Recovery of metal values from petroleum residua and other fractions

Claim 2

A process for heavy hydrocarbon oil demetallation and metals recovery which comprises: (a) heating an admixture of 70 to 95 wt % heavy hydrocarbon oil containing at least one metal selected from the group consisting of vanadium and nickel and 5 to 30 wt % particulate coal under visbreaking conditions to produce a visbroken liquid with a reduced metals content containing solids; and (b) recovering from the visbroken liquid an oil fraction with reduced metal content and a solids fraction containing at least about 30% of the metal in said heavy hydrocarbon oil.

Claim 3

The process of claim 1 wherein said admixture contains 75 to 85 wt % heavy hydrocarbon oil and 15 to 25 wt % coal.

Claim 4

The process of claim 1 wherein said visbroken liquid is separated into an oil fraction and a solids fraction by charging the visbroken liquid containing solids to a hot settler maintained at about 30° to 300° C. for a time sufficient to allow a majority of the particulate matter in said stream to settle.

Claim 5

The process of claim 1 wherein said solids fraction is oxidized with an oxygen containing gas to form a metal rich synthetic ore.

Claim 6

The process of claim 1 wherein said solids fraction is contacted with steam to remove steam strippable oil components from said solid fraction.

Claim 7

The process of claim 1 wherein said solids fraction is contacted with a solvent to remove solvent strippable oil components therefrom.

Claim 8

The process of claim 1 wherein said solids fraction is subjected to flotation separation to provide an organic solids float phase and an inorganic sink phase, and said sink phase is burned to form a metal rich synthetic ore containing a majority of the metals removed from the oil and substantially free from organic matter.

Claim 9

The process of claim 1 wherein the heavy hydrocarbon oil feedstock is a distillation residuum of crude oil.

Claim 10

The process of claim 1 wherein the particulate coal is finely divided bituminous coal.

Claim 11

The process of claim 1 wherein said admixture contains about 80 wt % heavy hydrocarbon oil and about 20 wt % coal.

Claim 12

The process of claim 1 in which said solid fraction is burned at a temperature below the fusion point of said coal.

Claim 13

The process of claim 1 wherein said solids fraction is burned in a fluidized bed.

Claim 14

The process of claim 11 wherein Na 2 CO 3 is added to said combustion zone.

Claim 15

A process for demetallation of heavy hydrocarbon oil containing at least 50 ppm of metals selected from the group comprising vanadium and nickel, which process comprises (a) heating an admixture of 75 to 85 wt % of said oil and 15 to 25 wt % particulate coal in a visbreaking reactor under visbreaking conditions which include a temperature of 800° to 950° F. and a weight hourly space velocity of about 1 to 100, and wherein said temperature and space velocity are sufficient to substantially reduce the viscosity of said oil while preventing coking of said feed to produce a visbroken liquid with a reduced viscosity and a reduced metals content but containing coal solids; (b) recovering from said visbroken liquid an oil fraction with a reduced metals content and a solids fraction containing at least about 30 percent of the metal in said oil feed, and wherein at least a majority of the metals removed from said oil are recovered on said solids; (c) oxidizing said solids fraction to form a metal rich synthetic ore.

Claim 16

A process for demetallation of heavy hydrocarbon oil containing at least 50 ppm of metals selected from the group comprising vanadium and nickel, which process comprises (a) heating an admixture of 75 to 85 wt % of said oil and 15 to 25 wt % particulate coal in a visbreaking reactor under visbreaking conditions which include a temperature of 800° to 950° F. and a weight hourly space velocity of about 1 to 100, and wherein said temperature and space velocity are sufficient to substantially reduce the viscosity of said oil while preventing coking of said feed to produce a visbroken liquid with a reduced viscosity and a reduced metals content but containing coal solids; (b) recovering from said visbroken liquid an oil fraction with a reduced metals content and a solids fraction containing at least about 30 percent of the metal in said oil feed, and wherein at least a majority of the metals removed from said oil are recovered on said solids; (c) oxidizing said solids fraction to form a metal rich synthetic ore.

Claim 17

The process of claim 14 wherein said visbroken liquid is separated into an oil fraction and a solids fraction by charging the visbroken liquid containing solids to a hot settler maintained at about 30° to 300° C. for a time sufficient to allow a majority of the particulate matter in said stream to settle.

Claim 18

The process of claim 14 wherein said solids fraction is oxidized in a fluidized bed, at a temperature below the fusion point of said solids, with an oxygen containing gas to form a metal rich synthetic ore.

Claim 19

The process of claim 14 wherein said solids fraction is contacted with steam or a solvent to remove strippable oil components therefrom.

Claim 20

The process of claim 14 wherein said admixture contains about 80 wt % heavy hydrocarbon oil which is a distillation residuum of crude oil, and about 20 wt % finely divided bituminous coal.