Integrated two stage coking and steam cracking process and apparatus therefor

Claim 2

In an integrated two stage coking and steam cracking process for the production of products including low molecular weight unsaturated hydrocarbons in which (a) a carbonaceous material is reacted in a reactor in a first stage coking zone containing a bed of fluidized solids wherein steam is present maintained at fluid coking conditions including a temperature in the range of about 950° F. to about 1150° F. to form a vaporous coking zone conversion product and coke, said coke depositing on said fluidized solids; (b) said vaporous coking zone conversion product is passed with entrained solids into a dilute phase to a second stage reaction zone; (c) hot solids at a sufficient temperature and in sufficient amount are introduced into said conversion product entering said second stage reaction zone to raise the conversion product to steam cracking temperatures within the range of 1200° F. to 1700° F. and supply the endothermic heat of reaction; and (d) solids are separated from product gas in a gas-solids separation zone, separated solids are passed to the coking zone and separated gas is quenched, the improvement which comprises: (e) introducing relatively low temperature steam into contact with said separated solids before they enter the coking zone to superheat the steam and cool the solids, discharging the resulting mixture into the dilute phase wherein the cooled solids are passed into the coking zone.

Claim 3

The process according to claim 1 in which the gas-solids separation zone comprises at least one cyclone and the relatively low temperature steam is contacted with separated solids passing from the cyclone dipleg.

Claim 4

The process according to claim 1 in which the temperature of the hot solids introduced into the conversion product entering the second stage reaction zone is in the range of 1600° to 1800° F.

Claim 5

The process according to claim 1 in which the coking zone conversion product is steam cracked at temperatures within the range of about 1300° to 1500° F.

Claim 6

The process according to claim 1 in which the temperature in the coking zone is in the range of about 950° to about 1050° F.

Claim 7

The process according to claim 1 in which the carbonaceous material is a vacuum residuum.

Claim 8

In an integrated, two stage coking and steam cracking process for the production of products including low molecular weight unsaturated hydrocarbons in which (a) a carbonaceous material is reacted in a reactor in a first stage coking zone containing a bed of fluidized solids wherein steam is present maintained at fluid coking conditions including a temperature in the range of about 950° to about 1100° F. to form a vaporous coking zone conversion product and coke, said coke depositing on said fluidized solids; (b) a portion of said solids with the coke deposition thereon is introduced into a heating zone maintained at a temperature of from about 1050° to about 1150° F.; (c) a portion of solids from said heating zone is introduced into a fluid bed gasification zone maintained at a temperature in the range of about 1600° to about 1800° F.; (d) said vaporous coking zone conversion product is passed with entrained solids into a dilute phase to a second stage reaction zone; (e) a portion of hot solids is withdrawn from the gasification zone; (f) said hot solids are brought into contact with said vaporous conversion product entering said second stage reaction zone to raise said conversion product to steam cracking temperatures within the range of about 1300° to 1500° F., solids are separated from product gas in a gas-solids separation zone, separated solids are passed to the coking zone and separated gas is quenched, the improvement which comprises: (g) introducing relatively low temperature steam into contact with said separated solids before they enter the coking zone to superheat the steam and cool the solids, discharging the resulting mixture into the dilute phase wherein the cooled solids are passed into the coking zone.

Claim 9

In an integrated, two stage coking and steam cracking process for the production of products including low molecular weight unsaturated hydrocarbons in which (a) a carbonaceous material is reacted in a reactor in a first stage coking zone containing a bed of fluidized solids wherein steam is present maintained at fluid coking conditions including a temperature in the range of about 950° to about 1100° F. to form a vaporous coking zone conversion product and coke, said coke depositing on said fluidized solids; (b) a portion of said solids with the coke deposition thereon is introduced into a heating zone maintained at a temperature of from about 1050° to about 1150° F.; (c) a portion of solids from said heating zone is introduced into a fluid bed gasification zone maintained at a temperature in the range of about 1600° to about 1800° F.; (d) said vaporous coking zone conversion product is passed with entrained solids into a dilute phase to a second stage reaction zone; (e) a portion of hot solids is withdrawn from the gasification zone; (f) said hot solids are brought into contact with said vaporous conversion product entering said second stage reaction zone to raise said conversion product to steam cracking temperatures within the range of about 1300° to 1500° F., solids are separated from product gas in a gas-solids separation zone, separated solids are passed to the coking zone and separated gas is quenched, the improvement which comprises: (g) introducing relatively low temperature steam into contact with said separated solids before they enter the coking zone to superheat the steam and cool the solids, discharging the resulting mixture into the dilute phase wherein the cooled solids are passed into the coking zone.

Claim 10

The process according to claim 1 or 7 in which at least a portion of C 5+ products recovered is recycled either to the coking zone or to the second stage reaction zone.

Claim 11

The process according to claim 1 or 7 in which the gas-solids separation zone comprises at least one cyclone and the contacting of relatively low temperature steam with separated solids is effected in a riser on the cyclone dipleg.