction zone maintained at a pressure between about 250 and 1,500 psig, and at a temperature between about 1,000*F and 1,600*F in the presence of a particulate catalyst composition comprising an alkali metal compound and a solid particulate material to produce a vaporous product comprising CH4 and other light hydrocarbon products, and a solid hydrocarbon material which deposits on said particulate catalyst composition; b. removing said vaporous product from said first reaction zone; c. passing at least a portion of said particulate catalyst composition with the solid hydrocarbon material deposition to a second reaction zone maintained at a pressure between about 250 and 1,500 psig and at a temperature between 1,000*F and 1, 600*F, said first reaction zone being maintained at a higher temperature than said second reaction zone, to contact steam introduced into said second reaction zone at a steam-to-carbon in solid hydrocarbon material of the second reaction zone mole ratio between 1 and 10, whereby at least a portion of the solid hydrocarbon material deposition is converted into a gaseous product comprising CH4, H2, CO and CH2; and d. removing said gaseous product from said second reaction zone.

Claim 23

A process for producing a methane-rich stream by treating the hydrocarbon feedstream containing a liquid hydrocarbon, which comprises: a. treating said feedstream in a first reaction zone maintained at a pressure between about 250 and 1,500 psig, and at a temperature between about 1,000*F and 1,600*F in the presence of a particulate catalyst composition comprising an alkali metal compound and a solid particulate material to produce a vaporous product comprising CH4 and other light hydrocarbon products, and a solid hydrocarbon material which deposits on said particulate catalyst composition; b. removing said vaporous product from said first reaction zone; c. passing at least a portion of said particulate catalyst composition with the solid hydrocarbon material deposition to a second reaction zone maintained at a pressure between about 250 and 1,500 psig and at a temperature between 1,000*F and 1, 600*F, said first reaction zone being maintained at a higher temperature than said second reaction zone, to contact steam introduced into said second reaction zone at a steam-to-carbon in solid hydrocarbon material of the second reaction zone mole ratio between 1 and 10, whereby at least a portion of the solid hydrocarbon material deposition is converted into a gaseous product comprising CH4, H2, CO and CH2; and d. removing said gaseous product from said second reaction zone.

Claim 24

A process for producing a methane-rich stream by treating a hydrocarbon feedstream containing a liquid hydrocarbon, which comprises: a. treating such feedstream in a first reaction zone maintained at a pressure between about 250 and 1,500 psig, and at a temperature between 1,300* and 1,600*F in the presence of a particulate catalyst composition comprising an alkali metal compound and a solid particulate material to produce a vaporous product comprising CH4 and other light hydrocarbon products, and a solid hydrocarbon material which deposits on said particulate catalyst composition; b. removing said vaporous product from said first reaction zOne; c. passing at least a portion of said particulate catalyst composition with the solid hydrocarbon deposition to a second reaction zone maintained at a temperature between 1,100* and 1, 300*F to contact steam introduced into said second reaction zone at a steam-to-carbon in solid hydrocarbon material of the second reaction zone mole ratio between 1 and 10, whereby at least a portion of the solid hydrocarbon material deposition is converted into a gaseous product comprising CH4, H2, CO, and CO2; and d. removing said gaseous product from said second reaction zone.

Claim 25

A process for producing a methane-rich stream by treating a hydrocarbon feedstream containing a liquid hydrocarbon, which comprises: a. treating such feedstream in a first reaction zone maintained at a pressure between about 250 and 1,500 psig, and at a temperature between 1,300* and 1,600*F in the presence of a particulate catalyst composition comprising an alkali metal compound and a solid particulate material to produce a vaporous product comprising CH4 and other light hydrocarbon products, and a solid hydrocarbon material which deposits on said particulate catalyst composition; b. removing said vaporous product from said first reaction zOne; c. passing at least a portion of said particulate catalyst composition with the solid hydrocarbon deposition to a second reaction zone maintained at a temperature between 1,100* and 1, 300*F to contact steam introduced into said second reaction zone at a steam-to-carbon in solid hydrocarbon material of the second reaction zone mole ratio between 1 and 10, whereby at least a portion of the solid hydrocarbon material deposition is converted into a gaseous product comprising CH4, H2, CO, and CO2; and d. removing said gaseous product from said second reaction zone.