Process for converting heavy petroleum residues to hydrogen and gaseous distillable hydrocarbons

Claim 2

An integrated process for converting heavy petroleum residues to hydrogen and to gaseous and distillable hydrocarbons, comprising: (a) a first step wherein the petroleum residue and hydrogen are simultaneously contacted, for about 0.1-60 seconds with a supported catalyst containing at least one oxide or carbonate of alkali or alkaline-earth metal, obtained in step (b), at a temperature of 530°-800° C., under a pressure of 15-100 bars, to produce hydrocarbons gases and vapors, and coke which deposits on the catalyst, the coked catalyst being separated from said hydrocarbons, (b) a second step wherein the coked catalyst, separated from hydrocarbons in step (a), is contacted with steam, substantially in the absence of molecular oxygen, at a temperature of 600°-800° C., under a pressure of 15-100 bars, for a sufficient time to gasify at least 90% of the deposited coke, to hydrogen, carbon monoxide, carbon dioxide and methane, said catalyst being recycled to step (a).

Claim 3

A process according to claim 1, wherein the pressure is substantially the same in both steps (a) and (b).

Claim 4

A process according to claim 1, wherein the content of alkali and alkaline-earth metals of the catalyst is from 1 to 50% by weight.

Claim 5

A process according to claim 1, wherein the catalyst comprises at least one sodium, potassium or calcium oxide or carbonate and at least one carrier.

Claim 6

A process according to claim 4, wherein the carrier is selected from the group of alumina, titanium oxide, limestone, dolomite, clay and oil coke.

Claim 7

A process according to claim 1, wherein the catalyst comprises at least one potassium, sodium or calcium oxide or carbonate and at least one compound of iron, vanadium or nickel, the metal proportion of the latter compound being from 0.01 to 0.5 atom per atom of potassium, sodium or calcium.

Claim 8

A process according to claim 1, wherein each of steps (a) and (b) is conducted in at least one vertically elongated reaction zone, said zones being arranged in a common enclosure and communicating with each other, step (a) being performed with ascending co-currents of petroleum residue, hydrogen and catalyst, and step (b) with an ascending current of steam and a descending current of catalyst; hydrogen, petroleum residue and steam being introduced at the bottom of their respective reaction zones and the products withdrawn from the top of said respective reaction zones.

Claim 9

A process according to claim 1, wherein the catalyst flow rate is 1-15 tons per ton of petroleum residue and the steam amount is 1.5-8 tons per ton of coke introduced with the catalyst in step (b).

Claim 10

A process according to claim 1, wherein the hydrogen flow rate is 200-3000 Nm 3 per ton of petroleum residue in the first step.

Claim 11

A process according to claim 1, wherein the contact time is about 0.5 to 30 seconds.

Claim 12

In a process for converting heavy petroleum residues to hydrogen and to gaseous and distillable hydrocarbons, comprising: (a) a first step wherein the petroleum residue and hydrogen are simultaneously contacted with a supported catalyst containing at least one oxide or carbonate of alkali or alkaline earth metal, obtained in step (b), to produce hydrocarbon gases and vapors, and coke which deposits on the catalyst, the coked catalyst being separated from said hydrocarbons, and (b) a second step wherein the coked catalyst, separated from the hydrocarbons in step (a), is contacted with steam, for a sufficient time to gasify at least 90% of the deposited coke, to hydrogen, carbon monoxide, carbon dioxide and methane, said catalyst being recycled to step (a), the improvement comprising conducting step (a) in at least one vertically elongated reaction zone, and conducting step (b) in at least one vertically elongated reaction zone separate from the step (a) reaction zone, all of said zones being arranged in a common enclosure and each zone of step (a) communicating with at least one zone of step (b), step (a) being performed with ascending co-currents of petroleum residue, hydrogen and catalyst and step (b) with an ascending current of steam and a descending current of catalyst; hydrogen, and petroleum residue being introduced at the bottom of each vertically elongated reaction zone of step (a) and steam being introduced at the bottom of each vertically elongated reaction zone of step (b), and resulting reaction products being withdrawn from the top of each zone, said improvement further comprising contacting the catalyst, petroleum residue and hydrogen in step (a) for about 0.1 to about 60 seconds and conducting step (b) substantially in the absence of molecular oxygen.

Claim 13

In a process for converting heavy petroleum residues to hydrogen and to gaseous and distillable hydrocarbons, comprising: (a) a first step wherein the petroleum residue and hydrogen are simultaneously contacted with a supported catalyst containing at least one oxide or carbonate of alkali or alkaline earth metal, obtained in step (b), to produce hydrocarbon gases and vapors, and coke which deposits on the catalyst, the coked catalyst being separated from said hydrocarbons, and (b) a second step wherein the coked catalyst, separated from the hydrocarbons in step (a), is contacted with steam, for a sufficient time to gasify at least 90% of the deposited coke, to hydrogen, carbon monoxide, carbon dioxide and methane, said catalyst being recycled to step (a), the improvement comprising conducting step (a) in at least one vertically elongated reaction zone, and conducting step (b) in at least one vertically elongated reaction zone separate from the step (a) reaction zone, all of said zones being arranged in a common enclosure and each zone of step (a) communicating with at least one zone of step (b), step (a) being performed with ascending co-currents of petroleum residue, hydrogen and catalyst and step (b) with an ascending current of steam and a descending current of catalyst; hydrogen, and petroleum residue being introduced at the bottom of each vertically elongated reaction zone of step (a) and steam being introduced at the bottom of each vertically elongated reaction zone of step (b), and resulting reaction products being withdrawn from the top of each zone, said improvement further comprising contacting the catalyst, petroleum residue and hydrogen in step (a) for about 0.1 to about 60 seconds and conducting step (b) substantially in the absence of molecular oxygen.

Claim 14

A process according to claim 11, wherein said vertically elongated reaction zones are arranged concentrically about a vertical axis such that the zones comprise an inner zone and an outer zone, said outer zone completely surrounding said inner zone.

Claim 15

A process according to claim 12, wherein step (a) takes place essentially in said inner zone, and step (b) takes place essentially in said outer zone, and wherein a single catalyst bed is present in the common enclosure.