Supercritical process for producing deasphalted demetallized and deresined oils

Claim 2

A process for producing a low metals content deasphalted oil from a heavy hydrocarbon material comprising: introducing a heavy hydrocarbon material comprising oils, resins, asphaltenes and associated organometallic compounds and a solvent into a first separation zone maintained at a temperature at least equal to the critical temperature of said solvent and a pressure at least equal to the critical pressure of said solvent to effect a separation of said heavy hydrocarbon material and solvent into a first light phase comprising oils, resins, some of the organometallic compounds and solvent and a first heavy phase comprising asphaltenes, organometallic compounds and some solvent; introducing said first light phase into a second separation zone maintained at a temperature level higher than the temperature in said first separation zone and at an elevated pressure to effect a separation of said first light phase into a second light phase comprising oils, entrained resins and organometallic compounds and solvent which collects in an upper portion of said second separation zone and a second heavy phase comprising resins and some solvent; withdrawing at least a portion of said second heavy phase from said second separation zone; recycling at least a portion of said withdrawn second heavy phase into said upper portion of said second separation zone to contact said second light phase and settle through said second light phase to remove at least a portion of the entrained resins and organometallic compounds; and recovering said second light phase comprising solvent and deasphalted oil having a reduced metals content after contact with said recycled second heavy phase.

Claim 3

The process of claim 1 defined further to include the step of: heating said portion of said recycled second heavy phase to a temperature level higher than the average temperature level within the second separation zone prior to introducing said recycled portion into said upper portion of said second separation zone.

Claim 4

The process of claim 1 defined further to include the step of: heating said portion of said recycled second heavy phase prior to introducing said recycled portion into said upper portion of said second separation zone to a temperature level sufficient to cause the formation of an internal reflux zone within said upper portion of said second separation zone upon introduction therein to scrub at least a portion of the entrained resins and organometallic compounds from said second light phase.

Claim 5

The process of claim 1 wherein providing said solvent is defined as: providing a solvent comprising at least one member selected from the group consisting of aromatic hydrocarbons having normal boiling points below 310 degrees F., paraffin hydrocarbons containing from 4 through 9 carbon atoms and mono-olefin hydrocarbons containing from 4 through 8 carbon atoms.

Claim 6

The process of claim 1 wherein said recycling of said second heavy phase into said upper portion of said second separation zone is defined further as: recycling said second heavy phase in an amount by volume of from about 10 percent of the volume of resins contained in said heavy hydrocarbon material to an amount equal to about all of the separated second heavy phase.

Claim 7

The process of claim 1 wherein the second separation zone is maintained at a temperature level above the first temperature level defined further as: maintaining said second separation zone at a temperature level in the range of from about 5 degrees F. to about 100 degrees F. higher than the temperature level in the first separation zone.

Claim 8

The process of claim 1 defined further to include the steps of: introducing said second light phase after contact with said recycled second heavy phase into a third separation zone maintained at an elevated temperature and pressure to effect a separation of said second light phase into a third light phase comprising solvent and third heavy phase comprising deasphalted oils having a reduced metals content; and recovering said deasphalted oils as a product.

Claim 9

The process of claim 7 wherein the third separation zone is maintained at an elevated temperature defined further as: maintaining said third separation zone at a temperature level higher than the temperature level in the second separation zone.

Claim 10

The process of claim 1 wherein the second separation zone is maintained at a temperature level in the range of from about 5 degrees F. to about 50 degrees F. above the critical temperature of the solvent.

Claim 11

The process of claim 1 defined further to include the steps of: flashing said second light phase after contact with said recycled second heavy phase to form at least one stream comprising solvent and one other stream comprising deasphalted oils having a reduced metals content; and recovering said deasphalted oils stream.

Claim 12

A process for producing a low metals content deasphalted oil from a heavy hydrocarbon material comprising: introducing a heavy hydrocarbon material comprising oils, resins, asphaltenes and associated organometallic compounds and a solvent into a first separation zone maintained at a temperature at least equal to the critical temperature of said solvent and a pressure at least equal to the critical pressure of said solvent to effect a separation of said heavy hydrocarbon material and solvent into a first light phase comprising oils, resins, some of the organometallic compounds and solvent and a first heavy phase comprising asphaltenes, organometallic compounds and some solvent; introducing said first light phase into a second separation zone maintained at a temperature level higher than the temperature in said first separation zone and at an elevated pressure to effect a separation of said first light phase into a second light phase comprising oils, entrained resins and organometallic compounds and solvent which collects in an upper portion of said second separation zone and a second heavy phase comprising resins and some solvent; withdrawing at least a portion of said second heavy phase from said second separation zone; recycling at least a portion of said withdrawn second heavy phase into said upper portion of said second separation zone to contact said second light phase to remove at least a portion of the entrained resins and organometallic compounds; introducing said second light phase after contact with said recycled second heavy phase into a third separation zone maintained at a temperature level above the temperature level in said second separation zone and at an elevated pressure to effect a separation of said second light phase into a third light phase comprising solvent and a third heavy phase comprising deasphalted oils having a reduced metals content; and recovering said deasphalted oils as a product.

Claim 13

A process for producing a low metals content deasphalted oil from a heavy hydrocarbon material comprising: introducing a heavy hydrocarbon material comprising oils, resins, asphaltenes and associated organometallic compounds and a solvent into a first separation zone maintained at a temperature at least equal to the critical temperature of said solvent and a pressure at least equal to the critical pressure of said solvent to effect a separation of said heavy hydrocarbon material and solvent into a first light phase comprising oils, resins, some of the organometallic compounds and solvent and a first heavy phase comprising asphaltenes, organometallic compounds and some solvent; introducing said first light phase into a second separation zone maintained at a temperature level higher than the temperature in said first separation zone and at an elevated pressure to effect a separation of said first light phase into a second light phase comprising oils, entrained resins and organometallic compounds and solvent which collects in an upper portion of said second separation zone and a second heavy phase comprising resins and some solvent; withdrawing at least a portion of said second heavy phase from said second separation zone; recycling at least a portion of said withdrawn second heavy phase into said upper portion of said second separation zone to contact said second light phase to remove at least a portion of the entrained resins and organometallic compounds; introducing said second light phase after contact with said recycled second heavy phase into a third separation zone maintained at a temperature level above the temperature level in said second separation zone and at an elevated pressure to effect a separation of said second light phase into a third light phase comprising solvent and a third heavy phase comprising deasphalted oils having a reduced metals content; and recovering said deasphalted oils as a product.

Claim 14

The process of claim 11 defined further to include the step of: heating said portion of said recycled second heavy phase to a temperature level higher than the average temperature level within the second separation zone prior to introducing said recycled portion into said upper portion of said second separation zone.

Claim 15

The process of claim 11 defined further to include the step of: heating said portion of said recycled second heavy phase prior to introducing said recycled portion into said upper portion of said second separation zone to a temperature level sufficient to cause the formation of an internal reflux zone within said upper portion of said second separation zone upon introduction therein to scrub at least a portion of the entrained resins and organometallic compounds from said second light phase.

Claim 16

The process of claim 11 wherein providing said solvent is defined as: providing a solvent comprising at least one member selected from the group consisting of aromatic hydrocarbons having normal boiling points below 310 degrees F., paraffin hyrocarbons containing from 4 through 9 carbon atoms and mono-olefin hydrocarbons containing from 4 through 8 carbon atoms.