Partial oxidation of vanadium-containing heavy liquid hydrocarbonaceous and solid carbonaceous fuels

Claim 2

In a partial oxidation process for the production of gaseous mixtures comprising H 2 +CO in the reaction zone of a down flowing gas generator, the improvement comprising: (1) mixing together the following materials to produce a feed mixture (i) a vanadium-containing fuel whose ash includes a minimum of 2.0 weight % of vanadium selected from the group consisting of liquid hydrocarbonaceous fuel, a slurry of solid carbonaceous fuel, and mixtures thereof; (ii) supplemental copper-containing additive; and (iii) at least a portion of the remainder of the copper-containing slag after separation of the coarse slag fraction in (5); (2) reacting by partial oxidation in a refractory-lined free-flow unpacked reaction zone of said gas generator the vanadium-containing feed mixture from (1) with a free-oxygen containing gas in the presence of a temperature moderator and in a reducing atmosphere to produce a hot raw effluent gas stream comprising H 2 +CO along with vanadium-containing molten slag comprising a liquid phase washing agent that collects and transports vanadium-containing laths and spinels and other ash components and refractory out of the reaction zone; (3) passing the hot raw effluent gas stream from (2) down through a coaxial discharge passage in the bottom of the reaction zone of said gas generator and then into a connecting slag separation chamber that is provided with a bottom outlet; depositing a portion of the slag entrained in said hot raw gas stream on the walls of said separation chamber and building up the thickness of said slag on the walls of said chamber until chunks of slag having a diameter in the range of about 1/4 inch to 10 inches and a Cu/V weight ratio which is less than that of the feed mixture in (1) separate from the wall and fall into quench water contained in a quench tank located below the bottom outlet in said separation chamber; (4) passing through said quench tank at least a portion of the hot effluent gas stream leaving said slag separation chamber to produce said gaseous mixture comprising H 2 +CO, and solidifying molten slag and separating out in said quench tank slag and particulate matter that were entrained in said hot raw gas stream; and (5) passing the water and solids from the bottom of said quench tank into a water-solids separation zone; removing a portion of the water from said vessel and recycling said water to the quench tank; and separating a coarse copper-containing slag fraction from the remainder of the slag and recycling said remainder of the slag to (1); wherein said coarse slag fraction has a Cu/V weight ratio which is less than that of the feed mixture in (1).

Claim 3

The process of claim 1 wherein the feed mixture in (1) has a Cu/V weight ratio in the range of about 5.0 to 75, and the coarse slag fraction separated in (5) has a Cu/V weight ratio of about 35% to 70% less than that of said feed mixture in (1).

Claim 4

The process of claim 1 wherein the remainder of the slag after separation of the coarse fraction in (5) has a Cu/V weight ratio in a range about equal to that of the feed mixture in (1) to 250% greater than that of the feed mixture in (1).

Claim 5

The process of claim 1 wherein all of the coarse slag fraction separated in (5) is comprised of all of the slag particles of a size equal to or greater than that retained by ASTM E11 U.S.A. Standard Series Sieve Designation Alternative 1.5.

Claim 6

The process of claim 1 wherein the feed mixture in (1) has the following particle size distribution: ______________________________________ U.S.A. Standard Series Sieve Designation Percent Alternative - ASTM E11 Microns Passing ______________________________________ No. 14 1,400 99.9 No. 40 425 99.5 No. 200 75 65 No. 325 45 45-55 ______________________________________

Claim 7

The process of claim 1 wherein the slag separation chamber in (3) has the shape of a hollow sphere, hemisphere, or vertical cylinder with coaxial inlet and outlet ports along the vertical axis.

Claim 8

The process of claim 1 wherein the slag separation chamber in (3) comprises a plurality of coaxial hollow vertical cylinders in tandem.

Claim 9

The process of claim 1 wherein the slag separation chamber in (3) is a hollow refractory lined vertical cylinder, having a length to diameter ratio in the range of about 0.25 to 3.0, such as 0.4 to 1.0 and the ratio of the diameter of the discharge passage in the bottom of the gas generator to the diameter of the slag separation chamber is in the range of about 0.3 to 0.8.

Claim 10

The process of claim 1 wherein the dwell time of the hot raw effluent gas stream in said slag separation chamber is in the range of about 0.05 to 0.50 seconds.

Claim 11

The process of claim 1 wherein the feed materials (i), (ii), and (iii) are ground together to produce said feed mixture.

Claim 12

The process of claim 1 where in the slag separation chamber in (3) from about 1.0 to 25 wt. % of the molten slag entrained in said hot raw gas stream separates out.

Claim 13

The process of claim 1 wherein the temperature of the raw effluent gas stream passing through the slag separation chamber in (3) is in the range of about 1900° F. to 2900° F.

Claim 14

The process of claim 1 wherein the temperature of the refractory walls of the slag separation chamber in (3) is in the range of about 1725° F. to 2500° F.

Claim 15

The process of claim 1 wherein slag on the walls of the slag separation chamber in (3) separates from the wall by gravity with or without help from a jet of gas.

Claim 16

The process of claim 1 wherein the water-solids separation zone in (5) is selected from the group of equipment consisting of lockhopper, hydroclone, filter, clarifier, sieves, settler, and combinations thereof.

Claim 17

The process of claim 1 provided with the steps of dewatering at least a portion of the remainder of the slag after separation of the coarse slag fraction in (5), and grinding said portion with supplemental copper-containing additive and fresh vanadium-containing fuel to produce the feed mixture in (1).

Claim 18

The process of claim 1 provided with the step of recovering vanadium from said coarse slag fraction separated in (5) in a metals reclaiming zone.

Claim 19

The process of claim 1 wherein said supplemental copper-containing additive comprises copper and/or a copper compound selected from the group consisting of oxides, sulfides sulfates, carbonates, cyanides, nitrates and mixtures thereof.

Claim 20

The process of claim 1 wherein said supplemental copper-containing additive is a cuprous or cupric organic compound selected from the group consisting of naphthenates, oxalates, acetates, benzoates, oleates, tartrates and mixtures thereof.

Claim 21

The process of claim 1 where included in the supplemental copper-containing additive in (1) is an additional material selected from the group of elements consisting of iron, calcium, fluorine, magnesium, chromium and mixtures thereof.

Claim 22

The process of claim 1 wherein said supplemental copper-containing additive in (1) comprises an inorganic or organic compound of copper.

Claim 23

The process of claim 1 wherein said supplemental copper-containing additive in (1) comprises concentrated copper ore comprising at least 20 weight % of copper.

Claim 24

The process of claim 22 wherein said concentrated copper ore is a mixture of the sulfides of copper, copper-iron and iron with a small amount of gangue minerals.

Claim 25

The process of claim 1 wherein said supplemental copper-containing additive comprises copper sulfide and/or copper oxide minerals.

Claim 26

The process of claim 1 wherein said supplemental copper-containing additive comprises copper sulfide minerals selected from the group consisting of bornite, chalcopyrite, tetrahedrite, tennentite, chalcocite, covellite, digenite, and mixtures thereof.

Claim 27

The process of claim 1 wherein said supplemental copper-containing additive comprises copper oxide minerals selected from the group consisting of cuprite, tenorite, malachite, azurite, brochantite, atacamite, chrysocolla, and mixtures thereof.

Claim 28

The process of claim 1 wherein the weight ratio of material (1) (iii) to materials (1) (ii)+(1) (iii) is in the range of about 0.25 to 0.9.

Claim 29

The process of claim 1 provided with the step of reducing the size of the solids from the bottom of the quench tank to a maximum of about 2 inches to 3 inches.

Claim 30

The process of claim 1 wherein the slag separation chamber in (3) is provided with a side outlet in addition to said bottom outlet, and the hot raw effluent gas stream is divided between said bottom and side outlets.

Claim 31

The process of claim 1 with the step of removing a portion of the hot effluent gas stream from the slag separation chamber in (3) by way of an outlet in the side of said slag separation chamber, and cooling said portion of hot effluent gas in a gas cooler.

Claim 32

The process of claim 1 wherein said vanadium-containing liquid hydrocarbonaceous fuel is a petroleum derived liquid fuel selected from the group consisting of whole crude, residua from petroleum distillation and cracking, petroleum distillate, reduced crude, asphalt, shale oil, tar sand oil, and mixtures thereof.

Claim 33

The process of claim 1 wherein said vanadium-containing solid carbonaceous fuel is selected from the group consisting of petroleum coke, asphalt, tar sands, shale, and mixtures thereof.

Claim 34

A partial oxidation process for the production of gaseous mixtures comprising H 2 +CO in a vertical free-flow down flowing gas generator said process comprising: (1) mixing together (i) a vanadium-containing heavy liquid hydrocarbonaceous fuel whose ash includes a minimum of 2.0 weight % of vanadium, (ii) supplemental copper-containing additive, and (iii) at least a portion of the remainder of the copper-containing slag fraction after separation of the coarse slag fraction in (7); (2) coking said mixture from (1) to produce petroleum coke having vanadium-containing ash and having dispersed therein said materials (1) (ii) and (1) (iii); wherein the Cu/V weight ratio of said petroleum coke is in the range of about 5.0 to 75; (3) introducing the petroleum coke from (2) into the partial oxidation reaction zone in (4) as a pumpable slurry of petroleum coke in water, liquid hydrocarbonaceous fluid or mixtures thereof, or as substantially dry petroleum coke entrained in a gaseous transport medium. (4) reacting said petroleum coke from (3) at a temperature in the range of 1900° F. to 2900° F. and a pressure in the range of about 5 to 250 atmospheres in a free-flow refractory lined partial oxidation reaction zone of a gas generator with a free-oxygen containing gas in the presence of a temperature moderator and in a reducing atmosphere to produce a hot raw effluent gas stream comprising H 2 +CO and entrained vanadium-containing molten slag comprising a liquid phase washing agent that collects and transports vanadium-containing laths and spinels and other ash components and refractory out of the reaction zone; and particulate matter; (5) passing the hot raw effluent gas stream from (4) down into a slag separation chamber, depositing a portion of the slag entrained in said hot raw gas stream on the walls of said slag separation chamber and building up the thickness of the said slag on the walls of said chamber until chunks of slag having a diameter in the range of about 1/4 inch to 10 inches and a Cu/V weight ratio of 40% to 70% less than the Cu/V weight ratio of the petroleum coke produced in (2) separate from the wall and fall into quench water contained in a quench tank located below said slag separation chamber; (6) passing through said quench tank at least a portion of the hot effluent gas stream leaving said slag separation chamber to produce said gaseous mixture comprising H 2 +CO, and solidifying molten slag and separating out in said quench tank slag and particulate matter that were entrained in said hot raw gas stream; and (7) passing the water and solids from the bottom of said quench tank into a water-solids separation zone; removing a portion of the water and recycling said water to the quench tank; and separating a coarse slag fraction from the remainder of the slag and recycling said remainder of the slag to (1); wherein said coarse slag fraction has a Cu/V weight ratio which is less than that of the petroleum coke in (2).

Claim 35

A partial oxidation process for the production of gaseous mixtures comprising H 2 +CO in a vertical free-flow down flowing gas generator said process comprising: (1) mixing together (i) a vanadium-containing heavy liquid hydrocarbonaceous fuel whose ash includes a minimum of 2.0 weight % of vanadium, (ii) supplemental copper-containing additive, and (iii) at least a portion of the remainder of the copper-containing slag fraction after separation of the coarse slag fraction in (7); (2) coking said mixture from (1) to produce petroleum coke having vanadium-containing ash and having dispersed therein said materials (1) (ii) and (1) (iii); wherein the Cu/V weight ratio of said petroleum coke is in the range of about 5.0 to 75; (3) introducing the petroleum coke from (2) into the partial oxidation reaction zone in (4) as a pumpable slurry of petroleum coke in water, liquid hydrocarbonaceous fluid or mixtures thereof, or as substantially dry petroleum coke entrained in a gaseous transport medium. (4) reacting said petroleum coke from (3) at a temperature in the range of 1900° F. to 2900° F. and a pressure in the range of about 5 to 250 atmospheres in a free-flow refractory lined partial oxidation reaction zone of a gas generator with a free-oxygen containing gas in the presence of a temperature moderator and in a reducing atmosphere to produce a hot raw effluent gas stream comprising H 2 +CO and entrained vanadium-containing molten slag comprising a liquid phase washing agent that collects and transports vanadium-containing laths and spinels and other ash components and refractory out of the reaction zone; and particulate matter; (5) passing the hot raw effluent gas stream from (4) down into a slag separation chamber, depositing a portion of the slag entrained in said hot raw gas stream on the walls of said slag separation chamber and building up the thickness of the said slag on the walls of said chamber until chunks of slag having a diameter in the range of about 1/4 inch to 10 inches and a Cu/V weight ratio of 40% to 70% less than the Cu/V weight ratio of the petroleum coke produced in (2) separate from the wall and fall into quench water contained in a quench tank located below said slag separation chamber; (6) passing through said quench tank at least a portion of the hot effluent gas stream leaving said slag separation chamber to produce said gaseous mixture comprising H 2 +CO, and solidifying molten slag and separating out in said quench tank slag and particulate matter that were entrained in said hot raw gas stream; and (7) passing the water and solids from the bottom of said quench tank into a water-solids separation zone; removing a portion of the water and recycling said water to the quench tank; and separating a coarse slag fraction from the remainder of the slag and recycling said remainder of the slag to (1); wherein said coarse slag fraction has a Cu/V weight ratio which is less than that of the petroleum coke in (2).

Claim 36

The process of claim 33 where in (2) the mixture from (1) at a temperature in the range of about 650° F. to 930° F. is introduced into a delayed coking zone where at a temperature in the range of about 800° F. to 895° F. and a pressure in the range of about 20 to 60 psig, uncondensed hydrocarbon effluent vapor and steam are removed overhead and said petroleum coke having a nickel and vanadium-containing ash and having uniformly dispersed therein said copper-containing additive is removed from the bottom.

Claim 37

The process of claim 33 where in (2) the mixture from (1) at a temperature in the range of about 550° F. to 750° F. is introduced into a fluidized bed coking zone where at a temperature in the range of about 1000° F. to 1200° F. and a pressure in the range of about 10 to 20 psig, uncondensed hydrocarbon effluent vapor and steam are removed overhead and said petroleum coke is removed from the bottom.

Claim 38

The process of claim 33 where included in the supplemental copper-containing additive in (1) is an additional material selected from the group of elements consisting of iron, calcium, fluorine, magnesium, chromium and mixtures thereof.

Claim 39

The process of claim 33 wherein the feed mixture in (1) has a Cu/V weight ratio in the range of about 5.0 to 75, and the coarse slag fraction separated in (5) has a Cu/V weight ratio of about 40% to 70% less than that of said feed mixture in (1).

Claim 40

The process of claim 33 wherein the remainder of the copper-containing slag after separation of the coarse slag fraction in (7) has a Cu/V weight ratio in a range about equal to that of the feed mixture in (1) to 250% greater than that of the feed mixture in (1).

Claim 41

The process of claim 33 wherein the dwell time of the hot raw effluent gas stream in said slag separation chamber is in the range of about 0.05 to 0.50 seconds.

Claim 42

The process of claim 33 wherein the amount of slag that builds up on the walls of the slag separation chamber in (5) is from about 1.0 to 25 wt. % of the molten slag entrained in said hot raw gas stream.

Claim 43

The process of claim 33 wherein said supplemental copper-containing additive comprises a copper compound selected from the group consisting of oxides, sulfides, sulfates, carbonates, cyanides, nitrates, and mixtures thereof.

Claim 44

The process of claim 33 wherein said supplemental copper-containing additive is a cuprous or cupric organic compound selected from the group consisting of naphthenates, oxalates, acetates, benzoates, oleates, tartrates and mixtures thereof.

Claim 45

The process of claim 33 wherein said supplemental copper-containing additive in (1) comprises concentrated copper ore comprising at least 30 weight % of copper.

Claim 46

The process of claim 33 wherein said supplemental concentrated copper ore is a mixture of the sulfides of copper, copper-iron and iron with smaller amounts of gangue minerals.

Claim 47

The process of claim 33 wherein said supplemental copper-containing additive comprises copper sulfide and/or copper oxide minerals.

Claim 48

The process of claim 33 wherein said supplemental copper-containing additive comprises copper sulfide minerals selected from the group consisting of bornite, chalcopyrite, tetrahedrite, tennentite, chalcocite, covellite, and mixtures thereof.

Claim 49

The process of claim 33 wherein said supplemental copper-containing additive comprises copper oxide minerals selected from the group consisting of cuprite, tenorite, malachite, aqurite, brochantite, atacamite, chrysocolla, and mixtures thereof.

Claim 50

The process of claim 33 wherein the water-solids separation zone in (7) is selected from the group consisting of lockhopper, hydroclone, filter, clarifier, sieves, settler, and combinations thereof.

Claim 51

The process of claim 33 provided with the step of reducing the size of the solids from the bottom of the quench tank to a maximum of about 2 inches to 3 inches.

Claim 52

The process of claim 33 wherein the coarse slag fraction separated in (7) has a Cu/V weight ratio of about 40% to 70% less than that of said petroleum coke in (2).

Claim 53

The process of claim 33 wherein the remainder of the slag after separation of the coarse slag fraction in (7) has a Cu/V weight ratio in a range of about equal to that of the petroleum coke in (2) to 250% greater than that of the petroleum coke in (2).

Claim 54

The process of claim 33 wherein the coarse slag fraction separated in (7) is comprised of all of the slag particles of a size equal to or greater than that retained by ASTM E11 U.S.A. Standard Series Size Designation Alternative 1.5.

Claim 55

The process of claim 33 wherein the petroleum coke in (3) has the following particle size distribution: ______________________________________ U.S.A. Standard Series Sieve Designation Percent Alternative - ASTM E11 Microns Passing ______________________________________ No. 14 1,400 99.9 No. 40 425 99.5 No. 200 75 65 No. 325 45 45-55 ______________________________________

Claim 56

The process of claim 33 with the step of removing a portion of the hot effluent gas stream from the slag separation chamber in (5) by way of an outlet in the side of said slag separation chamber, and cooling said portion of hot effluent gas in a gas cooler.

Claim 57

The process of claim 33 provided with the step of recovering vanadium from said coarse slag fraction in (7) in a metals reclaiming zone.

Claim 58

The process of claim 33 wherein said vanadium-containing liquid hydrocarbonaceous fuel is a petroleum derived liquid fuel selected from the group consisting of whole crude, residua from petroleum distillation and cracking, petroleum distillate, reduced crude, asphalt, shale oil, tar sand oil, and mixtures thereof.