Upgrading petroleum and residual fractions thereof

Claim 2

In a process for preparing premium products from crude petroleum by fractionally distilling the crude petroleum to separate gasoline and distillate gas oil from a residual fraction having a substantial Conradson Carbon number and charging the distillate gas oil to catalytic cracking; the improvement which comprises contacting said residual fraction in a rising confined vertical column with an inert solid material having a microactivity for catalyst cracking not substantially greater than 20 at low severity, including a temperature of at least about 900° F. for a period of time less than two seconds and less than that which induces substantial thermal cracking of said residual fraction, at the end of said period of time separating from said inert solid a decarbonized residual fraction of reduced Conradson Carbon number as compared with said residual fraction, reducing temperature of the said separated fraction to a level below that at which substantial thermal cracking takes place and adding said decarbonized residual fraction to said distillate gas oil as additional charge to said catalytic cracking.

Claim 3

A process according to claim 1 wherein said severity is at a level such that the quantity of said decarbonized residual fraction is less than said residual fraction by a weight percent no greater than twice said Conradson Carbon number.

Claim 4

A process according to claim 1 wherein said solid is introduced to said rising column at a temperature substantially above the temperature of said residual fraction.

Claim 5

A process according to claim 1 wherein said inert solid is subjected to air at elevated temperature after contact with said residual fraction to thereby remove combustible deposit from said solid by burning and thereby heat the solid.

Claim 6

A process according to claim 4 wherein the temperature of said contacting is provided by returning the heated solid after subjection to air as aforesaid to contact with residual fraction in said contacting.

Claim 7

A process according to claim 4 wherein the catalyst in said catalytic cracking is adapted to sorb oxides of sulfur in an oxidizing atmosphere and release sulfur oxides in a reducing atmosphere and combustion products from said burning are contacted with said catalyst for removal of oxides of sulfur from said combustion products.

Claim 8

A process according to claim 1 wherein said inert solid is calcined clay.

Claim 9

A process according to claim 1 wherein said period of time is less than about 0.5 second.

Claim 10

In a process for preparing premium products from crude petroleum by fractionally distilling the crude petroleum to separate distillates from a residual fraction having a substantial Conradson Carbon number; the improvement which comprises contacting said residual fraction in a rising confined vertical column which an inert solid material having a microactivity for catalytic cracking not substantially greater than 20 at low severity, including a temperature of at least about 900° F. for a period of time less than that which induces substantial thermal cracking of said residual fraction, separating from said contacting a decarbonized residual fraction of reduced Conradson Carbon number as compared with said residual fraction and promptly quenching said separated residual fraction to a temperature below that at which substantial thermal cracking takes place.

Claim 11

In a process for preparing premium products from crude petroleum by fractionally distilling the crude petroleum to separate distillates from a residual fraction having a substantial Conradson Carbon number; the improvement which comprises contacting said residual fraction in a rising confined vertical column which an inert solid material having a microactivity for catalytic cracking not substantially greater than 20 at low severity, including a temperature of at least about 900° F. for a period of time less than that which induces substantial thermal cracking of said residual fraction, separating from said contacting a decarbonized residual fraction of reduced Conradson Carbon number as compared with said residual fraction and promptly quenching said separated residual fraction to a temperature below that at which substantial thermal cracking takes place.

Claim 12

A process according to claim 9 wherein said severity is at a level such that the quantity of said decarbonized residual fraction is less than said residual fraction by a weight percent no greater than twice said Conradson Carbon number.

Claim 13

A process according to claim 9 wherein said solid is introduced to said rising column at a temperature substantially above the temperature of said residual fraction.

Claim 14

A process according to claim 9 wherein said inert solid is subjected to air at elevated temperature after contact with said residual fraction to thereby remove combustible deposit from said solid by burning and thereby heat the solid.

Claim 15

A process according to claim 12 wherein the temperature of said contacting is provided by returning the heated solid after subjection to air as aforesaid to contact with residual fraction in said contacting.

Claim 16

A process according to claim 9 wherein said inert solid is calcined clay.

Claim 17

A process according to claim 9 wherein said period of time is less than about 0.5 second.

Claim 18

A process according to claim 1 or claim 9 wherein said inert solid material is a porous solid having a low surface area below 100 square meters per gram.

Claim 19

A process according to claim 1 or claim 9 wherein said inert solid material is a porous solid having a low surface area between about 10 and about 15 square meters per gram.

Claim 20

A process according to claim 1 or claim 9 wherein said inert solid material is calcined kaolin.

Claim 21

A process according to claim 1 or claim 9 wherein said inert solid material is a porous solid in which most of the pores have diameters of 150 to 600 Angstrom Units.

Claim 22

A process according to claim 1 or claim 9 wherein hydrocarbons, steam or water is added to said residual fraction for contacting with said inert solid material in an amount to substantially decrease hydrocarbon partial pressure.

Claim 23

In a process for preparing premium products from crude petroleum by fractionally distilling the crude petroleum to separate gasoline and distillate gas oil from a residual fraction having a substantial Conradson Carbon number and charging the distillate gas oil to catalytic cracking; the improvement which comprises contacting said residual fraction and a quantity of water or steam to substantially decrease hydrocarbon partial pressure in a rising confined vertical column with an inert solid material having a microactivity for catalytic cracking not substantially greater than 20, a surface area of about 10 to about 15 square meters per gram and pores of which most are in the range of 150 to 600 Angstrom Units at low severity including a temperature of at least about 900° F. for a period of time below 0.5 seconds and less than that which induces substantially thermal cracking of said residual fraction, at the end of said period of time separating from said inert solid a decarbonized residual fraction of reduced Conradson Carbon number as compared with said residual fraction, reducing temperature of the said separated fraction to a level below that at which substantial thermal cracking takes place and adding said decarbonized residual fraction to said distillate gas oil as additional charge to said catalytic cracking.

Claim 24

In a process for preparing premium products from crude petroleum by fractionally distilling the crude petroleum to separate gasoline and distillate gas oil from a residual fraction having a substantial Conradson Carbon number and charging the distillate gas oil to catalytic cracking; the improvement which comprises contacting said residual fraction and a quantity of water or steam to substantially decrease hydrocarbon partial pressure in a rising confined vertical column with an inert solid material having a microactivity for catalytic cracking not substantially greater than 20, a surface area of about 10 to about 15 square meters per gram and pores of which most are in the range of 150 to 600 Angstrom Units at low severity including a temperature of at least about 900° F. for a period of time below 0.5 seconds and less than that which induces substantially thermal cracking of said residual fraction, at the end of said period of time separating from said inert solid a decarbonized residual fraction of reduced Conradson Carbon number as compared with said residual fraction, reducing temperature of the said separated fraction to a level below that at which substantial thermal cracking takes place and adding said decarbonized residual fraction to said distillate gas oil as additional charge to said catalytic cracking.

Claim 25

A process according to claim 21 wherein said inert solid material is calcinated kaolin.

Claim 26

In a process for preparing premium products from crude petroleum having a substantial Conradson Carbon number; the improvement which comprises contacting a charge of said crude or a residual fraction thereof containing the highest boiling components of said crude in a rising confined vertical column with an inert solid material having a microactivity for catalytic cracking not substantially greater than 20 at low severity, including a temperature at least equal to the average boiling point of said charge for a period of time less than two seconds and less than that which induces substantial thermal cracking of said charge, at the end of said period of time separating from said inert solid a decarbonized crude or residual fraction thereof product of reduced Conradson Carbon number as compared with said charge and reducing temperature of the said separated fraction to a level below that at which substantial thermal cracking takes place to thereby terminate said period of time.

Claim 27

In a process for preparing premium products from crude petroleum having a substantial Conradson Carbon number; the improvement which comprises contacting a charge of said crude or a residual fraction thereof containing the highest boiling components of said crude in a rising confined vertical column with an inert solid material having a microactivity for catalytic cracking not substantially greater than 20 at low severity, including a temperature at least equal to the average boiling point of said charge for a period of time less than two seconds and less than that which induces substantial thermal cracking of said charge, at the end of said period of time separating from said inert solid a decarbonized crude or residual fraction thereof product of reduced Conradson Carbon number as compared with said charge and reducing temperature of the said separated fraction to a level below that at which substantial thermal cracking takes place to thereby terminate said period of time.

Claim 28

A process according to claim 23 wherein said severity is at a level such that the quantity of said decarbonized crude or residual fraction thereof is less than said charge fraction by a weight percent no greater than twice said Conradson Carbon number.

Claim 29

A process according to claim 23 wherein said solid is introduced to said rising column at a temperature substantially above the temperature of said charge.

Claim 30

A process according to claim 23 wherein said inert solid is subjected to air at elevated temperature after contact with said charge to thereby remove combustible deposit from said solid by burning and thereby heat the solid.

Claim 31

A process according to claim 26 wherein the temperature of said contacting is provided by returning the heated solid after subjection to air as aforesaid to contact with charge in said contacting.

Claim 32

A process according to claim 23 wherein said inert solid is calcined clay.

Claim 33

A process according to claim 23 wherein said period of time is less than about 0.5 second.

Claim 34

A process according to claim 26 wherein said inert solid is calcined clay.

Claim 35

A process according to claim 23 wherein said inert solid material is a porous solid having a low surface area below 100 square meters per gram.

Claim 36

A process according to claim 23 wherein said inert solid material is a porous solid having a low surface area between about 10 and about 15 square meters per gram.

Claim 37

A process according to claim 23 wherein said inert solid material is calcined kaolin.

Claim 38

A process according to claim 23 wherein said inert solid material is a porous solid in which most of the pores have diameters of 150 to 600 Angstrom Units.

Claim 39

A process according to claim 23 wherein steam or water is added to said charge for contacting with said inert solid material in an amount to substantially decrease hydrocarbon partial pressure.

Claim 40

A process according to claim 1, 9, 21 or 23 wherein a light hydrocarbon boiling below the temperature of said contacting is introduced to said rising confined vertical column to aid in vaporization in said rising confined column.

Claim 41

A process according to claim 36 wherein said light hydrocarbon is separated from the effluent of said contacting and recycled in the process.

Claim 42

A process for upgrading a petroleum charge of a crude oil or a residual fraction which contains high boiling components of substantial Conradson Carbon number which comprises contacting said charge in a confined rising vertical column with a finely divided solid contact material consisting essentially of an inert solid material having a microactivity for catalytic cracking not substantially greater than 20 at low severity, including a temperature of at least about 900° F. for a period of time less than 2 seconds and less than that which induces substantial thermal cracking of said charge, at the end of said period of time separating from said inert solid a decarbonized hydrocarbon fraction of reduced Conradson Carbon number as compared with said charge and reducing temperature of said separated fraction to a level below that at which substantial thermal cracking takes place to terminate said period of time.

Claim 43

A process for upgrading a petroleum charge of a crude oil or a residual fraction which contains high boiling components of substantial Conradson Carbon number which comprises contacting said charge in a confined rising vertical column with a finely divided solid contact material consisting essentially of an inert solid material having a microactivity for catalytic cracking not substantially greater than 20 at low severity, including a temperature of at least about 900° F. for a period of time less than 2 seconds and less than that which induces substantial thermal cracking of said charge, at the end of said period of time separating from said inert solid a decarbonized hydrocarbon fraction of reduced Conradson Carbon number as compared with said charge and reducing temperature of said separated fraction to a level below that at which substantial thermal cracking takes place to terminate said period of time.

Claim 44

A process according to claim 38 wherein steam or water is added to said charge for contacting with said inert solid in an amount to substantially decrease hydrocarbon partial pressure.