Hydrocarbon processing

Claim 2

In a process for preparing premium products from petroleum hydrocarbon feedstock having a substantial Conradson Carbon number and metals content comprising contacting said feedstock in a decarbonizing zone with an inert fluidizable solid material having a micro activity for catalytic cracking not substantially greater than 20 at low severity, including a temperature at least equal to the average boiling point of said feedstock, for a period of time less than that which induces substantial thermal cracking of said feedstock, at the end of said period of time separating from said inert solid a decarbonized hydrocarbon fraction of reduced Conradson Carbon number and metals content as compared with said feedstock, reducing temperature of the said separated fraction to a level below that at which substantial thermal cracking takes place, subjecting said inert solid after contact with said feedstock to air at elevated temperature in a separate burning zone to thereby remove combustible deposit from said solid and heat the solid, and recycling at least a portion of said inert solid from the burning zone to the decarbonizing zone for further decarbonizing of said feedstock, the improvement to inhibit adverse effect of metal deposited on said inert solid material in said decarbonizing zone which comprises mixing a silica donor with said inert fluidizable solid material and subjecting the mixture to an elevated temperature in the presence of water vapor to induce migration of silica from said donor to said inert solid material and mask metal thereon.

Claim 3

The process according to claim 1 wherein said feedstock is a residual fraction of petroleum obtained by fractionally distilling a crude petroleum to separate distillates from the residual fraction thus produced.

Claim 4

The process of claim 1 wherein said burning zone comprises a lower dense phase of inert solid and an upper dilute hot gaseous phase.

Claim 5

The process of claim 1 wherein said inert solid has a B.E.T. surface area below about 100 m 2 /g.

Claim 6

The process of claim 1 wherein said inert solid has a B.E.T. surface area below about 15 m 2 /g.

Claim 7

The process of claim 3 wherein the temperature of said lower dense bed is in the range of about 900° F. to 1300° F. and the temperature in said dilute phase in the range of about 1200° F. to 1600° F.

Claim 8

The process of claim 1 wherein said silica donor is tetraethyl orthosilicate.

Claim 9

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 metals content and charging the distillate gas oil to catalytic cracking; the improvement which comprises; (a) contacting said residual fraction in a rising confined vertical column with an inert solid material having a low surface area and 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, and such that the quantity of such decarbonized petroleum fraction is less than said residual fraction by a weight percent no greater than three times said Conradson Carbon number, (b) at the end of said period of time separating from said inert solid a decarbonized hydrocarbon fraction of reduced Conradson Carbon number and metals content as compared with said residual fraction, (c) reducing temperature of the said separated fraction to a level below that at which substantial thermal cracking takes place, (d) adding said decarbonized hydrocarbon to said distillate gas oil as additional charge to said catalytic cracking, (e) subjecting said inert solid separated from said decarbonized hydrocarbon fraction and now containing a combustible deposit to air at elevated temperature to remove said combustible deposit by burning and thereby heat the inert solid in a burner operated with a lower fluidized dense phase and upper dilute hot vaporous phase, while mixing a silica donor with said inert solid material, (f) reacting the mixture of silica donor and inert solid material in the presence of steam to induce migration of silica from said donor to said inert solid material, (g) separating heated inert solids from hot vapors produced in step (e), (h) cycling at least a portion of said separated hot inert solid from step (g) to step (a), (i) and at least periodically withdrawing metal loaded inert solid from step (e) without cycling it to step (a).

Claim 10

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 metals content and charging the distillate gas oil to catalytic cracking; the improvement which comprises; (a) contacting said residual fraction in a rising confined vertical column with an inert solid material having a low surface area and 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, and such that the quantity of such decarbonized petroleum fraction is less than said residual fraction by a weight percent no greater than three times said Conradson Carbon number, (b) at the end of said period of time separating from said inert solid a decarbonized hydrocarbon fraction of reduced Conradson Carbon number and metals content as compared with said residual fraction, (c) reducing temperature of the said separated fraction to a level below that at which substantial thermal cracking takes place, (d) adding said decarbonized hydrocarbon to said distillate gas oil as additional charge to said catalytic cracking, (e) subjecting said inert solid separated from said decarbonized hydrocarbon fraction and now containing a combustible deposit to air at elevated temperature to remove said combustible deposit by burning and thereby heat the inert solid in a burner operated with a lower fluidized dense phase and upper dilute hot vaporous phase, while mixing a silica donor with said inert solid material, (f) reacting the mixture of silica donor and inert solid material in the presence of steam to induce migration of silica from said donor to said inert solid material, (g) separating heated inert solids from hot vapors produced in step (e), (h) cycling at least a portion of said separated hot inert solid from step (g) to step (a), (i) and at least periodically withdrawing metal loaded inert solid from step (e) without cycling it to step (a).

Claim 11

The process of claim 8 wherein said separated heated inert solids from step (g) are recycled while still hot into contact with further charge of residual fraction in step (a).

Claim 12

The process of claim 8 wherein said inert solid comprises thermally dehydrated clay.

Claim 13

The process of claim 8 wherein the temperature of said lower dense bed is in the range of about 900° F. to 1300° F. and the temperature in said dilute phase in the range of about 1200° F. to 1600° F.

Claim 14

The process of claim 8 wherein said silica donor is tetraethyl orthosilicate.

Claim 15

In a process for upgrading a petroleum charge which contains high boiling components of substantial metal and Conradson Carbon number which comprises contacting said charge with a confined rising vertical column of 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 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 and demetallized hydrocarbon fraction of reduced metal content and 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, the improvement to inhibit adverse effect of metal deposited on said inert solid material which comprises mixing a silica donor with said inert solid material and subjecting the mixture to an elevated temperature in the presence of water vapor to induce migration of silica from said donor to said inert solid material and mask metal thereon.

Claim 16

In a process for upgrading a petroleum charge which contains high boiling components of substantial metal and Conradson Carbon number which comprises contacting said charge with a confined rising vertical column of 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 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 and demetallized hydrocarbon fraction of reduced metal content and 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, the improvement to inhibit adverse effect of metal deposited on said inert solid material which comprises mixing a silica donor with said inert solid material and subjecting the mixture to an elevated temperature in the presence of water vapor to induce migration of silica from said donor to said inert solid material and mask metal thereon.

Claim 17

The process of claim 13 wherein said silica donor is tetraethyl orthosilicate.

Claim 18

The process of claim 1, 8 or 13 wherein said silica donor is mixed with said inert solid material at a rate to provide 0.1% to 10% of silicon dioxide by weight per day based on the total inventory of said inert solid material in the system.

Claim 19

The process of claim 1, 8 or 13 wherein the temperature at the point of said mixing of silica donor with said inert solid material is about 900° F. to about 1500° F.

Claim 20

A process according to claim 1, wherein said silica donor is sodium silicate.

Claim 21

A process according to claim 8, wherein said silica donor is sodium silicate.

Claim 22

A process according to claim 13, wherein said silica donor is sodium silicate.