Pretreating hydrocarbon feed stocks using deactivated FCC catalyst

Claim 2

In a process for preparing premium products from petroleum hydrocarbon feedstock having a substantial Conradson Carbon number and metals content which comprises contacting said feed in a decarbonizing zone with a fluidizable solid material having a low microactivity for catalytic cracking at low severity, including a temperature of at least 900° F., 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 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 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 which comprises utilizing as at least a portion of said fluidizable solid so recycled to the decarbonizing zone particles of equilibrium fluid cracking catalyst that have previously been treated by addition of a sintering agent followed by heating to sinter said particles, in order to reduce catalyst cracking activity and surface area without substantially increasing coke and hydrogen forming properties.

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 according to claim 1 wherein said feedstock is a residual fraction of petroleum obtained as the atmospheric bottoms product of conventional atmospheric distillation.

Claim 5

The process of claim 1 wherein equilibrium catalyst has a BET surface area below 100 m 2 /g after being treated to reduce activity and surface area.

Claim 6

The process according to claim 1 wherein said particles of equilibrium catalyst has been treated by addition of at least one sodium compound as sintering agent followed by heating to sinter said particles.

Claim 7

The process of claim 5 wherein said sodium compound is selected from the group consisting of sodium borate, sodium phosphate, sodium hydroxide, sodium nitrate and sodium silicate.

Claim 8

The process of claim 6 wherein said particles are sintered at a temperature in the range of about 1200° F. to 2000° F.

Claim 9

The process according to claim 7 wherein said particles are sintered in the presence of steam in said burning zone.

Claim 10

The process of claim 5 wherein said equilibrium catalyst containing said added sodium compound is introduced into said burning zone and said burning zone includes a steam atmosphere and is at a temperature above 1200° F., whereby said equilibrium catalyst containing said sodium compound is treated to reduce activity and surface area in said burning zone.

Claim 11

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 in a cyclic fluid catalytic cracking unit using a fluid zeolitic cracking catalyst and withdrawing equilibrium cracking catalyst, which process comprises; (a) contacting said residual fraction in a rising confined vertical column with an inert solid material having a low surface area and a low microactivity for catalytic cracking 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, (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 containig a combustible deposit to air at elevated temperature in a burner to remove said combustible deposit, and thereby heat the inert solid, (f) separating heated inert solids from hot vapors produced in step (e), (g) cycling at least a portion of said separated hot inert solid from steps (e) to (a); and, (h) at least periodically withdrawing metal loaded inert solid from step (e) without cycling it to step (a); the improvement which comprises: (i) adding at least one sintering agent to at least a portion of said withdrawn equilibrium catalyst, (j) heating the product of step (i) at a temperature and for a time sufficient to reduce microactivity below about 20 and surface area below about 50 m 2 /g; and, (k) introducing at least a portion of the product of step (j) to said rising column in step (a) for cycling to steps (b), (c), (e) and (g).

Claim 12

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 in a cyclic fluid catalytic cracking unit using a fluid zeolitic cracking catalyst and withdrawing equilibrium cracking catalyst, which process comprises; (a) contacting said residual fraction in a rising confined vertical column with an inert solid material having a low surface area and a low microactivity for catalytic cracking 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, (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 containig a combustible deposit to air at elevated temperature in a burner to remove said combustible deposit, and thereby heat the inert solid, (f) separating heated inert solids from hot vapors produced in step (e), (g) cycling at least a portion of said separated hot inert solid from steps (e) to (a); and, (h) at least periodically withdrawing metal loaded inert solid from step (e) without cycling it to step (a); the improvement which comprises: (i) adding at least one sintering agent to at least a portion of said withdrawn equilibrium catalyst, (j) heating the product of step (i) at a temperature and for a time sufficient to reduce microactivity below about 20 and surface area below about 50 m 2 /g; and, (k) introducing at least a portion of the product of step (j) to said rising column in step (a) for cycling to steps (b), (c), (e) and (g).

Claim 13

The process of claim 10 wherein said sintering agent is a sodium compound.

Claim 14

The process of claim 11 wherein said sintering agent is selected from the group consisting of sodium borate, sodium phosphate, sodium hydroxide, sodium nitrate and sodium silicate.

Claim 15

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 in the presence of a zeolitic cracking catalyst by; (a) contacting said residual fraction in a rising confined vertical column with fluidizable particles which are catalytically inert or substantially so under conditions of elevated temperature and short contact time such as to avoid substantial thermal cracking of said residual fraction and selectivity vaporize hydrocarbons and deposit hydrocarbons contributing to Conradson Carbon number on said fluidizable particles, (b) at the end of said period of time separating from said particles of inert material now having a deposit of hydrocarbon and metals from a decarbonized hydrocarbon fraction of reduced Conradson Carbon number as compared with said residual fraction, (c) reducing temperature of the separated hydrocarbon 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) burning combustibles from said particles of said inert material in a burner operated with lower dense phase comprising said particles and a hot upper gaseous phase include water vapor to remove said combustible deposit and thereby heat the inert solid, (f) separating hot gases from the burning of combustibles from hot inert solids in said burner, and (g) recycling at least a portion of said hot inert solids into contact with further charge of said residual fraction, (h) regenerating zeolitic cracking catalyst from catalytic cracking of distillate gas oil in a regenerator separate from the burner used in step (e), and; (i) periodically withdrawing equilibrium cracking catalyst from said regenerator used in step (h) in order to maintain desired catalytic cracking activity and selectivity of said circulating inventory of cracking catalyst, the improvement which comprises: (j) applying a sintering agent to at least a portion of said withdrawn equilibrium cracking catalyst, and heating said catalyst with added sintering agent to reduce catalytic activity and surface area, and cycling the resulting material into contact with further change of said residual fraction in step (a).

Claim 16

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 in the presence of a zeolitic cracking catalyst by; (a) contacting said residual fraction in a rising confined vertical column with fluidizable particles which are catalytically inert or substantially so under conditions of elevated temperature and short contact time such as to avoid substantial thermal cracking of said residual fraction and selectivity vaporize hydrocarbons and deposit hydrocarbons contributing to Conradson Carbon number on said fluidizable particles, (b) at the end of said period of time separating from said particles of inert material now having a deposit of hydrocarbon and metals from a decarbonized hydrocarbon fraction of reduced Conradson Carbon number as compared with said residual fraction, (c) reducing temperature of the separated hydrocarbon 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) burning combustibles from said particles of said inert material in a burner operated with lower dense phase comprising said particles and a hot upper gaseous phase include water vapor to remove said combustible deposit and thereby heat the inert solid, (f) separating hot gases from the burning of combustibles from hot inert solids in said burner, and (g) recycling at least a portion of said hot inert solids into contact with further charge of said residual fraction, (h) regenerating zeolitic cracking catalyst from catalytic cracking of distillate gas oil in a regenerator separate from the burner used in step (e), and; (i) periodically withdrawing equilibrium cracking catalyst from said regenerator used in step (h) in order to maintain desired catalytic cracking activity and selectivity of said circulating inventory of cracking catalyst, the improvement which comprises: (j) applying a sintering agent to at least a portion of said withdrawn equilibrium cracking catalyst, and heating said catalyst with added sintering agent to reduce catalytic activity and surface area, and cycling the resulting material into contact with further change of said residual fraction in step (a).

Claim 17

The process of any one of claims 1, 10 or 13, wherein said sintering agent is an alkali or alkaline earth metal compound.

Claim 18

The process of any one of claims 1, 10 or 13, wherein said sintering agent is employed in an amount between about 1% to about 20% by weight relative to said equilibrium catalyst.