Converting and stripping heavy hydrocarbons in two stages of riser conversion with regenerated catalyst

Claim 3

The method of claim 1 wherein the catalyst regeneration operation comprises at least two separate dense fluid beds of catalyst through which the catalyst is sequentially passed countercurrent to combustion supporting regeneration gas.

Claim 4

The process of claim 1 wherein said 650° F.+ material represents at least about 70% by volume of said feed and includes at least about 10% by volume of material which will not boil below about 1000° F.

Claim 5

A process according to claim 1 wherein the carbon residue of the feed encompasses a Conradson carbon value in the range of about 2 to 12.

Claim 6

The process according to claim 1 wherein the feed encompasses at least about 4 parts per million of Nickel Equivalents of heavy metal present in the form of elemental metal(s) and/or metal compound(s), of which at least about 2 parts per million is nickel.

Claim 7

The process of claim 5 wherein the feed comprises recycled gaseous product of fresh feed conversion products.

Claim 8

The process according to claim 1 wherein the catalyst charged to the hydrocarbon conversion zone is a crystalline zeolite containing at least about 15% by weight of catalytic zeolite.

Claim 9

The process according to claim 1 wherein the catalyst charged to the reaction zone comprises a crystalline zeolite catalyst comprising an accumulation of heavy metal(s) on said catalyst derived from conversion of carbo-metallic oil, said accumulation including about 3000 ppm to about 30,000 ppm of Nickel Equivalents of heavy metal(s) by weight, present in the form of elemental metal(s) and/or metal compound(s), as measured on regenerated equilibrium catalyst.

Claim 10

The process according to claim 1 wherein make-up catalyst is added to replace catalyst lost or withdrawn from the system, said make-up catalyst as introduced having a relative activity of at least about 60 percent.

Claim 11

The process of claim 1 wherein the oil feed comprises added gaseous and/or vaporizable material in a weight ratio, relative to feed, in the range of about 0.02 to about 0.4.

Claim 12

The process of claim 1 in which water is brought together with the oil feed at the time of or prior to bringing the feed into contact with the cracking catalyst.

Claim 13

The process of claim 1 wherein the residence time of the feed and product vapors in each reaction zone is about 3 seconds or less.

Claim 14

The process of claim 1 wherein the temperature of said reaction zones is maintained to provide a riser outlet temperature in the range of about 975° F. to about 1200° F.

Claim 15

The process of claim 1 wherein the temperature of said reaction zones is maintained to provide an outlet temperature in the range of about 980° F. to about 1150° F.

Claim 16

The process of claim 1 wherein the oil feed partial pressure in said first reaction zone is maintained in the range of about 3 to about 30 psia.

Claim 17

The process of claim 1 wherein carbonaceous material deposited on the catalyst during initial carbo-metallic oil processing comprises carbonaceous material solids and heavy liquid hydrocarbons.

Claim 18

The process of claim 1 wherein the catalyst obtained from the first reaction zone contains about 10 or more percent of high boiling hydrocarbons.

Claim 19

The process according to claim 1 wherein said regenerated catalyst is present in said mixture introduced into said second reaction zone in an amount from about 1.0 to about 10 times by weight of the spent catalyst.

Claim 20

The process according to claim 1 wherein said regenerated catalyst is present in said mixture introduced into said second reaction zone in an amount from about 2 to about 5 times by weight of the spent catalyst.

Claim 21

The process according to claim 1 wherein the regenerated catalyst brought together with said spent catalyst is at a temperature at least about 200° F. higher than the temperature of said spent catalyst.

Claim 22

The process according to claim 1 wherein the regenerated catalyst brought together with said spent catalyst is at a temperature at least about 250° F. higher than the temperature of said spent catalyst.

Claim 23

The process according to claim 1 wherein the temperature of the regenerated catalyst is at least about 1200° F.

Claim 24

The process according to claim 1 wherein the temperature of the regenerated catalyst is at least about 1300° F.

Claim 25

The process according to claim 1 wherein the residence time in said second reaction zone of the mixture of catalysts is from about 1 to about 20 seconds.

Claim 26

The process according to claim 1 wherein at least one component of said gas employed to cause the mixture of catalysts to move through said second reaction zone is selected from the group consisting of steam, flue gas, nitrogen, hydrogen, carbon dioxide, and methane.

Claim 27

The process according to claim 1 wherein the hydrocarbons separated from the catalyst in the reaction zones are recovered as a combined stream from the reactor.

Claim 28

The process according to claim 1 wherein the MAT relative activity of the regenerated catalyst is at least about 60.

Claim 29

The process according to claim 1 wherein the MAT relative activity of the regenerated catalyst is at least about 50.

Claim 30

The process according to claim 1 wherein said regeneration operation is conducted at a temperature in the range of about 1200° F. to about 1425° F.

Claim 31

The process according to claim 1 wherein the regenerated catalyst particles contain about 0.1% or less by weight of coke.

Claim 32

The process according to claim 1 wherein the regenerated catalyst particles contain about 0.05 or less by weight of coke.

Claim 33

In a process for converting carbo-metallic oils to lighter products including liquid fuel products wherein a residual oil feed containing 650° F.+ material, characterized by a carbon residue on pyrolysis of at least about 1 and containing at least about 4 parts per million of nickel equivalents of heavy metal(s) is contacted with a cracking catalyst to form a suspension thereof passed through a progressive flow elongated riser reaction zone for a predetermined vapor riser residence time in the range of about 0.5 to about 10 seconds at a temperature of from about 900 to about 1400° F. and a pressure of from about 10 to about 50 pounds per square inch absolute and sufficient for obtaining a conversion per pass in the range of from about 50% to about 90% while depositing heavy liquid hydrocarbon and carbonaceous material in the range of from about 6 to about 14% by weight based on fresh feed, the improvement which comprises, (a) separating and recovering spent heavy unvaporized liquid oil laden catalyst from vaporous hydrocarbons following traverse of said elongated reaction zone, (b) passing the recovered liquid hydrocarbon laden catalyst to the bottom portion of a second hydrocarbon conversion--riser stripping zone, (c) mixing hot regenerated catalyst with said spent catalyst passed to said second riser zone and suspending the mixture of hot regenerated and spent liquid laden catalyst in a lift gas to form a suspension thereof for flow through said second riser at an elevated temperature into a separation zone, (d) separating the second riser suspension to recover stripped catalysts from a gaseous stream containing vaporized hydrocarbons and recovering the vaporized hydrocarbons with hydrocarbon products of said elongated reaction zone, (e) passing the recovered and thus stripped catalysts into a second separate downstream stripping zone wherein said catalyst is further contacted with a stripping gas to recover vaporous material therefrom (f) separating the stripped catalyst from stripping gases following contact in said second stripping zone, (g) introducing the stripped catalysts into a regeneration zone for contact with an oxygen-containing, combustion-supporting gas under conditions of time, temperature and atmosphere sufficient to reduce the coke on said catalyst by combustion to at least about 0.25 percent while forming combustion products comprising CO and CO 2 ; and (h) recycling a portion of the resulting regenerated catalyst to each of said riser reaction zones.

Claim 34

In a process for converting carbo-metallic oils to lighter products including liquid fuel products wherein a residual oil feed containing 650° F.+ material, characterized by a carbon residue on pyrolysis of at least about 1 and containing at least about 4 parts per million of nickel equivalents of heavy metal(s) is contacted with a cracking catalyst to form a suspension thereof passed through a progressive flow elongated riser reaction zone for a predetermined vapor riser residence time in the range of about 0.5 to about 10 seconds at a temperature of from about 900 to about 1400° F. and a pressure of from about 10 to about 50 pounds per square inch absolute and sufficient for obtaining a conversion per pass in the range of from about 50% to about 90% while depositing heavy liquid hydrocarbon and carbonaceous material in the range of from about 6 to about 14% by weight based on fresh feed, the improvement which comprises, (a) separating and recovering spent heavy unvaporized liquid oil laden catalyst from vaporous hydrocarbons following traverse of said elongated reaction zone, (b) passing the recovered liquid hydrocarbon laden catalyst to the bottom portion of a second hydrocarbon conversion--riser stripping zone, (c) mixing hot regenerated catalyst with said spent catalyst passed to said second riser zone and suspending the mixture of hot regenerated and spent liquid laden catalyst in a lift gas to form a suspension thereof for flow through said second riser at an elevated temperature into a separation zone, (d) separating the second riser suspension to recover stripped catalysts from a gaseous stream containing vaporized hydrocarbons and recovering the vaporized hydrocarbons with hydrocarbon products of said elongated reaction zone, (e) passing the recovered and thus stripped catalysts into a second separate downstream stripping zone wherein said catalyst is further contacted with a stripping gas to recover vaporous material therefrom (f) separating the stripped catalyst from stripping gases following contact in said second stripping zone, (g) introducing the stripped catalysts into a regeneration zone for contact with an oxygen-containing, combustion-supporting gas under conditions of time, temperature and atmosphere sufficient to reduce the coke on said catalyst by combustion to at least about 0.25 percent while forming combustion products comprising CO and CO 2 ; and (h) recycling a portion of the resulting regenerated catalyst to each of said riser reaction zones.