Abstract: Liquid fuel products are produced at least partially from coal by passing into a progressive flow catalytic cracking zone a mixture stream of coal and carbometallic oil, forming mobile hydrogen within said zone under conditions including vapor residence time of up to about 10 seconds, at 900.degree.-1,400.degree. F., and total pressure of about 10 to about 50 pounds per square inch absolute introducing said mobile hydrogen into said mixture stream; contacting said stream with zeolite cracking catalyst to produce liquid products while laying down coke on said catalyst; and separating said coked catalyst from said liquid products.

Abstract: A process for upgrading residual portions of crude oils comprising metal contaminants and Conradson Carbon contributing components by the combination of thermal visbreaking with fluid inert solids and catalytic upgrading of naphtha and higher boiling components of thermal visbreaking in separate systems of riser conversion and solids regeneration is discussed. Heat management of the regeneration systems is restricted in substantial measure by a novel external solids heat exchange apparatus arrangement utilized to partially cool hot regenerated solids utilized in the solids regeneration systems.

Abstract: Solids e.g. catalysts are separated from suspensions in gases e.g. products from catalytic cracking of crude oil fractions a discharging of suspensions against a surface positioned above the outlet of a riser conduit through which the suspensions are flowing and collecting the displaced gases for passage to cyclones.

Abstract: A process is disclosed for the conversion of a hydrocarbon oil feed having a significant content of vanadium to lighter oil products by contacting the feed under conversion conditions in a conversion zone with a catalyst containing a metal additive to immobilize vanadium compounds. Conversion conditions are such that coke and vanadium are deposited on the catalyst in the conversion zone. Coked catalyst is regenerated in the presence of an oxygen containing gas at a temperature sufficient to remove the coke and regenerated catalyst is recycled to the conversion zone for contact with fresh feed. The metal additive is present on the catalyst in an amount sufficient to immobilize the vanadium compounds in the presence of oxygen containing gas at the catalyst regeneration temperature.

Abstract: An apparatus for upgrading residual portions of crude oils comprising metal contaminants and Conradson Carbon contributing components by the combination of thermal visbreaking with fluid inert solids and catalytic upgrading of naphtha and higher boiling components of thermal visbreaking in separate systems of riser conversion and solids regeneration includes an external solids heat exchange apparatus arrangement utilized to partially cool hot regenerated solids utilized in the solids regeneration systems.

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: A process is disclosed for the treatment of a hydrocarbon oil feed having a significant content of vanadium to provide a higher grade of oil products by contacting the feed under treatment conditions in a treatment zone with sorbent material containing a metal additive to immobilize vanadium compounds. Treatment conditions are such that coke and vanadium are deposited on the sorbent in the treatment zone. Coked sorbent is regenerated in the presence of an oxygen containing gas at a temperature sufficient to remove the coke, and regenerated sorbent is recycled to the treatment zone for contact with fresh feed. The metal additive is present on the sorbent in an amount sufficient to immobilize the vanadium compounds in the presence of oxygen containing gas at the sorbent regeneration temperature. A sorbent composition disclosed comprises a kaolin clay containing the metal additive, which may be introduced into the clay during the treatment process or during sorbent manufacture.

Abstract: A process is disclosed for the treatment of a hydrocarbon oil feed having a significant content of vanadium to provide a higher grade of oil products by contacting the feed under treatment conditions in a treatment zone with sorbent material containing a metal additive to immobilize vanadium compounds. Treatment conditions are such that coke and vanadium are deposited on the sorbent in the treatment zone. Coked sorbent is regenerated in the presence of an oxygen containing gas at a temperature sufficient to remove the coke, and regenerated sorbent is recycled to the treatment zone for contact with fresh feed. The metal additive is present on the sorbent in an amount sufficient to immobilize the vanadium compounds in the presence of oxygen containing gas at the sorbent regeneration temperature. A sorbent composition disclosed comprises a kaolin clay containing the metal additive, which may be introduced into the clay during the treatment process or during sorbent manufacture.

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: 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 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: A process is disclosed for economically converting carbo-metallic oils to liquid fuel products by bringing a converter feed containing 650.degree. F.+ material characterized by a carbon residue on pyrolysis of at least about 1 and by containing at least about 4 ppm of Nickel Equivalents of heavy metals, including nickel, into contact with a particulate cracking catalyst in a progressive flow type reactor having an elongated conversion zone. The suspension of catalyst and feed in the reactor has a vapor residence time in the range of about 0.5 to about 10 seconds, a temperature of about 900.degree. F. to about 1400.degree. F. and a pressure of about 10 to about 50 pounds per square inch absolute for causing a conversion per pass in the range of about 50 to about 90 percent while depositing nickel on the catalyst and coke on the catalyst in amounts in the range of about 0.3 to about 3 percent by weight.

Abstract: A process is disclosed for the conversion of a hydrocarbon oil feed having a significant content of vanadium to lighter oil products by contacting the feed under conversion conditions in a conversion zone with a catalyst containing a metal additive to immobilize vanadium compounds. Conversion conditions are such that coke and vanadium are deposited on the catalyst in the conversion zone. Coked catalyst is regenerated in the presence of an oxygen containing gas at a temperature sufficient to remove the coke and regenerated catalyst is recycled to the conversion zone for contact with fresh feed. The metal additive is present on the catalyst in an amount sufficient to immobilize the vanadium compounds in the presence of oxygen containing gas at the catalyst regeneration temperature.

Abstract: A process is disclosed for upgrading a hydrocarbon oil feed having a significant content of metals, especially vanadium, to provide a higher grade of oil products by contacting the feed under sorbing conditions in an upgrading zone with a high surface area, high pore volume sorbent material containing an added alkaline metal to neutralize acidic cracking sites. Upgrading conditions are such that coke and metals are deposited on the sorbent in the upgrading zone. Coked sorbent is regenerated by contact with an oxygen containing gas under regeneration conditions to remove the coke, and regenerated sorbent is recycled to the upgrading zone for contact with fresh feed. The added alkaline metal is present on the sorbent in an amount sufficient to neutralize substantially all of the acidic cracking sites and provide a sorbent material having a MAT relative activity in the range of about 0 to about 1 percent.

Abstract: Method to improve mixing water-and charge in a hydrocarbon conversion unit comprising foaming the charge with a foaming agent e.g. selected from the group consisting of sulfonates or polymer resins (preferably some oil soluble, some water soluble).