US4412914A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Endothermic removal of coke deposited on sorbent materials during carbo-metallic oil conversion
Assignee: Ashland LLC
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Filing: 1981-08-10
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Granted: 1983-11-01
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Expires: 2001-08-10
Abstract
Abstract A process is disclosed for decarbonization-demetallization of a poor quality residual oil feed boiling above about 650° F. and comprising substantial Conradson carbon components to provide a higher grade of oil feed by contacting the poor quality oil feed with sorbent particle material containing one or more metal additives selected to catalyze the endothermic removal of coke with CO 2 . Sorbent decarbonization conditions are selected so that substantial quantities of carbonaceous material and metals are deposited on the sorbent in the decarbonizing zone. Sorbent material with metals and hydrocarbonaceous deposits is regenerated in the presence of an oxygen and carbon dioxide containing gas streams in separate sorbent regeneration zones at a temperature sufficiently elevated to remove residual coke to a desired low level. Regenerated sorbent particle material at an elevated temperature below about 1500° F. is recycled to the poor quality oil feed decarbonizing zone for contact with additional feed. A select metal additive is provided in the sorbent particle material in an amount sufficient to particularly catalyze the endothermic removal of coke in the presence of a carbon dioxide rich gas at a selected sorbent regeneration temperature. A sorbent particle composition suitable for use in the process comprises a kaolin clay containing one or more of the metal additives which may be introduced into the clay during the oil feed decarbonizing process or during sorbent manufacture. Metal additives include water soluble inorganic metal salts and hydrocarbon soluble organo-metallic compounds of a select group of metals.
Inventors
- 👤 William P. Hettinger, Jr.
- 👤 James F. Hoffman
- 👤 Stephen M. Kovach
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-29 18:34
CPC Classifications
C; C10; C10G; C10G29/00; C10G29/04; C10G25/00; C10G25/06; C10G25/12
Claims Analysis
Total Claims: 39
Claim 1
Independent Claim
234 words
In a process combination for preparing premium products from residual oils comprising metal contaminants and Conradson carbon producing components by contact with solid sorbent clay particle material to lay down metal contaminants and Conradson carbon hydrocabonaceous material components on said clay particles from said residual oil before effecting fluid catalytic cracking of a resultant demetallized and decarbonized residual oil product and regenerating the solid sorbent particle material comprising substantial Conradson carbon hydrocarbonaceous material and metal deposits by combusting said hydrocarbonaceous material with an oxygen containing gas, the improvement for limiting and controlling temperatures encountered during combustion of substantial hydrocarbonaceous deposits on said solid particles which comprises: A. initially contacting said solid sorbent clay particle material comprising hydrocarbonaceous material and metal deposits with a quantity of oxygen containing gas under conditions restricting the regeneration temperature within the range of 1350° to 1600° F. during partial removal of deposited hydrocarbonaceous material by combustion and B. removing at a sufficiently high rate greater than 40 weight percent of carbonaceous material deposits from said solid sorbent material with carbon dioxide following said initial oxidation step at temperatures up to 1600° F. while maintaining at least 0.5 weight percent of metal additive elements on said sorbent particles selected from the group comprising one or more of Li, Na, Sr, Re, Fe, Co, Ni, Ru, Rh, Pt, Pd, Os, Ir, Cu, Ag and Au during said contact with carbon dioxide.
Claim 2
Dependent Claim
234 words
In a process combination for preparing premium products from residual oils comprising metal contaminants and Conradson carbon producing components by contact with solid sorbent clay particle material to lay down metal contaminants and Conradson carbon hydrocabonaceous material components on said clay particles from said residual oil before effecting fluid catalytic cracking of a resultant demetallized and decarbonized residual oil product and regenerating the solid sorbent particle material comprising substantial Conradson carbon hydrocarbonaceous material and metal deposits by combusting said hydrocarbonaceous material with an oxygen containing gas, the improvement for limiting and controlling temperatures encountered during combustion of substantial hydrocarbonaceous deposits on said solid particles which comprises: A. initially contacting said solid sorbent clay particle material comprising hydrocarbonaceous material and metal deposits with a quantity of oxygen containing gas under conditions restricting the regeneration temperature within the range of 1350° to 1600° F. during partial removal of deposited hydrocarbonaceous material by combustion and B. removing at a sufficiently high rate greater than 40 weight percent of carbonaceous material deposits from said solid sorbent material with carbon dioxide following said initial oxidation step at temperatures up to 1600° F. while maintaining at least 0.5 weight percent of metal additive elements on said sorbent particles selected from the group comprising one or more of Li, Na, Sr, Re, Fe, Co, Ni, Ru, Rh, Pt, Pd, Os, Ir, Cu, Ag and Au during said contact with carbon dioxide.
Claim 3
Dependent Claim
40 words
The process of claim 1 wherein the endothermic reaction of CO 2 with carbon at a rate sufficient to remove at least 40 weight percent of carbonaceous material is implemented by the presence of Ni plus V in substantial amounts.
Claim 4
Dependent Claim
34 words
The process of claim 1 wherein said metal additive to catalyze the endothermic removal of carbon in the presence of carbon dioxide is deposited on the sorbent from a carbo-metallic containing residual oil feed.
Claim 5
Dependent Claim
45 words
The process of claim 1 wherein said metal element additive to catalyze the endothermic removal of carbon in the presence of carbon dioxide comprises a vanadium immobilization metal additive selected from the group consisting of one or more of Ti, Zr, Mn, In and Bi.
Claim 6
Dependent Claim
41 words
The process of claim 1 wherein said metal additive to catalyze the endothermic removal of carbon in the presence of carbon dioxide comprises one or a combination of metals selected from the group consisting of Fe, Co, Ni, Cu and Mo.
Claim 7
Dependent Claim
24 words
The process of claim 1 wherein said metal additive to catalyze the endothermic removal of carbon in the presence of carbon dioxide comprises copper.
Claim 8
Dependent Claim
44 words
The process of claim 1 wherein said metal additive to catalyze the endothermic removal of carbon in the presence of carbon dioxide is present in the sorbent in the range of about 0.5 to 10 wt%, preferably 1% to 5 wt% of said catalyst.
Claim 9
Dependent Claim
32 words
The process of claim 1 wherein said solid sorbent comprises a hydrated clay and has a surface area below 50 m 2 /g and a pore volume of at least 0.2 cc/g.
Claim 10
Dependent Claim
39 words
The process of claim 1 wherein said solid sorbent material is in spherical form and of a particle size suitable for use as fluid particles in a riser transfer zone, or for use in a moving bed contact zone.
Claim 11
Dependent Claim
30 words
The process of claim 1 wherein said solid sorbent is prepared from clays such as bentonite, kaolin, montmorillonites, smectites, 2-layered lamellar silicates, mullite, pumice, silica, laterite, or pillared interlayered clays.
Claim 12
Dependent Claim
24 words
The process of claim 1 wherein said metal element additive is initially a water soluble inorganic metal salt or a hydrocarbon soluble organo-metallic compound.
Claim 13
Dependent Claim
36 words
The process of claim 1 wherein said metal element additive is added to an aqueous slurry of the ingredients comprising said sorbent and said aqueous slurry containing said additive is spray dried to provide sorbent particles.
Claim 14
Dependent Claim
20 words
The process of claim 1 wherein said metal element additive is added to a spray dried sorbent by impregnation techniques.
Claim 15
Dependent Claim
43 words
The process of claim 1 wherein said metal additive is introduced into said solid sorbent as an aqueous solution of a metal salt or as a hydrocarbon solution of an organometallic compound at any appropriate point in the cycle flow of the sorbent.
Claim 16
Dependent Claim
37 words
The process of claim 1 wherein said metal additive is introduced onto a coked sorbent separated from the decarbonizing zone as an aqueous solution of a metal salt or as a hydrocarbon solution of an organo-metallic compound.
Claim 17
Dependent Claim
43 words
The process of claim 1 wherein said metal element additive is a water soluble organic metal salt selected from the group comprising a halide, a nitrate, a sulfate,, a sulfite or a carbonate or a combination of two or more said said salts.
Claim 18
Dependent Claim
35 words
The process of claim 1 wherein said metal element additive is a hydrocarbon soluble metal compound selected from the group comprising an alcoholate, ester, phenolate, naphthenate, carboxylate or a dienyl sandwich compound, and the like.
Claim 19
Dependent Claim
26 words
The process of claim 1 wherein deactivated sorbent separated from the decarbonizing zone contains from 1 to 3 wt% carbon based on weight of virgin sorbent.
Claim 20
Dependent Claim
40 words
The process of claim 1 wherein the carbonaceous deposits accumulated on said sorbent during processing of carbometallic containing residual oils contains from 2% to 10% hydrogen, and most usually from 3% to 6% hydrogen, by weight of the hydrocarbonaceous deposit.
Claim 21
Dependent Claim
44 words
The process of claim 1 wherein the residual oil feed is a reduced crude portion of a crude oil containing 200 ppm or less of metals consisting of Ni, V, Fe and Cu and having a Conradson carbon value of 6 wt% or more.
Claim 22
Dependent Claim
45 words
The process of claim 1 wherein the residual oil feed is a reduced crude portion of a crude oil containing from 20 to 600 ppm of metals consisting of Ni, V, Fe and Cu and having a Conradson carbon value of 12 wt% or more.
Claim 23
Dependent Claim
55 words
The process of claim 1 wherein the oil feed is a reduced crude portion of a crude oil containing from 50 ppm to 600 ppm of metals consisting of Ni, V, Fe and Cu of which vanadium is in major portion and having a Conradson carbon value in the range of 6 to 24 wt%.
Claim 24
Dependent Claim
69 words
The process of claim 1 wherein the residual oil feed is selected from the group consisting of vacuum gas oil, reduced crude, topped crude, vacuum gas oil containing 0 to 25 wt% of a reduced crude, whole crude oil, a residual oil comprising porphyrins, asphaltenes and polycyclic high molecular with C-H compounds, with and without combination with liquid fractions from coal liquefaction, oil shale retorting and tar sands beneficiation.
Claim 25
Dependent Claim
33 words
The process of claim 1 wherein the hydrocarbonaceous material deposited on the catalyst during carbo-metallic oil processing is in the range of 10 wt% to 28 wt% based on weight of feedstock processed.
Claim 26
Dependent Claim
27 words
The process of claim 1 wherein the oil feed product of sorbent decarbonization and demetallization treatment is thereafter utilized in a zeolite containing fluid catalytic cracking process.
Claim 27
Dependent Claim
39 words
The process of claim 1 wherein a liquid oil product of solid sorbent decarbonization step comprises less than 100 ppm Ni+V and less than 8 wt% Conradson carbon and is utilized as feed in a reduced crude cracking process.
Claim 28
Dependent Claim
30 words
The process of claim 1 wherein the oil product of solid sorbent decarbonization treatment contains from 50 to 100 ppm of Ni+V metals and less than 10 wt% Conradson carbon.
Claim 29
Dependent Claim
31 words
The process of claim 1 wherein the regeneration zone comprises two or more fluidized beds of solid sorbent particle contact material stacked one above the other or in a side-by-side relationship.
Claim 30
Dependent Claim
82 words
The process of claim 1 wherein regeneration of solid sorbent particle material is initially partially effected with an oxygen containing gas in an upflowing sorbent particle contact zone under conditions to restrict the temperatures thereof below about 1600° F. and produce a CO rich flue gas, the partially regenerated sorbent is thereafter contacted with CO 2 to remove residual carbon from the partially regenerated sorbent under catalyzed endothermic reaction conditions and regenerated sorbent is thereafter passed to said hydrocarbon feed contact zone.
Claim 31
Dependent Claim
32 words
The process of claim 1 wherein the regeneration operation comprises two or more sequentially arranged homogenous fluid sorbent particle contact zones with or without a riser contact regeneration zone in combination therewith.
Claim 32
Dependent Claim
28 words
The process of claim 1 wherein a CO reaction product of carbon with CO 2 is passed upwardly through the sorbent being partially regenerated with oxygen containing gas.
Claim 33
Dependent Claim
25 words
The process of claim 1 wherein carbon dioxide used in completing regeneration of sorbent material is a product of combustion of carbonaceous material and CO.
Claim 34
Dependent Claim
25 words
The process of claim 1 wherein the carbon dioxide containing gas is a flue gas substantially freed of CO and obtained from an FCC operation.
Claim 35
Dependent Claim
23 words
The process of claim 1 wherein the carbon dioxide containing gas is a product of the CO rich flue gas of claim 33.
Claim 36
Dependent Claim
25 words
The process of claim 1 wherein the carbon dioxide containing gas is a flue gas product of a CO boiler attached to a regeneration process.
Claim 37
Dependent Claim
26 words
The process of claim 1 wherein the carbon dioxide containing regeneration gas is a flue gas which contains less than combustion supporting amounts of carbon monoxide.
Claim 38
Dependent Claim
37 words
The process of claim 1 wherein a flue gas from said sorbent regeneration operation is processed in a CO boiler to lower the CO content to less than 1 vol% and more usually less than 0.5 vol%.
Claim 39
Dependent Claim
36 words
The process of claim 1 wherein the rate of exothermic combustion with air and the rate of endothermic reaction between carbon and carbon dioxide are balanced to restrict the regeneration temperature not to exceed 1500° F.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1986-10-31 | 1987-05-02 | 1987-11-01 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1990-10-31 | 1991-05-02 | 1991-11-01 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1994-10-31 | 1995-05-02 | 1995-11-01 | $7700.00 | Window Closed / Lapsed |