Process for vis-breaking asphaltenes

Claim 2

A process comprising: introducing a heavy hydrocarbon material comprising oils, resins, asphaltenes and associated organometallic compounds and a first solvent into a first separation zone maintained at an elevated temperature and pressure level to effect a separation of said heavy hydrocarbon material and first solvent into a first light phase including first solvent and a first heavy phase comprising asphaltenes, organometallic compounds and some first solvent; recovering first solvent from said first light phase in a second separation zone; introducing said first heavy phase into a vis-breaking zone maintained at an elevated temperature and pressure level to crack said asphaltenes in said first heavy phase to produce distillable and substantially nondistillable liquid vis-broken products including organometallic compounds, said pressure level being such that substantially a single condensed phase exists within said vis-breaking zone; introducing said distillable and substantially non-distillable liquid products from said vis-breaking zone into a third separation zone to separate at least a portion of said distillable liquid products from the remainder; introducing said remainder from said third separation zone and a second solvent into a fourth separation zone maintained at an elevated temperature and pressure to effect a separation of said mixture into a fourth light phase comprising nondistillable liquid products substantially free of organometallic compounds, any distillable liquid products present and second solvent and a fourth heavy phase comprising a residue including organometallic compounds and some second solvent; and

Claim 3

The process of claim 1 wherein said first solvent comprises at least one member selected from the group consisting of paraffin hydrocarbons containing from 4 through 9 carbon atoms, cycloparaffin hydrocarbons containing fewer than 10 carbon atoms and mono-olefin hydrocarbons containing from 4 through 8 carbon atoms.

Claim 4

The process of claim 1 wherein said second solvent comprises at least one member selected from the group consisting of paraffin hydrocarbons containing from 4 through 9 carbon atoms, cycloparaffin hydrocarbons containing fewer than 10 carbon atoms and mono-olefin hydrocarbons containing from 4 through 8 carbon atoms.

Claim 5

The process of claim 1 wherein the first separation zone is maintained at an elevated temperature and pressure defined further as: maintaining said first separation zone at a temperature level in the range of from about 150° F. to above the critical temperature of the first solvent and a pressure level at least equal to the vapor pressure of the first solvent at temperatures below the critical temperature of the first solvent and at least equal to the critical pressure of the first solvent at temperatures equal to or above the critical temperature of the first solvent.

Claim 6

The process of claim 1 wherein the fourth separation zone is maintained at an elevated temperature and pressure defined further as: maintaining said fourth separation zone at a temperature level in the range of from about 150° F. to above the critical temperature of the second solvent and a pressure level at least equal to the vapor pressure of the second solvent at temperatures below the critical temperature of the second solvent and at least equal to the critical pressure of the second solvent at temperatures equal to or above the critical temperature of the second solvent.

Claim 7

The process of claim 1 defined further to include the steps of: introducing said fourth light phase into a fifth separation zone maintained at a temperature level above the temperature level of said third separation zone and at an elevated pressure level to effect a separation of said fourth light phase into a fifth light phase comprising second solvent and a fifth heavy phase comprising substantially nondistillable liquid products and any remaining distillable liquid products that were produced in said vis-breaking zone; and recovering said fifth heavy phase.

Claim 8

The process of claim 6 wherein the fifth separation zone is maintained at a temperature level above the temperature level of the fourth separation zone defined further as: maintaining said fifth separation zone at a temperature level in the range of from about 5° F. to about 100° F. higher than the temperature level in said fourth separation zone.

Claim 9

The process of claim 6 wherein the fifth separation zone is maintained at a temperature level above the critical temperature of the second solvent.

Claim 10

The process of claim 1 wherein the first separation zone is maintained at a temperature level above the critical temperature of the first solvent.

Claim 11

The process of claim 1 defined further to include the steps of: flashing said fourth light phase to form at least one stream comprising second solvent and one other stream comprising substantially nondistillable liquid products from said visbreaking zone having a reduced metals content; and recovering said substantially nondistillable liquid products.

Claim 12

The process of claim 1 defined further to include the step of: recovering second solvent from said fourth light phase in a fifth separation zone.

Claim 13

A process comprising: introducing a heavy hydrocarbon material comprising oils, resins, asphaltenes and associated organometallic compounds and a first solvent into a first separation zone maintained at an elevated temperature and pressure level to effect a separation of said heavy hydrocarbon material and first solvent into a first light phase including first solvent and a first heavy phase comprising asphaltenes, organometallic compounds and some first solvent; recovering first solvent from said first light phase in a second separation zone; admixing said first heavy phase with a diluent comprising a hydrocarbon to form a mixture; introducing said mixture into a vis-breaking zone maintained at an elevated temperature and pressure level to crack said asphaltenes in said first heavy phase to produce distillable and substantially nondistillable liquid vis-broken products including said organometallic compounds in association with said diluent, said pressure level within said visbreaking zone being sufficient that substantially a single condensed phase exists within said vis-breaking zone; separating at least a portion of said diluent and distillable liquid products from said substantially nondistillable liquid products; introducing said substantially nondistillable liquid products and a second solvent into a third separation zone maintained at an elevated temperature and pressure level to effect a separation of said same into a third light phase comprising substantially nondistillable liquid products substantially free of organometallic compounds and a second solvent and a third heavy phase comprising a residue including organometallic compounds; and recovering said substantially nondistillable liquid products of said third light phase.

Claim 14

A process comprising: introducing a heavy hydrocarbon material comprising oils, resins, asphaltenes and associated organometallic compounds and a first solvent into a first separation zone maintained at an elevated temperature and pressure level to effect a separation of said heavy hydrocarbon material and first solvent into a first light phase including first solvent and a first heavy phase comprising asphaltenes, organometallic compounds and some first solvent; recovering first solvent from said first light phase in a second separation zone; admixing said first heavy phase with a diluent comprising a hydrocarbon to form a mixture; introducing said mixture into a vis-breaking zone maintained at an elevated temperature and pressure level to crack said asphaltenes in said first heavy phase to produce distillable and substantially nondistillable liquid vis-broken products including said organometallic compounds in association with said diluent, said pressure level within said visbreaking zone being sufficient that substantially a single condensed phase exists within said vis-breaking zone; separating at least a portion of said diluent and distillable liquid products from said substantially nondistillable liquid products; introducing said substantially nondistillable liquid products and a second solvent into a third separation zone maintained at an elevated temperature and pressure level to effect a separation of said same into a third light phase comprising substantially nondistillable liquid products substantially free of organometallic compounds and a second solvent and a third heavy phase comprising a residue including organometallic compounds; and recovering said substantially nondistillable liquid products of said third light phase.

Claim 15

The process of claim 12 wherein said first solvent comprises at least one member selected from the group consisting of paraffin hydrocarbons containing from 4 through 9 carbon atoms, cycloparaffin hydrocarbons containing fewer than 10 carbon atoms and mono-olefin hydrocarbons containing from 4 through 8 carbon atoms.

Claim 16

The process of claim 12 wherein said second solvent comprises at least one member selected from the group consisting of paraffin hydrocarbons containing from 4 through 9 carbon atoms, cycloparaffin hydrocarbons containing fewer than 10 carbon atoms and mono-olefin hydrocarbons containing from 4 through 8 carbon atoms.

Claim 17

The process of claim 12 wherein the first separation zone is maintained at an elevated temperature and pressure level defined further as: maintaining said first separation zone at a temperature level in the range of from about 150° F. to above the critical temperature of the first solvent and a pressure level at least equal to the vapor pressure of the first solvent at temperatures below the critical temperature of the first solvent and at least equal to the critical pressure of the first solvent at temperatures equal to or above the critical temperature of the first solvent.

Claim 18

The process of claim 12 wherein the third separation zone is maintained at an elevated temperature and pressure level defined further as: maintaining said third separation zone at a temperature level in the range of from about 150° F. to above the critical temperature of the second solvent and a pressure level at least equal to the vapor pressure of the second solvent at temperatures below the critical temperature of the second solvent and at least equal to the critical pressure of the second solvent at temperatures equal to or above the critical temperature of the second solvent.

Claim 19

The process of claim 12 in which the first solvent and second solvent are the same.

Claim 20

The process of claim 12 defined further to include the step of: separating at least a portion of said first solvent from said first heavy phase prior to admixing said first heavy phase with said diluent.

Claim 21

The process of claim 12 wherein the temperature level and pressure level of the third separation zone is maintained above the critical temperature and pressure of the second solvent.

Claim 22

The process of claim 12 wherein the diluent consists essentially of a hydrocarbon fraction having a boiling temperature range of from about 400° F. to about 1000° F.

Claim 23

A process comprising: admixing a hydrocarbon material comprising asphaltenes and associated organometallic compounds with a diluent to form a mixture; introducing said mixture into a vis-breaking zone maintained at an elevated temperature and pressure level to crack said asphaltenes in said mixture to produce vis-breaking products comprising distillable and substantially nondistillable liquid vis-broken products including said organometallic compounds in association with said diluent, said pressure level within said vis-breaking zone being sufficient that substantially a single condensed phase exists within said vis-breaking zone; separating at least a portion of said diluent and distillable liquid products from said substantially nondistillable liquid products of said vis-breaking; admixing said substantially nondistillable liquid products with a solvent to form a second mixture; introducing said second mixture into a separation zone maintained at an elevated temperature and pressure level to effect a separation of said second mixture into a light phase comprising substantially nondistillable liquid products substantially free of organometallic compounds and solvent and a heavy phase comprising a residue including said organometallic compounds; and recovering said substantially nondistillable liquid products of said light phase.

Claim 24

A process comprising: admixing a hydrocarbon material comprising asphaltenes and associated organometallic compounds with a diluent to form a mixture; introducing said mixture into a vis-breaking zone maintained at an elevated temperature and pressure level to crack said asphaltenes in said mixture to produce vis-breaking products comprising distillable and substantially nondistillable liquid vis-broken products including said organometallic compounds in association with said diluent, said pressure level within said vis-breaking zone being sufficient that substantially a single condensed phase exists within said vis-breaking zone; separating at least a portion of said diluent and distillable liquid products from said substantially nondistillable liquid products of said vis-breaking; admixing said substantially nondistillable liquid products with a solvent to form a second mixture; introducing said second mixture into a separation zone maintained at an elevated temperature and pressure level to effect a separation of said second mixture into a light phase comprising substantially nondistillable liquid products substantially free of organometallic compounds and solvent and a heavy phase comprising a residue including said organometallic compounds; and recovering said substantially nondistillable liquid products of said light phase.

Claim 25

The process of claim 21 wherein said diluent consists essentially of a hydrocarbon fraction having a boiling temperature range of from about 400° F. to about 1000° F.

Claim 26

The process of claim 21 wherein said solvent comprises at least one member selected from the group consisting of paraffin hydrocarbons containing from 4 through 9 carbon atoms, cycloparaffin hydrocarbons containing fewer than 10carbon atoms and mono-olefin hydrocarbons containing from 4 through 8 carbon atoms.

Claim 27

The process of claim 21 wherein the elevated temperature level and pressure level of said separation zone is defined further as a temperature level in the range of from about 150° F. to above the critical temperature of the solvent and a pressure level at least equal to the vapor pressure of the solvent at temperatures below the critical temperature of the solvent and at least equal to the critical pressure of the solvent at temperatures equal to or above the critical temperature of the solvent.

Claim 28

The process of claim 21 wherein separating at least a portion of said diluent and distillable liquid products from said substantially nondistillable liquid products and residue of said vis-breaking products is effected by flashing said vis-breaking products to a sufficiently low pressure level to produce at least one overhead stream comprising at least a portion of said diluent and distillable liquid products and one other stream comprising said substantially nondistillable liquid products.