Partial oxidation process of sulfur, nickel, and vanadium-containing fuels

Claim 2

A process for the production of gaseous mixtures comprising H 2 +CO by the partial oxidation of a fuel feedstock comprising a heavy liquid hydrocarbonaceous fuel having a nickel and vanadium containing ash or petroleum coke having a nickel and vanadium-containing ash or mixtures thereof; and said feedstock includes a minimum of 0.5 wt. % of sulfur; and said ash includes a minimum of 5.0 wt. % vanadium and a minimum of 0.5 ppm nickel, said process comprising: (1) mixing together a basalt additive with said fuel feedstock; wherein the weight ratio of basalt additive to ash in said fuel feedstock is in the range of about 1.0-8.0 and there is at least 10 parts by weight of Si+Fe+Ca for each part by weight of vanadium; and wherein said basalt additive has the following composition comprising in weight percent (wt. %) SiO 2 in the range of about 38 to 53, and the oxides Fe, Ca, Al, and Mg each in the range of about 5 to 15; (2) reacting said mixture from (1) at a temperature in the range of 2100° F. to 2600° F. and a pressure in the range of about 5 to 250 atmospheres in a free-flow refractory lined partial oxidation reaction zone 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 molten slag; and where in said reaction zone said basalt additive interacts with the said ash and sulfur from said feedstock to produce molten slag comprising a minor amount of oxysulfide liquid phase washing agent, and a major amount of liquid silicate phase; and wherein from about 5.0 to 35 wt. % of vanadium-containing oxide laths and spinels and other ash components and bits of refractory are washed out of the reaction zone by said oxysulfide liquid phase, and the remainder of said vanadium-containing oxide laths and spinels are washed out of the reaction zone and/or are dissolved by said silicate phase; and (3) separating nongaseous materials from said hot raw effluent gas stream.

Claim 3

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

Claim 4

The process of claim 1 wherein the fuel feedstock comprises a pumpable slurry of petroleum coke in water, liquid hydrocarbonaceous fuel, or mixtures thereof.

Claim 5

The process of claim 1 wherein said basalt additive is natural basalt.

Claim 6

The process of claim 1 wherein said basalt additive comprises in wt. %: SiO 2 about 38 to 53; the oxides of Fe, Ca, Al and Mg each in the range of about 5 to 15; and the oxides selected from the group consisting of Ti, Mn, Na, K and mixtures thereof each less than about 2.

Claim 7

The process of claim wherein said additive is basaltic lava.

Claim 8

The process of claim 4 wherein said natural basalt has a grain size of less than about 1 mm.

Claim 9

The process of claim 4 wherein said natural basalt comprises less than about 20 wt. % of minerals selected from the group consisting of olivine, calcium-poor pyroxene, iron-titanium oxides and mixtures thereof; and the remainder comprising about equal parts by weight of plagioclase feldspar and calcium-rich pyroxene.

Claim 10

The process of claim 1 where in (1) said basalt additive is introduced in the feed to or the bottoms from a vacuum distillation unit.

Claim 11

The process of claim I wherein said mixture of basalt additive and fuel feedstock from (1) has a particle size such that substantially all of said material passes through a sieve in the range of ASTM E-11 Standard Sieve Designation of about 425 microns to 38 microns, or below.

Claim 12

The process of claim 1 wherein a comparatively small supplemental amount of a comminuted second additive comprising a compound from the group of elements consisting of iron, calcium, magnesium, chromium, and mixtures thereof is mixed with the basalt additive and the fuel feedstock in (1).

Claim 13

The process of claim 11 wherein said supplemental second additive is selected from the group of compounds consisting of oxide, sulfate, sulfide, carbonate, chloride, nitrate, hydroxide and mixtures thereof.

Claim 14

The process of claim 1 wherein a large proportion of the sulfur in said feedstock leaves the reaction zone in the slag.

Claim 15

The process of claim 1 wherein a supplemental iron and/or calcium compound is introduced into the partial oxidation reaction zone to reduce the softening temperature of the slag and to increase the solubility of the V in the silicate phase.

Claim 16

The process of claim 11 wherein said supplemental second additive comprising the compounds of Fe, Mg, Cr and mixtures thereof is introduced into the reaction zone in the amount of about 1.0 to 10.0 wt. % of said basalt addition agent; and said supplemental calcium compound is introduced into the reaction zone in the amount of about 2.0 to 8.0 wt. % of said basalt addition agent.

Claim 17

The process of claim 1 wherein said minor oxysulfide liquid phase washing agent substantially comprises in wt. %: Fe about 40 to 80, Ni about 0.1 to 5.0, and Sulfur about 10 to 32.

Claim 18

The process of claim 1 wherein said minor oxysulfide liquid phase washing agent is present in the reaction zone in the amount of about 5 to 35% of the weight of said molten slag.

Claim 19

The process of claim 1 wherein said major liquid silicate phase is present in said reaction zone in the amount of about 60 to 93% of the weight of said molten slag.

Claim 20

The process of claim wherein said major silicate liquid phase substantially comprises in wt. %: Si about 30 to 60, Fe about 2.0 to 20, Ca about 1.0 to 15, Al about 5.0 to 25, and Mg about 0.2 to 5.0.

Claim 21

A process for the production of gaseous mixtures comprising H 2 +CO by the partial oxidation of feedstock comprising a heavy liquid hydrocarbonaceous fuel having a nickel and vanadium-containing ash, or petroleum coke having a nickel and vanadium-containing ash, or mixtures thereof; and said feedstock includes a minimum of 0.5 wt. % of sulfur; and said ash includes a minimum of 5.0 wt. % vanadium and a minimum of 0.5 ppm nickel; said process comprising: (1) mixing together a basalt additive with said feedstock; wherein the weight ratio of basalt additive to ash in the fuel feedstock is in the range of about 1.0-8.0, and there is at least 10 parts by weight of Si+Fe+Ca for each part by weight of vanadium; and wherein said basalt additive has the following composition comprising in weight percent (wt. %) SiO 2 in the range of about 38 to 53, and the oxides Fe, Ca, Al, and Mg each in the range of about 5 to 15; (2) coking said mixture from (1) to produce petroleum coke having a nickel and vanadium-containing ash and having dispersed therein said basalt additive; (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; and (4) reacting said petroleum coke from (3) at a temperature in the range of 2100° F. to 2600° F. and a pressure in the range of about 5 to 250 atmospheres in said free-flow refractory lined partial oxidation reaction zone 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 molten slag; and where in said reaction zone said basalt additive interacts with the said ash and sulfur from said feedstock to produce molten slag comprising a minor amount of oxysulfide liquid phase washing agent, and a major amount of liquid silicate phase; and wherein from about 5.0 to 35 wt. % of the vanadium-containing oxide laths and spinels and other ash components and bits of refractory are washed out of the reaction zone by said oxysulfide liquid phase, and the remainder of said vanadium-containing oxide laths and spinels are washed out of the reaction zone and/or are dissolved by said silicate phase; and (5) separating nongaseous materials from said hot raw effluent gas stream.

Claim 22

A process for the production of gaseous mixtures comprising H 2 +CO by the partial oxidation of feedstock comprising a heavy liquid hydrocarbonaceous fuel having a nickel and vanadium-containing ash, or petroleum coke having a nickel and vanadium-containing ash, or mixtures thereof; and said feedstock includes a minimum of 0.5 wt. % of sulfur; and said ash includes a minimum of 5.0 wt. % vanadium and a minimum of 0.5 ppm nickel; said process comprising: (1) mixing together a basalt additive with said feedstock; wherein the weight ratio of basalt additive to ash in the fuel feedstock is in the range of about 1.0-8.0, and there is at least 10 parts by weight of Si+Fe+Ca for each part by weight of vanadium; and wherein said basalt additive has the following composition comprising in weight percent (wt. %) SiO 2 in the range of about 38 to 53, and the oxides Fe, Ca, Al, and Mg each in the range of about 5 to 15; (2) coking said mixture from (1) to produce petroleum coke having a nickel and vanadium-containing ash and having dispersed therein said basalt additive; (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; and (4) reacting said petroleum coke from (3) at a temperature in the range of 2100° F. to 2600° F. and a pressure in the range of about 5 to 250 atmospheres in said free-flow refractory lined partial oxidation reaction zone 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 molten slag; and where in said reaction zone said basalt additive interacts with the said ash and sulfur from said feedstock to produce molten slag comprising a minor amount of oxysulfide liquid phase washing agent, and a major amount of liquid silicate phase; and wherein from about 5.0 to 35 wt. % of the vanadium-containing oxide laths and spinels and other ash components and bits of refractory are washed out of the reaction zone by said oxysulfide liquid phase, and the remainder of said vanadium-containing oxide laths and spinels are washed out of the reaction zone and/or are dissolved by said silicate phase; and (5) separating nongaseous materials from said hot raw effluent gas stream.

Claim 23

The process of claim 20 wherein said mixture of basalt additive and fuel feedstock from (1) has a particle size such that substantially all of said material passes through a sieve in the range of ASTM E-11 Standard Sieve Designation of about 425 microns to 38 microns or below.

Claim 24

The process of claim 20 wherein said basalt additive is natural basalt.

Claim 25

The process of claim 20 wherein said basalt additive comprises in wt. %: SiO 2 about 38 to 53; the oxide of Fe, Ca, Al and Mg each in the range of about 5 to 15; and oxides selected from the group consisting of Ti, Mn, Na, K, and mixtures thereof each less than about 2.

Claim 26

The process of claim 20 wherein said additive is basaltic lava.

Claim 27

The process of claim 22 wherein said natural basalt has a grain size of less than about 1 mm.

Claim 28

The process of claim 22 Wherein said natural basalt comprises less than about 20 wt. % of minerals selected from the group consisting of olivine, calcium-poor pyroxene, iron-titanium oxides and mixtures thereof; and the remainder comprising about equal parts by weight of plagioclase, feldspar and calcium-rich pyroxene.

Claim 29

The process of claim 20 wherein said ash-containing heavy liquid hydrocarbonaceous fuel is a high boiling liquid petroleum feed to or the bottoms from a vacuum tower or a fractionator.

Claim 30

The process of claim 20 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 basalt additive is removed from the bottom.

Claim 31

The process of claim 20 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 32

The process of claim 20 where in (5) said nongaseous materials are separated from said hot effluent gas stream by contacting the gas stream from (4) with a water or oil scrubbing medium.

Claim 33

The process of claim 20 wherein a comparatively small supplemental amount of a comminuted second additive comprising a compound from the group of elements consisting of iron, calcium, magnesium, chromium, and mixtures thereof is mixed with the basalt additive and the feedstock in (1); and said second additive is uniformly dispersed in the petroleum coke produced in (2).

Claim 34

The process of claim 31 wherein said supplemental second additive is selected from the group of compounds consisting of oxide, sulfate, sulfide, carbonate, chloride, nitrate, hydroxide and mixtures thereof.

Claim 35

The process of claim 32 wherein said supplemental second additive comprising the compounds of Fe, Mg, Cr and mixtures thereof is introduced into the reaction zone in the amount of about 1.0 to 10.0 wt. % of said basalt addition agent; and said supplemental calcium compound is introduced into the reaction zone in the amount of about 2.0 to 8.0 wt. % of said basalt addition agent.

Claim 36

The process of claim 20 wherein a large proportion of the sulfur in said feedstock leaves the reaction zone in the slag.

Claim 37

The process of claim 20 wherein a supplemental iron and/or calcium compound is introduced into the reaction zone of the partial oxidation gasifier to reduce the softening temperature of the slag, and to increase the solubility of the V in the silicate phase.