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 catalyst which is a hollow microsphere comprising an outer shell in which there are feeder pores and an active ingredient arranged within the shell. The microsphere has a diameter ranging from 20 to 120 microns and the shell has a thickness ranging from 0.1 to 20.0 microns. The active ingredient fills 1.0% to 100% of the void space within the microsphere.

Abstract: Disclosed is a catalyst, a method for its preparation, and a process for its use in the production of high octane gasoline and/or other valuable liquid hydrocarbon products from carbo-metallic oils contaminated with heavy metals and coke precursors. The catalyst is prepared from a shapable composition containing reticulated carbon black particles which are subsequently removed by burning, as in a catalyst regenerator, to provide large feeder pores in a shaped catalyst structure. The catalyst and process conditions for its use facilitate conversion of the contaminated oils to lighter products at catalytic sites within the catalyst structure which may contain zeolitic materials.

Abstract: A solid sorbent particulate, its method of preparation and use is disclosed for the treatment of a residual hydrocarbon oil feed, etc. comprising metal contaminants and high carbon forming constituents with a high pore volume solid sorbent material of at least 0.4 cc/g in a visbreaking zone in which operation the effectiveness of the high pore volume sorbent material is further improved by a metal additive to immobilize low melting point vanadium compounds. The sorbent pore volume, sorbent to oil ratio and operating conditions are such that the volume of sorbent pores filled with oil feed is limited to the range of 1/4 to 2/3 and along with carbonaceous material and metal contaminants are encouraged to deposit within the pores rather than on the exterior surface of the solid sorbent in a hydrothermal visbreaking operation in the absence of added molecular hydrogen.

Abstract: A process is disclosed for increasing the volume of lubricating oil base stocks recovered from a crude oil. A fraction having an atmospheric boiling range of about 675.degree. to 1100.degree. F. is recovered by vacuum distillation. This fraction is treated with furfural to extract a hydrocarbon mixture containing at least 50 volume % aromatic hydrocarbons. The raffinate is a lubricating oil base stock very high in paraffinic hydrocarbons and low in naphthenic hydrocarbons. The fraction extracted by the furfural contains at least about 50 volume % aromatic hydrocarbons and less than about 10 volume % paraffinic hydrocarbons. The mixture is hydrotreated to hydrogenate a substantial portion of the aromatic hydrocarbons. The hydrotreated product then is catalytically dewaxed. After removal of low boiling components, the finished lubricating oil base stock has a viscosity of at least about 200 SUS at 100.degree. F., a pour point of less than 20.degree. F.

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: A process for economically converting carbo-metallic oils to lighter products. The carbo-metallic oils contain 650.degree. F.+ material which is characterized by containing material which will not boil below about 1025.degree. F., a carbon residue on pyrolysis of at least about 2, and a nickel plus vanadium content of at least about 4 parts per million. This process comprises adding an additive to the feedstock consisting of a compound containing titanium, zirconium, or aluminum so as to restore cracking activity of high metal contaminated and deactivated, zeolite containing catalysts, resulting from processing of these carbo-metallic oils.

Abstract: A process is disclosed for the treatment of a hydrocarbon oil feed having a significant content of metals to lighter oil products by contacting the feed under conversion conditions in a conversion zone with a catalyst containing a sacrificial trap material sufficient to immobilize Ni-V-Na compounds. Conversion conditions are such that carbonaceous material and metals are deposited on the catalyst in the conversion zone. The catalyst is regenerated in the presence of an oxygen containing gas at a temperature sufficient to remove the carbonaceous deposits, and regenerated catalyst is recycled to the conversion zone for a contact with fresh feed. The sacrificial trap material is present on the catalyst in an amount sufficient to substantially immobilize the metal compounds in the presence of oxygen containing gas at the catalyst regeneration temperature.

Abstract: A catalyst nominally containing zeolite, preferably HY zeolite and/or ultrastable HY zeolite, clay, alumina and an acidic silica-alumina co-gel matrix. The zeolite is preferably partially exchanged with high La/Ce ratio solution in a wetting step, and rare earths are precipitated onto the matrix. The catalyst has high metals tolerance and is capable of cracking heavy reduced crude oils, producing higher LCO/slurry oil ratio.

Abstract: The present invention is directed to a method and sequence of processing steps within an apparatus arrangement comprising two separate fluidized relatively dense catalyst beds undergoing regeneration to remove carbonaceous deposits wherein catalyst particles are circulated between catalyst beds to transfer heat from one bed to another and transfer partially regenerated catalyst from one bed to a second heat generating catalyst bed, said catalyst regeneration system arranged to maintain a desired heat balanced temperature restriction less than 787.degree. C. (1450.degree. F.) and the generation of a CO.sub.2 rich flue gas with utilization thereof to achieve reaction with carbon form carbon monoxide under endothermic reaction temperature conditions.

Abstract: An improved method of in situ retorting of oil shale wherein a cavern of crushed shale is created within an oil shale deposit, preferably by igniting a powerful explosion within the oil shale deposit, thereby creating a localized area or cavern of rubblized oil shale. Combustion gases are injected into the bottom of this cavern and particulate material, preferably a cracking catalyst, is deposited into a void at the top of the cavern and allowed to trickle down and fill the voids in the rubblized cavern. The oil shale is ignited at the bottom of the cavern and a combustion zone proceeds upwardly while the particulate material is caused by gas flow to percolate downwardly. A fluidized bed of particulate material is thereby formed at the combustion zone providing a controlled, evenly advancing combustion zone.

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: 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 process for economically converting carbo-metallic oils to lighter products. The carbo-metallic oils contain 650.degree. F. plus 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 about 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 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 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: 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: Disclosed is a catalyst, a method for its preparation, and a process for its use in the production of high octane gasoline and/or other valuable liquid hydrocarbon products from carbo-metallic oils contaminated with heavy metals and coke precursors. The catalyst is prepared from a shapable composition containing reticulated carbon black particles which are subsequently removed by burning, as in a catalyst regenerator, to provide large feeder pores in a shaped catalyst structure. The catalyst and process conditions for its use facilitate conversion of the contaminated oils to lighter products at catalytic sites within the catalyst structure which may contain zeolitic materials.