Abstract: A system is described for control of sulfur oxides in emissions to the atmosphere from regenerators of cyclic Fluid Catalytic Cracking Units (FCC). By the disclosed system, hot regenerator flue gas is cooled, air (oxygen) is injected into the cooled flue gas unless oxygen is already present, and then the cooled flue gas is contacted with a solid particulate material which has the capability of associating with and binding sulfur oxides in the flue gas to form a stable solid material which is separated from the gases.

Abstract: An improvement is disclosed on selective vaporization for decarbonizing and demetallizing heavy petroleum stocks by short time riser contact with hot inert solid contact material. Flexibility is imparted to that process by suspending the contact material in steam generated by injection of liquid water and adding the heavy petroleum stock at variable levels in the riser.

Abstract: A process for upgrading a petroleum charge of crude oil or residual fractions thereof, in which the charge is dispersed into a descending curtain of heated, substantially inert contact material. This contact material preferably has a conversion rate not substantially greater than 10% in the CAT D test. The vapors generated on contact of the charge with the curtain are collected on the side of the curtain opposite from where the charge is dispersed. The recovered product has a substantially reduced metals content and Conradson Carbon number and is suitable for catalytic cracking or use as heavy fuel or a heavy fuel precursor.

Abstract: An improvement is disclosed on selective vaporization for decarbonizing and demetallizing heavy petroleum stocks by short time contact with hot inert solid contact material. Flexibility is imparted to that process by suspending the contact material in steam or other carrier gas and adding the heavy petroleum stock at variable levels in the selective vaporization contactor.

Abstract: An improved process is provided for decarbonizing, demetallizing and/or desalting a hydrocarbon feed stock by: contacting, in a selective vaporization step, for a short hydrocarbon residence time at an elevated contact temperature, the feed stock with an inert solid contact material in a confined rising vertical column to vaporize a major portion of the feed stock and to provide, as combustible deposits on the contact material, an unvaporized minor portion of the feed stock which includes high Conradson Carbon components and/or metal-containing components of the feed stock; separating the vaporized major portion of the feed stock from the contact material bearing the combustible deposits; contacting in a combustion step the contact material, bearing the combustible deposits, with an oxidizing gas to oxidize the combustible deposits and generate heat, whereby the contact material is heated by combustion of the combustible deposits; and recycling the so-heated contact material to contact further feed stock in t

Abstract: An improvement is disclosed on selective vaporization for decarbonizing and demetallizing heavy petroleum stocks by short time riser contact with hot inert solid contact material. Flexibility is imparted to that process by suspending the contact material in steam or other carrier gas and adding the heavy petroleum stock at variable levels in the riser.

Abstract: A system is described for control of sulfur oxide in emissions to the atmosphere from the combined flue gases of selective vaporization and FCC cracking of the improved charge stock resulting from selective vaporization. The invention provides for reduction in sulfur oxide content of the waste gases from the FCC regenerator and the selective vaporization burner and adds a new controllable variable for a heat balanced FCC Unit. The cracking catalyst used has the capability of reversibly reacting with sulfur oxides in the combined flue gases to carry the sulfur back into the reactor where it is converted, at least in part, to hydrogen sulfide which is removed from reaction products in the normal course of treating the cracked products from the reactor. By the disclosed system, the blend of flue gas is cooled and then contacted with hot regenerated catalyst from the regenerator for sorption of sulfur oxides by the catalyst and to cool the catalyst for control of reaction parameters in the FCC reactor.

Abstract: Metals deposited on an inert contact material during high temperature decarbonizing and demetallizing of heavy petroleum stocks are inactivated by mixing the contact material with a silica donor and reacting the mixture at high temperature in the presence of steam to induce migration of silica from the donor to mask metal on the contact material.

Abstract: Whole crude and residual fractions from distillation of petroleum and like feed stocks are subjected to selective vaporization to prepare heavy fractions of reduced Conradson Carbon and/or metals content by short-term, high temperature riser contact with a substantially inert solid contact material of low surface area in a selective vaporization zone. High boiling point components of the charge which are of high Conradson Carbon number and/or high metal content remain on the contact material as a combustible deposit which is then burned off in a combustion zone whereby the contact material is heated to a high temperature for return to the selective vaporization zone to supply the heat required therein. The system is dynamically controlled for fuel supply in the combustion zone by the lower hydrogen content, least valuable components of the feed.

Abstract: Gasoline and a heavier fraction from selective vaporization of crude or residual petroleum stocks are separately supplied to a riser reactor of the FCC type. The crude or resid is contacted at low cracking severity with hot inert solids in a riser. The vaporized product is fractionated to provide a gasoline injected to the bottom of an FCC riser and a bottoms fraction introduced at a higher point in the FCC riser.

Abstract: Residual fractions from distillation of petroleum are rendered suitable for charge to catalytic cracking by high temperature, short time contact in a decarbonizing zone with fluidizable solid particles of essentially inert character and low surface area to deposit high boiling components of the crude and metals on the fluidizable solid particles whereby Conradson Carbon values and metal content of the hydrocarbon feedstock are reduced to levels tolerable in catalytic cracking and carbon laid down on the inert fluidizable particles is burned in a burning zone separate from the decarbonizing zone. Heated inert particles are recycled at least in part to the decarbonizing zone and then to the burning zone.

Abstract: Metal contaminated heavy oils such as residual fractions from petroleum distillation are economically converted to gasoline and other light products in catalytic cracking by practice of a novel catalyst makeup policy of adding controlled proportions of both an active cracking catalyst and a substantially inert, large pore solid to replace the amount of catalyst withdrawn from the inventory of a continuous cracking unit wherein catalyst inventory is continuously circulated between a reactor for cracking charge hydrocarbons and a regenerator for burning off the carbonaceous deposit laid down on catalyst in the cracking reaction.

Abstract: A system is described for control of sulfur oxide in emissions to the atmosphere from regenerators of Fluid Catalytic Cracking Units (FCC) in a manner which provides an added controllable variable in heat balanced units. The cracking catalyst used has the capability of reversibly reacting with sulfur oxides in the regenerator flue gas to carry the sulfur back into the reactor where it is converted, at least in part, to hydrogen sulfide which is removed from reaction products in the normal course of treating the cracked products from the reactor. By the disclosed system, regenerator flue gas is cooled and then contacted with hot regenerated catalyst from the regenerator for sorption of sulfur oxides by the catalyst and to cool the catalyst for control of reaction parameters in the FCC reactor.

Abstract: Process and system are described for control of sulfur oxide in emissions to the atmosphere from regenerators of Fluid Catalytic Cracking Units (FCC) in a manner which improves the operation of the regenerator and/or the reactor. Spent FCC cracking catalyst containing sulfur-bearing inactivating carbonaceous deposit is partially oxidized, preferably in the presence of steam, thereby producing a mixture of CO and CO.sub.2 and releasing sulfur in the resulting reducing atmosphere as vaporous hydrogen sulfide before the catalyst is regenerated, whereby the amount of sulfur convertible to noxious SOx in the regenerator flue gas is reduced. By the disclosed process and system, the quantity of oxygen introduced is predetermined and controlled in response to hydrogen content of the coke on the partially oxidized catalyst or an SOx analyzer associated with the regenerator can be used as a control tool.

Abstract: Whole crude and bottoms fractions from distillation of petroleum are upgraded by high temperature, short time contact with a fluidizable solid of essentially inert character to deposit high boiling components of the charge on the solid whereby Conradson Carbon values, salt content and metal content are reduced. The upgraded hydrocarbon fraction may be supplied to fractionator, in which case the high temperatue contactor serves as a heater, e.g. crude heater for crude distillation, in addition to improving quality of the fractions derived by distillation. For charge stocks boiling above about 500.degree.-650.degree. F., the upgrading process yields a product suitable for charge to catalytic cracking in that Conradson Carbon, salts and metals are reduced to levels tolerable in catalytic cracking.

Abstract: Petroleum crudes, residual stocks, gas oils and the like which contain metals are pretreated with a sulfonating agent and the mixture separated into two fractions of which the lesser in volume has a greater concentration of metal and Conradson Carbon components. One or both of those fractions is mixed with a catalytically inert solid at high temperature to transfer metallic compounds and Conradson Carbon components to the solid for improvement of the fraction.

Abstract: Residual fractions from distillation of petroleum are rendered suitable for charge to catalytic cracking by high temperature, short time contact in a decarbonizing zone with a fluidizable solid particles of essentially inert character and low surface area to deposit high boiling components of the crude and metals on the fluidizable solid particles whereby Conradson Carbon values and metal content of the hydrocarbon feedstock are reduced to levels tolerable in catalytic cracking and carbon laid down on the inert fluidizable particles is burned in a burning zone separate from the decarbonizing zone. Heated inert particles are recycled at least in part to the decarbonizing zone and then to the burning zone.

Abstract: A method for initiating essentially complete oxidation of carbon monoxide, resulting from the oxidative removal of coke from spent FCC catalyst, to carbon monoxide in a dense-phase bed of catalyst maintained in a regeneration zone. Coke is oxidized at first oxidizing conditions including a temperature of from about 750.degree. F. to about 1250.degree. F. to produce partially spent regeneration gas and regenerated catalyst having a first carbon content. The essentially complete oxidation of carbon monoxide is initiated by: (a) increasing the coke on regenerated catalyst from the first carbon content to a second carbon content and then (b) passing to the dense bed fresh regeneration gas at a flow rate at least stoichiometrically sufficient to produce regenerated catalyst having a third carbon content, less than the first carbon content, and sufficient to produce spent regeneration gas.

Abstract: A method of injecting a hydrocarbon feed into a catalytic conversion zone whereby wall temperatures within the conversion zone are reduced and overcracking of the hydrocarbon feed is minimized.

Abstract: A hydrocarbon-feed distributor for injecting a hydrocarbon feed into contact with a fluidizable catalyst at conversion conditions in the lower end of the riser reactor conduit whereby wall temperatures within the conversion zone are reduced and overcracking of the hydrocarbon feed is minimized.