Abstract: A process and apparatus for direct coking of tar sands which includes contacting the tar sand with heat transfer particles resulting from combustion of coked sand effluent from the coking process, and transporting the combination up a riser/mixer to a coking vessel whereby separation of oil and hydrocarbon gases from the sand is initiated. The tar sand is introduced into a fluid coking vessel which has at least two coking zones. The first coking zone is substantially at the top of the vessel whereas the second coking zone is immediately below the first coking zone and includes a stream of hot spent sand so that a more severe coking temperature is present in the second coking zone. A product stream of oil and light hydrocarbon gases, recovered from the riser/mixer and coking process, is directed to a separator located above said coking vessel in which the heavy oil is removed and preferably directed to the second coking zone.

Abstract: An improved fluid coking process is provided in which an aqueous sludge comprising an organic waste is used as quench in a quench elutriator to cool the coke product and convert at least a portion of the organic waste to a vaporous compound (e.g., hydrocarbon) which is recycled to the heating zone to increase the fuel value of the heating zone gaseous effluent.

Abstract: A process for cracking heavy hydrocarbon feedstocks by separation into light and heavy fractions and concommitantly thermally cracking the light fraction and coking the heavy fraction.

Abstract: A two-stage process for staged combustion of crushed retorted particles, especially sulfur and nitrogen-bearing shale, provides maximum heat from combustible materials in shale while emissions of carbon monoxide and oxides of sulfur and nitrogen are minimized. In the first stage, combustion is maintained under fluidizing conditions with a substoichiometric amount of oxygen. Off-gases from the first stage are burned in a second-stage combustion zone utilizing an oxygen-containing gas stream controlled to limit emission of carbon monoxide in the flue gas. To minimize production of sulfur oxides, combustion temperature is concurrently maintained below a peak value of 1700.degree. F. by introducing inert gas or recycled decarbonized fines to the first-stage combustion zone to reduce temperature therein.

Abstract: This invention relates to an apparatus and method embodied in a TRC system for rapidly separating particulate solids from a mixed phase solids-gas stream which may be at velocities up to 150 ft./sec. and at high temperature. Specifically, the device is designed for incorporation at the discharge of solid-gas reacting TRC systems having low residence time requirements and carried out in tubular type reactors. Separation is effected by projecting solids by centrifugal force against a bed of solids as the gas phase makes a 180.degree. directional change, said solids changing direction only 90.degree. relative to the incoming stream.

Abstract: A hydrocarbon feed injection method is provided in which concentric inlet conduits carry hydrocarbon liquid and steam. Small nozzles located on the outer steam-carrying conduit discharge steam in the direction of the inner wall of the transfer line reactor to protect the inner wall from carbonaceous deposits. The hydrocarbon feed nozzles are staged along a line parallel to the longitudinal axis of the transfer line.

Abstract: Coal and residual oil are simultaneously processed in a reactor with a combustion zone at the bottom and a fluidized bed on top of it. The residual oil is injected into heat exchange relationship with the top of the fluidized bed where it is cracked with heat generated by the combustion.

Abstract: A coking process is provided in which a stream of heavy oil product, which typically is recycled to the coking zone, is first subjected to solvent separation using coker naphtha as solvent to separate the heavy oil into a high Conradson carbon content product comprising a minor portion of the coker naphtha and a lower Conradson carbon content product comprising a major portion of the coker naphtha and, thereafter, recovering the lower Conradson carbon content product and recycling the high Conradson content product, including the minor portion of coker naphtha, to the coking zone.

Abstract: The extent of hydrodesulfurization of coke formed by coking bitumen is enhanced by the addition of small amounts of sodium hydroxide to the bitumen prior to coking the same.

Abstract: A coking process is provided in which a stream of heavy oil product, which typically is recycled to the coking zone, is first subjected to solvent separation using coker naphtha as solvent to separate the heavy oil into a high Conradson carbon content product comprising a minor portion of the coker naphtha and a lower Conradson carbon content product comprising a major portion of the coker naphtha and, thereafter, recycling the high Conradson content product, including the minor portion of coker naphtha, to the coking zone, and separating the lower Conradson carbon content product in the coker product fractionator.

Abstract: The sulphur emissive capability, on combustion, of coke which is formed during upgrading of sulphur-containing heavy crude oils, including oil sands bitumen, and residua, is decreased by the addition of calcium carbonate, preferably in the form of limestone, to the heavy crude oil prior to coking. The presence of the limestone leads to an increased yield of liquid distillates from the coking process under preferred coking conditions. Ash remaining after combustion of the coke may be leached to recover nickel and vanadium values therefrom.

Abstract: The sulphur emissive capability, on combustion, of coke which is formed during upgrading of sulphur-containing heavy crude oils, including oil sands bitumen, or residua is decreased by the addition of slaked lime or calcium oxide to the heavy crude oil prior to coking. The presence of the slaked lime or calcium oxide leads to an increased yield of liquid distillates at coking temperatures of about 450.degree. to about 500.degree. C. Ash remaining after combustion of the coke may be leached to recover nickel and vanadium values therefrom.

Abstract: Coking of residual oil and devolatization/partial gasification and desulfurization of solid particulate fuel are carried out in a single reactor. The particulate fuel is burned in a combustion zone in the bottom of the reactor. A bed of particulate fuel is fluidized above the combustion zone with gases rising from the combustion zone. The fluidized bed is maintained at a temperature which cokes the residual oil and volatizes the particulate fuel. A high temperature, low velocity zone is maintained between the combustion zone and the fluidized bed for calcination and desulfurization of the solid fuel.

Abstract: This invention provides a two-stage visbreaking process for increasing the production of a visbroken hydrocarbon product from heavy oil feedstock, which meets heating oil viscosity specifications with little or no blending with external cutter stocks.The second stage visbreaking is conducted at a relatively high Severity in contact with a fluidized bed of particulate solids.

Abstract: A fluid coking process is provided in which a stream of heavy oil product, which typically is recycled to the coking zone, is first subjected to solvent separation to separate it into a high Conradson carbon product and a lower Conradson carbon product and, thereafter, at least a portion of the lower Conradson carbon product is recovered and the high Conradson carbon product is recycled to the coking zone.

Abstract: An improved process and apparatus for generating fuel gas and decoking particulate solids used as the source of heat to effect chemical reactions in a TRC system.

Abstract: In a process for thermal cracking of heavy oils in which a heavy petroleum oil is caused to contact a heated fluidized bed of solid particles in the presence of steam thereby to obtain principally light petroelum oils, the solid particles are stable at the temperature of the thermal cracking and are of substantially spherical shape of porous nature of a pore volume of 0.10 to 1.0 cm.sup.3 /g, a specific surface area of 50 to 1,500 m.sup.2 /g, and a weight-mean diameter of 0.025 to 0.25 mm.

Abstract: A fixed-sulfur, solid fuel product is obtained by an improved coking process wherein petroleum fractions are coked in the presence of added alkaline earth metal oxides. The fixed-sulfur, solid fuel product comprises coke and from about 3 to 30 weight percent, preferably from about 5 to 15 weight percent, "ash" (calculated as calcium oxide) derived from the alkaline earth additive. The quantity alkaline earth metal oxide or precursor thereof added to the coking zone is dependent on the sulfur content of the product coke and on the desired ash content of the solid fuel product. The coking zone may comprise delayed, fluid bed, or moving bed cokers.

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 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: Coke deposited within the gas passages of a dual tower type, fluidized bed apparatus for thermally cracking hydrocarbon oils is removed by combustion through contact with a stream of an oxygen-containing, high temperature combustion gas without a need to disjoint the apparatus. The apparatus is comprised of heating and cracking towers each adapted for containing a mass of fluidized solid particles continuously recirculating between the two towers. In one embodiment, all of the solid particles are discharged from the apparatus and a stream of the oxygen-containing combustion gas, produced in a combustion furnace connected to the heating tower, is allowed to pass through the gas passages.

Abstract: The activity of a fresh alkaline earth metal perovskite-containing catalyst can be increased by contacting the fresh catalyst with a reducing gas at reducing conditions prior to use. The activated catalyst is useful in hydrocarbon treating processes such as catalytic cracking and fluid coking.

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 quenching and cooling the reactor effluent in a thermal regenerative cracking (TRC) system is disclosed. The process for quenching the reactor effluent includes the steps of introducing particulate solids into the reactor effluent stream, passing the composite stream of reactor effluent and particulate solids in indirect heat exchange relationship with a coolant, separating the solids and quenched effluent and returning the separated solids to quench effluent.

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: The oxidation resistance of carbon bodies formed from petroleum coke is increased by inhibiting the catalytic effects of vanadium and/or nickel impurities in the coker feedstock through utilization of an effective amount of an inorganic magnesium compound or an organo-magnesium compound present in such feedstock during coking.

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: Apparatus for quenching and cooling the reactor effluent in a thermal regenerative cracking (TRC) system. The quench apparatus includes a section for introducing relatively cool particulate solids into a hot effluent stream to effect initial quenching and a section to further cool the composite of quenched effluent and solids.

Abstract: A fluid coking process is provided in which a carbonaceous feed is first coked in a dense fluidized bed first coking zone and the effluent of the dense bed is passed as a suspension through a transferline second coking zone. A major portion of the solids is separated from the effluent of the upper end of the transferline and passed to a third coking zone which is operated at a higher temperature than the other coking zones and in which the first and second coking zones are positioned.

Abstract: A fluid coking process is provided in which a catalyst comprising an alkaline earth metal ferrite is present in the fluid coking zone.

Abstract: The invention relates to an improvement in an integrated, two stage coking and steam cracking process for the production of unsaturated light hydrocarbons. A heavy hydrocarbonaceous oil is first coked in a fluidized bed coking zone. The vaporous conversion product is passed to a dilute phase. High temperature cracking in the presence of steam is carried out on the vaporous coker conversion product by injecting into the vapors a stream of hot coke particles at a sufficient temperature and in sufficient amount to raise the coker vapors to steam cracking temperature and supply the endothermic heat of reaction. Solids are separated from product gas in a gas-solids separation zone such as one or more cyclones and sent to the fluid coking zone and the gas is quenched to stop olefin degradation reactions. According to the improvement, relatively low temperature steam is introduced into contact with the separated solids to superheat the steam and cool the solids.

Abstract: A multi-zone fluidized bed hydrocarbon conversion process and apparatus for producing gas and distillable liquid products from heavy hydrocarbon feedstocks. The feedstock is introduced into an upper fluidized bed primary cracking zone maintained at temperature of 850.degree.-1400.degree. F. for cracking reactions therein, and resulting tars and coke are deposited on and within a particulate carrier material contained therein. The carrier material containing said tars and coke descends successively through a stripping zone to remove tars and an interim controlled temperature zone for secondary cracking against an upflowing hot reducing gas, then descends into a lower fluidized bed gasification zone. The gasification zone is maintained at temperature of 1600.degree.-1900.degree. F. by oxygen-containing gas and steam introduced therein to gasify the coke deposits and produce the reducing gas.

Abstract: A process for treating liquid hydrocarbons to remove toxic, mutagenic and/or carcinogenic aromatic hydrocarbons comprises feeding the hydrocarbons into a reactor where vapors are thermally treated in contact with a catalyst consisting essentially of calcium oxide or a calcium oxide containing mineral. Thermally treating liquid hydrocarbons in contact with calcium oxide preferentially increases the cracking of aromatics thus producing a product having a reduced amount of aromatic compounds.

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).

Abstract: An improved process for economically converting carbo-metallic oils to lighter products. Enhanced catalyst activity is enjoyed through use of a select process to vaporize and atomize the high boiling portion of a carbo-metallic oil feed. The carbo-metallic oil feed is dispersed into droplets having a diameter of at least smaller than 350 microns and preferably 100 microns or less. These small droplets ensure more even coverage of the catalyst surface and decrease diffusion problems. The water utilized for dispersion of the carbo-metallic oil feed is present as a homogenized mixture in fine oil droplets with an average diameter below 1,000 microns. The water is dispersed in the carbo-metallic oil feed through use of a select mixing apparatus and can be dispersed as finer droplet sizes through use of an emulsifying or dispersing agent. The ratio of water to carbo-metallic oil feed ranges from about 0.04 to 0.25 by weight and the concentration of emulsifying agent ranges from 0.01 to 10 wt.

Abstract: A fluid coking process is provided in which a polymetaphosphoric acid, a salt of a polymetaphosphoric acid or precursors thereof are present in the fluid coking zone.

Abstract: The invention relates to an improvement in an integrated, two stage coking and steam cracking process for the production of unsaturated light hydrocarbons. A heavy hydrocarbonaceous oil is first coked in a fluid coking zone. High temperature cracking in the presence of steam is carried out on the vaporous coker conversion product by injecting into the vapors a stream of hot coke particles at a sufficient temperature and in sufficient amount to raise the coker vapors to steam cracking temperature and supply the endothermic heat of reaction. Solids are separated from gas in a gas-solids separation zone such as one or more cyclones and sent to the fluid coking zone and the gas is quenched to stop olefin degradation reactions. According to the improvement, a portion of the separated solids is diverted from entering the fluid coking zone so that the amount of separated solids it receives is only sufficient to satisfy its heat requirement. Solids may be diverted via the cyclone dipleg.

Abstract: A process for increasing coker distillate yield in a coking process by adding a small amount, generally 0.005-10% by weight of a free radical inhibitor selected from the group consisting of hydroquinone and N-phenyl-2-naphthylamine to the coker feed material.

Abstract: Method for converting a heavy or high boiling fraction oil to separate upgraded products, namely synthetic natural gas and carbon-coated aluminum, by hydrocracking the residual oil in the presence of particulate alumina at elevated temperature and pressure. The product streams, carbon-impregnated alumina and hydrocracked gaseous products, upon purification, are each of separate value. Economics of the process are improved by integration of certain purification steps and by the provision of hydrogen, for the hydrocracking process, by recycle from separated hydrogen in the synthetic natural gas stream and from partial oxidation of an additional portion of residual oil feedstock and separated heavy aromatics from the hydrocracking unit.

Abstract: An improved Thermal Regenerative Cracking (TRC) apparatus and process includes: (10) an improved low residence time solid-gas separation device and system; and (2) an improved solids feeding device and system; as well as an improved sequential thermal cracking process; an improved solids quench boiler and process; an improved preheat vaporization system; and an improved fuel gas generation system for solids heated. One or more of the improvements may be incorporated in a conventional TRC system.

Abstract: A fluid coking process is provided in which inert particles, such as coke, are added to the coker feed, in a specified amount.

Abstract: An improved solid fuel obtained by blending fluid coke with 2 to 20 wt. % of a heavy petroleum liquid.

Abstract: Apparatus for quenching and cooling the reactor effluent in a thermal regenerative cracking (TRC) system. The quench apparatus includes a section for introducing relatively cool particulate solids into a hot effluent stream to effect initial quenching and a section to further cool the composite of quenched effluent and solids.

Abstract: In a TRC process and system, an improved process and system for regulating the rate of solids added continuously to a solids-fluid reaction system, the solids participating in the reaction as a reactant, catalyst, or inert heat supply medium.

Abstract: In a hydrocarbon conversion operation employing a fluidized cracking catalyst wherein the cracking catalyst has been passivated to render contaminating metals thereon substantially inactive thus to avoid undesired reactions and wherein the used catalyst is regenerated and the regeneration step yields catalyst fines and a flue gas and the flue gas and fines are separated in at least two stages a first stage yielding coarse fines and a later stage yielding finer fines the step of treating finer fines to render metals thereon non-leachable or having substantially reduced leachability to render the finer fines usable as land fill which comprises treating the finer fines with a tin and/or indium and/or a compound of tin and/or a compound of indium.

Abstract: An apparatus and process for delivering fluidization gas to a bed of particulate solids to selectively locally fluidize the solids above a delivery conduit in communication with a reaction chamber. Also an apparatus and process for intimately mixing hydrocarbon feed with the particulate solids at the end of the delivery conduit in the reaction chamber.

Abstract: An integrated fluid coking and gasification process is provided in which a portion of the coke is gasified in a first gasification zone in the presence of an oxygen-containing gas to produce a hot gas and hot coke. A portion of the resulting hot coke is gasified in a second gasification zone in the presence of steam to produce a gas comprising hydrogen and carbon monoxide, which is suitable, after conventional shift and clean up, for use as synthesis gas.

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: An integrated catalytic fluid coking and gasification process is provided in which a portion of the coke produced in the coker is steam gasified to produce a hydrogen-containing gas and a catalytic partially gasified coke. Subsequently, a portion of the catalytic partially gasified coke is burned to provide heated partially gasified coke which is recycled to the gasification zone. A portion of the catalytic partially gasified coke is passed from the gasification zone to the coker to contact the coker vapor phase product comprising normally liquid hydrocarbons and to crack at least a portion of the normally liquid hydrocarbons. Optionally, solid fines recovered from the gaseous effluent of the gasification zone may be recycled to the carbonaceous chargestock of the coker.