Abstract: A combination operation for upgrading reduced crudes is described which particularly restricts the contact time between hydrocarbons, solid sorbent material and cracking catalyst particles whereby quenching of visbroken product vapors is eliminated, coke formation is substantially restricted and catalytic cracking of hot product vapors of visbreaking contributes to the catalytic cracking thereof in a time-temperature restricted atmosphere providing substantial yields of gasoline and gasoline precursors.

Abstract: Green briquette agglomerates (10) are manufactured by simultaneously crushing and blending high sulfur petroleum coke (20), a high R/B softening point, high sulfur and metals content asphaltene binder (22), and dolomitic limestone (24) as a sulfur sorbent in pulverizer (26). The uniform mixture is cold pressed on roll briquetting machine (85) into durable briquettes (104). On gasification or combustion, a high percentage of the sulfur combines with the Dolomite and is discharged from the gasifier or furnace with the ash. The sorbent effectiveness and degree of sulfur oxide emission control are significantly enhanced versus prior art when burning a high sulfur coke in the improved briquette of the invention.

Abstract: A particular aspect of the invention concepts disclosed and described is directed to the use of a vented cup ballistic separation device and method of use for achieving rapid separation of a suspension of fluidized solid particulate and gasiform material. The vented cup ballistic separation apparatus is particularly discussed in conjunction with separating a suspension of catalyst particles from vaporous hydrocarbon reaction products of catalytic cracking discharged from a riser cracking operation. The vented cup ballistic separation apparatus particularly comprises an annular chamber about the upper periphery of an open ended riser conduit. The annular chamber is open in the upper end and one or more open end conduits extend outwardly from the annular chamber comprising means for attachment to cyclone separation means. The riser with vented cup or annular chamber terminates within a larger diameter chamber.

Abstract: The method and means of this invention comprises discharging a suspension of solids (inert or catalytic) in gasiform material (whether hydrocarbon vapors, combustion product flue gases, stripping gases or combinations thereof) from a riser contact zone through a plurality of radiating confined passageway emanating from the upper discharge periphery of the riser each of which is in tangential communication at the outer end of the confined passageway with a cylinder open in the bottom end thereof. The cylinder is closed at the top except for a coaxially aligned conduit of smaller diameter extending downwardly through said cylinder with its bottom open end terminating adjacent a lower portion of the inlet of the confined passageway.

Abstract: A method and apparatus for separating regenerated catalyst from gaseous combustion products within a regenerator. The apparatus comprises a downcomer within the regenerator vessel through which the catalyst and gaseous combustion products flow. Means are provided at the lower end of the downcomer for utilizing the momentum of the catalyst particles to separate them from the gaseous combustion products.

Abstract: A high pore volume solid sorbent material of low cracking activity and comprising a select group of metal additives to immobilize accumulated vanadium compounds deposited on the sorbent material in a heavy oil feed visbreaking zone is described and the conditions employed to effect demetallization and decarbonization of the heavy oil feed to produce vaporous products boiling up to about 1000.degree. F. Deposition of metal contaminants within the pores of the high pore volume material is encouraged by restricting the volume of the sorbent pores filled with oil feed to within the range of 1/4 to 2/3.

Abstract: A process for economically converting carbo-metallic oils to lighter products. The carbo-metallic oils contain 650.degree. F. and material which is characterized by a carbon residue on pyrolysis of at least about 1 and a Nickel Equivalents of heavy metals content of at least about 4 parts per million. This process comprises flowing the carbo-metallic oil together with particulate cracking catalyst through a progressive flow type reactor having an elongated reaction chamber, which is at least in part vertical or inclined, for a predetermined vapor riser residence time in the range of about 0.5 to about 10 seconds, at a temperature of about 900.degree. to about 1400.degree. F., and under a pressure of about 10 to about 50 pounds per square inch absolute sufficient for causing a conversion per pass in the range of about 50% to 90% while producing coke in amounts in the range of about 6 to about 14% by weight based on fresh feed, and laying down coke on the catalyst in amounts in the range of about 0.

Abstract: An improved process and catalyst for economically converting carbo-metallic oils to lighter products. This process is practiced in accordance with effective metals management, carbon management and catalyst activity management combined with feed atomization-vaporization, efficient stripping of carbonaceous material from the coked catalyst, exothermic and endothermic removal of hydrocarbonaceous material to effectively maintain the RCC unit in heat balance. This reduced crude cracking process is practiced with a new and improved catalyst composition identified as RCCC-1 Special that is characterized by the following composition; at least 30 wt % rare earth exchanged "Y" faujasite crystalline zeolite with a silica to alumina ratio of at least 5 of a high lanthanum to cerium ratio and residual sodium content less than 0.30 wt %, is provided with a pore volume greater than 0.35 cc/gm. and comprises a clay matrix material that may or may not be acidic with pore size openings in the range of 500 to 2,000 angstroms.

Abstract: A select group of hydrocarbon conversion catalysts suitable for converting carbo-metallic oil containing hydrocarbons to lower boiling transportation fuels are characterized and their method of preparation described. The select catalysts of this invention contain at least one zeolite in high concentration and said zeolite possessing a high silica-alumina ratio and a high lanthanum exchange content dispersed in a matrix possessing high pore volume and large pore size. In addition, the matrix material of large pore size and high pore volume is prepared to provide some acidic cracking activity and contains select metals as the oxide for the immobilization of vanadium and/or select materials for the trapping of deposited metals (Ni, V, Fe, Na) to counteract the detrimental effects of these metals in the regenerator section.

Abstract: The invention is concerned with substantially eliminating the deactivating effects of alkaline materials and metal contaminants and compounds thereof existing in crude oils by first desalting the crude oil and thereafter adding a select neutralizing and immobilizing metal component or compound thereof to said desalted crude oil prior to and/or during distillation thereof to obtain select fractions subsequently catalytically processed as by catalytic cracking with a crystalline zeolite containing catalyst.

Abstract: Novel riser reactor design with associated multiple feed inlet means for contacting regenerated catalyst particles with low quality naphtha, C.sub.5 minus wet gas product of hydrocarbon conversion and a residual oil feed comprising components boiling above about 1025.degree. F. and comprising metal contaminants. Low quality naphtha from thermal cracking is charged either separately or in admixture with C.sub.5 and lower boiling wet gas product of hydrocarbon conversion to the bottom portion of the riser conversion zone for contact with freshly regenerated zeolite cracking catalyst. The vaporous material thus charged conveys the regenerated catalyst at an acceptable velocity to an expanded section of the riser wherein residual oil is charged by a plurality of nozzle means penetrating the wall of the riser in the transition section to the expander user section.

Abstract: A combination process is described for upgrading residual oils and high boiling portions thereof comprising metal contaminants and high boiling Conradson carbon forming compounds comprising a thermal visbreaking operation with fluidizable inert solids followed by a fluidized zeolite catalytic cracking operation processing demetallized products of the visbreaking operation, regenerating solid particulate of each operation under conditions to provide CO rich flue gases relied upon to generate steam used in each of the fluidized solids conversion operation and downstream product separation arrangements, separating the wet gas product stream of each operation in a common product recovery arrangement and processing the high boiling feed product of visbreaking comprising up to 100 ppm Ni +V metal contaminant over a recycled crystalline zeolite cracking catalyst distributed in a sorbent matrix material comprising a high level of Ni +V metal contaminant.

Abstract: The invention described is directed to the fluid catalytic conversion of hydrocarbons and is concerned particularly with the method and means for obtaining atomized-vaporized contact of residual oils and reduced crudes with high temperature dispersed phase fluid catalyst particles. More particularly, one embodiment of the invention is directed to atomizing an oil-water emulsion thereafter discharged into up-flowing dispersed phase catalyst particles at velocities up to sonic velocities to form a suspension under hydrocarbon conversion conditions.

Abstract: The invention described is concerned with atomizing an oil fraction of crude oil to provide a fog of oil droplets in diluent gaseous material which is sprayed into an upwardly flowing annular dense mass of catalyst particles to form a high temperature suspension therewith and conveyed through a riser conversion zone under selected hydrocarbon conversion conditions suitable for cracking the oil droplets to gasoline and light cycle oil boiling range products. The oil feed preparation and distribution arrangement to form a suspension with catalyst particles of desired elevated temperature is employed in combination with a two-stage catalyst regeneration operation designed and operated to achieve catalyst temperatures at least equal to the pseudo-critical temperature of the oil feed and at least above the end boiling point of gas oil boiling range material and resid product of vacuum distillation.

Abstract: The method and means for effecting selective visbreaking of residual oil feeds comprising metallo-organic compounds with a fluid solid sorbent particle material in the presence of process sour water and wet gas recycle material is described to provide a gas oil rich product more suitable for crystalline zeolite fluid catalytic cracking operations.

Abstract: An integrated combination of fluid catalytic cracking and hydrocracking select fractions of crude oil and FCC cycle oils to conserve hydrogen process requirements in the production of gasoline is discussed. Liquid products of hydrocracking are separated into low boiling components and a high boiling fraction is recycled to the FCC operation. Select fractions obtained from hydrocracking, FCC and crude oil distillation are upgraded by reforming and alkylation.

Abstract: A process is disclosed for the conversion of high boiling oil feeds having a significant level of Conradson carbon components and metals to form lighter oil products by contacting the feed under catalytic conversion conditions with a catalyst containing one of a select group of metal additives to catalyze the endothermic removal of carbon with CO.sub.2. Conversion conditions are such that hydrocarbonaceous material and metals are deposited to deactivate the catalyst in the conversion zone. Deactivated catalyst is partially regenerated in the presence of carbon dioxide containing gas before or after oxygen regeneration at a temperature below 1600.degree. F. to provide a regenerated catalyst which is recycled to the conversion zone for further contact with fresh feed. The metal additive is present on the catalyst in an amount sufficient to catalyze the endothermic removal of carbonaceous material in the presence of a carbon dioxide rich gas at regeneration temperature below 1500.degree. F.

Abstract: A process for economically converting carbo-metallic oils to lighter products. The carbo-metallic oils contain 650.degree. F.+ material which is characterized by a carbon residue on pyrolysis of at least about 1 and a Nickel Equivalents of heavy metals content of at least about 4 parts per million. This process comprises flowing the carbo-metallic oil together with particulate cracking catalyst through a progressive flow type reactor having an elongated reaction chamber, which is at least in part vertical or inclined, for a predetermined vapor riser residence time in the range of about 0.5 to about 10 seconds, at a temperature of about 900.degree. to about 1400.degree. F., and under a pressure of about 10 to about 50 pounds per square inch absolute sufficient for causing a conversion per pass in the range of about 40% to 90% while producing coke in amounts in the range of about 6 to about 14% by weight based on fresh feed, and laying down coke on the catalyst in amounts in the range of about 0.

Abstract: A process for converting residual oil comprising vacuum bottoms in the presence of a cracking catalyst of high surface area and comprising an ultrastable zeolite is described. More particularly, a conversion process particularly contributing to producing cycle oil and gasoline boiling range products with reduced carbon deposition in combination with a relatively high regeneration temperature operation of at least 1350.degree. F. and above, and a short contact time riser hydrocarbon conversion operation contributing to reducing slurry oil product in favor of lower boiling products is described. A fluid cracking catalyst comprising a special ultrastable crystalline zeolite of high silica to alumina ratio provides hydrothermal stability of acceptable tolerance in the environment employed.

Abstract: A process is disclosed for decarbonization-demetallization of a poor quality residual oil feed boiling above about 650.degree. F. and comprising substantial Conradson carbon components to provide a higher grade of oil feed by contacting the poor quality oil feed with sorbent particle material containing one or more metal additives selected to catalyze the endothermic removal of coke with CO.sub.2. Sorbent decarbonization conditions are selected so that substantial quantities of carbonaceous material and metals are deposited on the sorbent in the decarbonizing zone. Sorbent material with metals and hydrocarbonaceous deposits is regenerated in the presence of an oxygen and carbon dioxide containing gas streams in separate sorbent regeneration zones at a temperature sufficiently elevated to remove residual coke to a desired low level. Regenerated sorbent particle material at an elevated temperature below about 1500.degree. F.