Abstract: Gas oil components, coking process recycle, and heavier hydrocarbons are cracked or coked in the coking vessel by injecting an additive into the vapors of traditional coking processes in the coking vessel. The additive contains catalyst(s), seeding agent(s), excess reactant(s), quenching agent(s), carrier(s), or any combination thereof to modify reaction kinetics to preferentially crack or coke these components. Modifications of the catalysts in the additive improve performance for certain desired outcomes. One exemplary embodiment of the present invention uses the olefin production capabilities from newly developed catalysts to increase the production of light olefins (e.g. ethylene, propylenes, butylenes, pentenes) for alkylation process unit feed, the production of oxygenates, and petrochemical feedstocks, such as plastics manufacture. Another exemplary embodiment of the present invention is the use of the olefin production from newly developed catalysts to improve the coker naphtha quality.

Abstract: A reactor process added to a coking process to modify the quantity or yield of a coking process product and/or modify certain characteristics or properties of coking process products.

Abstract: A reactor process added to a coking process to modify the quantity or yield of a coking process product and/or modify certain characteristics or properties of coking process products.

Abstract: Undesirable gas oil components are selectively cracked or coked in a coking vessel by injecting an additive into the vapors of traditional coking processes in the coking vessel prior to fractionation. The additive contains catalyst(s), seeding agent(s), excess reactant(s), quenching agent(s), carrier(s), or any combination thereof to modify reaction kinetics to preferentially crack or coke these undesirable components that typically have a high propensity to coke. Exemplary embodiments of the present invention also provide methods to control the (1) coke crystalline structure and (2) the quantity and quality of volatile combustible materials (VCMs) in the resulting coke. That is, by varying the quantity and quality of the catalyst, seeding agent, and/or excess reactant the process may affect the quality and quantity of the coke produced, particularly with respect to the crystalline structure (or morphology) of the coke and the quantity & quality of the VCMs in the coke.

Abstract: Gas oil components, coking process recycle, and heavier hydrocarbons are cracked or coked in the coking vessel by injecting an additive into the vapors of traditional coking processes in the coking vessel. The additive contains catalyst(s), seeding agent(s), excess reactant(s), quenching agent(s), carrier(s), or any combination thereof to modify reaction kinetics to preferentially crack or coke these components. Modifications of the catalysts in the additive improve performance for certain desired outcomes. One exemplary embodiment of the present invention uses the olefin production capabilities from newly developed catalysts to increase the production of light olefins (e.g. ethylene, propylenes, butylenes, pentenes) for alkylation process unit feed, the production of oxygenates, and petrochemical feedstocks, such as plastics manufacture. Another exemplary embodiment of the present invention is the use of the olefin production from newly developed catalysts to improve the coker naphtha quality.

Abstract: Gas oil components, coking process recycle, and heavier hydrocarbons are cracked or coked in the coking vessel by injecting an additive into the vapors of traditional coking processes in the coking vessel. The additive contains catalyst(s), seeding agent(s), excess reactant(s), quenching agent(s), carrier(s), or any combination thereof to modify reaction kinetics to preferentially crack or coke these components. The quenching effect of the additive can be effectively used to condense the highest boiling point compounds onto the catalyst(s), thereby focusing the catalyst exposure to these target reactants. With a catalyst to crack these highest boiling point materials, this mechanism can effectively increase the catalyst's selectivity, thereby increasing its efficiency and reducing catalyst requirements and costs.

Abstract: A reactor process added to a coking process to modify the quantity or yield of a coking process product and/or modify certain characteristics or properties of coking process products.

Abstract: A premium “fuel-grade” petroleum coke is produced by modifying petroleum coking technology. Coking process parameters are controlled to consistently produce petroleum coke within a predetermined range for volatile combustible material (VCM) content. The invention includes a process of producing a coke fuel, the method comprising steps: (a) obtaining a coke precursor material derived from crude oil and having a volatile organic component; and (b) subjecting the coke precursor material to a thermal cracking process for sufficient time and at sufficient temperature and under sufficient pressure so as to produce a coke product having volatile combustible materials (VCMs) present in an amount in the range of from about 13% to about 50% by weight. Most preferably, the volatile combustible materials in the coke product typically may be in the range of from about 15% to about 30% by weight.

Abstract: A premium “fuel-grade” petroleum coke is produced by modifying petroleum coking technology. Coking process parameters are controlled to consistently produce petroleum coke within a predetermined range for volatile combustible material (VCM) content. The invention includes a process of producing a coke fuel, the method comprising steps: (a) obtaining a coke precursor material derived from crude oil and having a volatile organic component; and (b) subjecting the coke precursor material to a thermal cracking process for sufficient time and at sufficient temperature and under sufficient pressure so as to produce a coke product having a volatile combustible material (VCM) present in an amount in the range of from about 13% to about 50% by weight. Most preferably, the volatile combustible material in the coke product typically may be in the range of from about 15% to about 30% by weight.