Abstract: An improved Thermal Regenerative Cracking (TRC) apparatus and process includes: (1) 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 burner vessel or regenerator vessel is disclosed which has an elliptical bottom head which supports a particulate refractory fill which in turn supports and stabilizes an air distributor inlet manifold. The manifold is supported at radially arranged distribution pipes so that the main air header floats freely for expansion and contraction. A fluidized bed of particulate is combusted above the refractory fill layer. Other appropriate operation apparatus for the vessel are also disclosed. The burner vessel is used in a fluid coker apparatus and the regenerator vessel is used in a fluid catalytic cracking unit.

Abstract: An improved method for retorting oil shale with heat-carrying bodies comprising relatively coarse attrition resistant, non-oil sorbing, shale ash particles wherein oil recovery is maximized. After retorting, the spent oil shale and heat-carrying bodies are transferred to a reheating vessel or combustor. The reheating vessel contains a dense phase fluidized bed wherein the fixed carbon contained in the spent shale is combusted at temperatures between 1100.degree. F. and 1600.degree. F. to reheat the heat-carrying bodies. The invention is based on the finding that the decomposition of kerogen, which is present as a binder in raw oil shale, leaves pores within kerogen-rich shale which results in relatively large surface areas. Attrition of the kerogen-rich shale in the dense phase fluidized bed at a superificial gas velocity of 7-14 ft/sec reduces the size of this porous, friable material and allows it to be removed in the exit gas stream as fines.

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: 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: A solid product resulting from the nucleated growth of the product on solid material of either the same or different composition and having a density higher than the reaction medium is formed from one or more liquid phase reactants by a method which comprises tangentially introducing the liquid phase reaction medium into the lower, smaller end of an inverted, frusto-conical reactor-separator, thereby imparting an upward swirling motion to the reaction medium in the reactor-separator, the horizontal velocity at the bottom of the reactor-separator being sufficiently large to cause fluidization of larger, solid product particles and concentration of them in the central lower portion of the reactor-separator and the vertical velocity at the top of the reactor-separator being sufficiently small to avoid carry-over of the smaller solid particles but sufficiently large to concentrate them in the upper portion of the reactor-separator; at least periodically recovering the larger, solid product particles in spherical

Abstract: A process and system for vaporizing heavy oil prior to thermal cracking in a TRC system having low residence time on the order of 0.05 to 2 seconds, and at a temperature between 1300.degree. and 2500.degree. F.

Abstract: Unsaturated light hydrocarbons are produced by coking a heavy hydrocarbonaceous oil in a conventional fluid coking zone and subsequently heating the vaporous coker product to a higher temperature in a gas-solids separation zone, such as the coking reactor's cyclone separator, with hot solids derived from a coke gasification zone.

Abstract: A fluid coking process is provided in which the recycling of coke particles of less than about 44 microns in diameter to the coking reactor is minimized by passing the stream of coke withdrawn from the coking reactor to a vessel comprising a fluidized bed of solids separated into two zones. The coke withdrawn from the coker is passed into one zone where seed generation for the process is performed. Coke recycled to the coker is withdrawn from the second zone which is operated as an elutriation zone. The solid fines of less than 44 microns are removed overhead from the vessel with the gaseous effluent of the vessel. This improvement is particularly suitable for once-through fluid coking to minimize small fines being present in the coker liquid product.

Abstract: Heat transfer in a hydrocarbon conversion process utilizing a magnetically stabilized fluid bed reactor and a magnetically stabilized catalyst regenerator is improved by the use of a fluidizable solids mixture comprising substantially inert heat carrier particles and magnetizable catalyst particles wherein the inert particles have settling rates higher than the settling rates of the catalyst particles. The heat carrier particles and the magnetizable catalyst particles are completely or partially separated in settling zones associated with the reactor and regenerator. The separated heat carrier particles and catalyst particles are independently circulated between the reactor and regenerator so that the heat carrier particles can be passed through one or more heat exchangers to provide the desired temperature levels in the system.

Abstract: A hydrocarbon conversion process wherein a hydrocarbon feedstock is contacted with a magnetically stabilized fluid bed of particulate solids comprising a mixture of separate, discrete (a) magnetizable substantially non-catalytic particles, and (b) non-magnetizable catalytic particles. The particulate solids mixture is withdrawn from the magnetically stabilized, fluidized bed and separated into magnetizable, substantially non-catalytic particles and non-magnetizable catalyst particles. The non-magnetizable catalytic particles are thereafter regenerated and returned to the hydrocarbon conversion zone. The separated magnetizable, substantially non-catalytic particles are subjected to heat transfer prior to their return to the conversion zone.

Abstract: In an integrated coking and gasification process wherein a stream of fluidized solids is passed from a fluidized bed coking zone to a second fluidized bed and wherein entrained solid fines are recovered by a scrubbing process and wherein the resulting solids-liquid slurry is stripped with a stripping gas to remove acidic gases, at least a portion of the stripping gas comprises a gas comprising hydrogen, nitrogen and methane separated from the coker products.

Abstract: An integrated fluid coking and gasification process is provided in which a solid cracking catalyst is added to the coker chargestock and in which a partially gasified coke matrix comprising the cracking catalyst is recycled to the coker vapor phase product.

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: A process for producing olefines by using a fluidized bed of coke particles rovided in each of a reactor and a heater, circulating coke particles through the reactor and the heater, heating the coke particles by a combustion of fuel and if desired, a part of the coke particles in the heater, thermally cracking a heavy oil with a heated coke particles as a heat carrier in the reactor, the improvement which comprises a distillation residue is converted into a high-temperature, low-calorie gas in a combustion chamber, and the coke particles is heated with the gas in the heater, further an increment of coke deposited on a surface of the coke particles is burned by blowing air to the heater.

Abstract: The quantity and quality of liquids produced from solid coal can be enhanced by a process comprising a liquefaction zone and a pyrolysis reactor, preferably a fluid coking zone, wherein the heavy liquids obtained in the pyrolysis reactor, e.g., 1000.degree. F.+ materials having a Conradson Carbon content of at least 15 wt. % are recycled to the liquefaction zone, rather than to the pyrolysis reactor, for further treatment under hydrogenation conditions and, consequently, conversion of the heavy liquids to lower boiling liquids which may be removed from the pyrolysis reactor feed by distillation is achieved.

Abstract: A high pressure fluid hydrocoking process is provided in which certain metal compounds which act as coke forming inhibitors are dispersed in the coker chargestock. Preferred compounds are molybdenum compounds, for example, molybdenum naphthenate. The hydrogen-containing fluidizing gas may also comprise hydrogen sulfide.

Abstract: The thermal cracking of retort oil vapors in an elongated reactor is improved by passing the effluent oil vapors and gases from a retort to a thermal cracking unit before the temperature of the retort effluent falls below 680.degree. F. This encourages the more desirable cracking reactions, increases the thermal efficiency of the process, and avoids preheater coking.

Abstract: In a reactor for cracking heavy hydrocarbon oil through a fluidized bed of particles of natural ores, coke-like materials are deposited on a top of the reactor or pipe inside surfaces of a transfer line from the reactor to a scrubber. To effectively scour out the deposited coke-like materials, particles of natural ores having a mean diameter of a few hundred .mu.m is made to be contained in an effluent gas from the top of reactor, passing through the transfer line at a concentration of 1 to 40 g/m.sup.3. The particles of natural ores have a good effect of scouring out the deposited coke-like materials and can keep the transfer line efficiently clean even with a small amount of the particles of natural ores, decreasing a pressure drop in the transfer line.

Abstract: A fluidized stream of coal particles is introduced into the bottom of a vertical reaction zone in a fluidized bed process at a velocity of greater than about 200 ft/sec in a vertically upwards direction, wherein agglomeration of the fluidized bed is prevented. A separate liquid hydrocarbon stream is simultaneously introduced as a separate injection stream in a vertically upwards direction, said coal particles and said liquid hydrocarbons being rapidly and uniformly dispersed within the fluidized bed and reacted therein with a suitable reagent.

Abstract: The heat requirements of a fluid coking zone are provided by introducing a hot vaporous hydrocarbon stream into the coking zone instead of the conventional hot coke stream. The fluid coking process may be integrated with a coke gasification process.

Abstract: A combination slurry hydroconversion, coking and coke gasification process is provided wherein carbonaceous solids having an average particle size of less than 10 microns in diameter or the ashes thereof are used as a catalyst in the hydroconversion stage.

Abstract: Fresh carbonaceous particles are introduced into a fluid-bed reaction zone containing a bed of non-agglomerating particles at an injection velocity in excess of about 200 ft/sec with the fresh particles having been preheated to a temperature within the plastic transformation range of the particles and introduced rapidly and directly into said bed of non-agglomerating particles. The reaction zone may be a hydrocarbonization zone, a carbonization zone, a gasification zone or any other fluid-bed reaction zone in which defluidization may be caused by undue agglomeration of the feed particles. A fluidized stream of the preheated carbonaceous particles may be introduced at said high injection velocity in a vertically upwards direction or otherwise, as from one or more injection points positioned vertically along the side of the reaction zone.

Abstract: In the introduction of fresh carbonaceous particles into a fluid-bed reaction zone at injection velocities in excess of 20 ft/sec, a shroud gas is passed through a shroud passage on the injection nozzle at a velocity in excess of about 750 ft/sec, preferably at from about 1,000 to about 5,000 ft/sec, in sufficient quantities to supply a substantial portion of the overall energy input into the reaction zone for dispersion of the fresh particles and for breaking up of any agglomerates formed upon injection of the fresh particles into the reaction zone. By accommodating the agglomerating tendencies of the fresh feed material, the high energy shroud gas effectively contributes to the prevention of defluidization of the bed. The shroud gas may be inert or may comprise a gaseous reagent that reacts with the fresh carbonaceous particles in the reaction zone. The energy supplied by the shroud gas desirably is at least about 80% of said energy input to the reaction zone.

Abstract: An integrated process for production of light hydrocarbons and synthesis gas is disclosed. The process is characterized by pyrolysis of hydrocarbonaceous materials utilizing a solid particulate heat carrier, the heat carrier also providing heat for the conversion of a carbonaceous material to synthesis gas.

Abstract: A combination slurry hydroconversion, coking and coke gasification process is provided wherein solid fines having an average particle size of less than 10 microns in diameter or the ashes thereof recovered from a gaseous product derived from the coke gasification are used as a catalyst in the hydroconversion stage in combination with a catalyst produced from an oil soluble metal compound in situ in the chargestock of the hydroconversion zone.

Abstract: A thermal cracking process and apparatus are disclosed for economical manufacture of lower olefins and valuable coproducts by pyrolysis of liquid or gaseous hydrocarbon feedstocks ranging from ethane to tar sands, particularly feedstocks, such as gas oil, naphtha, residual oils or tar sands. The pyrolysis unit is a riser reactor heated by hot agglomerated ash particles and designed for short residence time to minimize the time of contact of the feedstock with the hot ash. The agglomerated ash is continually produced in a fluidized bed combustion unit by burning particles of coal or other solid carbonaceous material, and the hot agglomerated ash is continually forced upwardly through the riser by superheated steam which is further superheated in the riser reactor and which serves as dilution steam for hydrocarbon partial pressure reduction. Additional dilution steam enters the reactor with the preheated feedstock.

Abstract: A combination slurry hydroconversion, coking and coke gasification process is provided wherein solid fines having an average particle size of less than 10 microns in diameter or the ashes thereof recovered from a gaseous product derived from the coke gasification are used as a catalyst in the hydroconversion stage.

Abstract: Char fines produced by the gasification of coal or other carbonaceous solids are coked in the presence of heavy hydrocarbon oils, preferably 1000.degree. F.+ bottoms products from a coal liquefaction process, to produce gaseous products, liquids, and larger coke particles. The coke particles thus produced may be fed to the gasifier for the production of additional gaseous products which can be used as fuel, employed as a source of hydrogen for coal liquefaction operations, or utilized for the production of hydrocarbon liquids.

Abstract: In a thermal cracking process employing inert hot solids as a heat source, the cracker effluent solids are passed to a burner for combustion of deposited and entrained coke. The liquid product of the thermal cracking process is distilled and the liquid residue comprises a low value solids-containing slurry which is used as a torch oil in the coke burner. The liquid residue from a catalytic cracking process also comprises a low value slurry since it contains particles of cracking catalyst and in the present process is used as auxiliary torch oil in the solids burner. The catalyst particles are rendered inert at the high temperature of the burner, thereby enhancing the quantity of inert solids circulating in the thermal cracking process. The use of a second slurry as torch oil reduces the quantity of thermally cracked liquid residue required as torch oil and enhances the quantity of more valuable solids-free distillate liquid recoverable from the thermal cracking process.

Abstract: A process for thermal cracking of petroleum light gas oil to produce a product including ethylene comprising passing said oil, a diluent gas and entrained hot solids through a cracking zone at a temperature between 1,300.degree. and 2,500.degree. F. at a relatively high cracking severity corresponding to a methane yield of at least 12 weight percent based on hydrocarbon feed oil and with a weight ratio of diluent gas to feed oil of at least 0.3. A naphtha feedstock can be separately cracked at a lower severity using a lower weight ratio of diluent gas to feed oil, with the inert solids from both cracking zones being sent to a common burner whose fuel comprises heavy oil product from both cracking zones.

Abstract: In the process of thermally cracking a heavy hydrocarbon oil by feeding said oil into a fluidized bed reactor as a high-velocity atomized gas stream by blowing said oil therein from a gas-mixing type nozzle along with an atomizing gas and carrying out the thermal cracking of the oil at above 500.degree. C., the improvement which comprises blowing in an inert gas to the eddying part formed in the environs of said atomized gas stream in said fluidized bed reactor thereby blocking the formation of eddies to thus prevent the accumulation of coke deposits on the outside wall of said nozzle and the walls of the fluidized bed reactor in the vicinity of said nozzle.

Abstract: A continuous deep hydrogenation coal liquefaction process is disclosed wherein a slurry of powdered coal or other carbonaceous material in a recycle solvent is passed with hydrogen through a hydroextraction unit, the heavy coal extract remaining after removal of gas and oil is then fed into a low-temperature fluidized-bed pyrolysis unit, and the char and ash is fed from the pyrolysis unit to a high-temperature fluidized-bed char gasification unit. The gasification unit is specially constructed to provide continuous ash agglomeration and has a funnel-shaped grid plate at the bottom of the fluidized bed and an elutriation leg of reduced diameter at the bottom of the grid plate. Air or oxygen is introduced near the top of the elutriation leg to provide a high temperature such that the ash particles are continuously softened and caused to accrete or agglomerate in a hot spouting zone at the base of the grid plate.

Abstract: In a coal liquefaction process wherein heavy bottoms produced in a liquefaction zone are upgraded by coking or a similar pyrolysis step, pyrolysis liquids boiling in excess of about 1000.degree. F. are further reacted with molecular hydrogen in a reaction zone external of the liquefaction zone, the resulting effluent is fractionated to produce one or more distillate fractions and a bottoms fraction, a portion of this bottoms fraction is recycled to the reaction zone, and the remaining portion of the bottoms fraction is recycled to the pyrolysis step.

Abstract: A process for the non-catalytic riser cracking of shale oil to produce ethylene in the presence of entrained hot, inert solids.

Abstract: A low sulfur content coke is obtained in an integrated coking and gasification process wherein a portion or all of the steam reactant conventionally introduced into the gasification zone is replaced by a hydrogen-containing gas.

Abstract: Coal is liquefied by treatment with a hydrogen-donor solvent and gaseous hydrogen, a heavy bottoms product boiling primarily in excess of about 1000.degree. F. is recovered, and this bottoms product is then pyrolyzed with fresh coal to produce surprisingly high yields of liquid product. The coke formed during the pyrolysis step may be gasified to generate hydrogen for use in the liquefaction operation and additional gas which can be employed as a fuel or upgraded for other uses.

Abstract: In a coking process wherein a stream of fluidized solids is passed from a fluidized bed coking zone to a second fluidized bed, entrained coke fines recovered from the gaseous effluent of the second fluidized bed zone are recycled as dry fines to the coking zone.

Abstract: A process for the production of ethylene by the non-catalytic riser cracking of hydrodesulfurized residual petroleum oils in the presence of entrained hot, inert solids.

Abstract: A hydrocarbonaceous oil is introduced to a quench and scrubbing zone mounted on a fluid coking reactor. Heat from the coker vapor product vaporizes a portion of the hydrocarbonaceous oil. The unvaporized portion of the oil is used to quench and scrub the coker vapor product. The bottoms fraction of the quench and scrubbing zone is passed to a vacuum distillation zone to recover a heavy oil fraction and to produce a vacuum residuum for use as coker feed.

Abstract: In the thermal cracking of a hydrocarbon feed oil to produce a product including ethylene, the feed oil is passed together with entrained hot solids through a high temperature cracking zone. Coke-laden hot solids are recovered and passed to a burner zone together with crushed oil shale as supplementary fuel. An acidic material, such as HF catalyst from an alkylation unit, can also be employed as supplementary fuel. The acidic material will react with alkaline components in the oil shale to form stable neutral salts which circulate as heat carrier solids.

Abstract: In a fluid coking process, a gas containing coke particles is elutriated in a riser portion of a vessel to remove selectively the larger coke particles. The elutriated gas flows into a bed of solids positioned in the upper portion of the vessel.

Abstract: A process for producing coke from sulfur-containing hydrocarbon feedstocks which involves contacting at least a portion of the feedstock with a peroxy oxidant in the presence of a metal-containing catalyst to preferentially oxidize a portion of the hydrocarbon feedstock, subjecting the feedstock to coking conditions to form coke and recovering a coke product. The present process can provide improved yields of coke having substantially reduced sulfur content.

Abstract: A fluid coking process is provided in which a relatively large amount of hydrogen sulfide is added to the coker fluidizing gas. A preferred fluidizing gas is a mixture of hydrogen and hydrogen sulfide.

Abstract: A process for controlling the coke balance as well as the size of coke particles within a fluidized bed in the range adapted for continuous operation of a heavy residual oil cracking apparatus, wherein thermal cracking of heavy residual oil is performed under fluidization of coke particles and steam, which comprises classifying one portion of the coke particles withdrawn from the fluidized bed into coarse particles and fine particles by means of a pneumatic classifier, and after the size of said coarse particles have been reduced by combustion, returning them to the fluidized bed along with said fine particles.

Abstract: A process for the thermal cracking of heavy oils with a fluidized particulate heat carrier is carried out while recovering particles of the heat carrier accompanied by a stream of the reaction product by means of a cyclone and a gravitational separator, returning the particles of the heat carrier recovered by the cyclone directly to the reactor and returning the particles of the heat carrier recovered by the gravitational separator to the reactor in the form of suspension in a cracked oil.

Abstract: In the thermal cracking of heavy petroleum oil (having an API specific gravity of not more than 25) in a tubular type heating furnace, a specific inorganic substance is added in a specific proportion to the heavy petroleum oil to prevent the heavy oil from undergoing coking inside the furnace.

Abstract: In the thermal cracking of a heavy petroleum oil (having an API specific gravity of not more than 25) in a tubular type heating furnace, possible occurrence of coking trouble inside the furnace can be prevented by applying a magnetic field of fixed magnitude transversely to the flow of the heavy petroleum oil being introduced into the furnace or by applying a fixed magnitude of magnetic field transversely and, at the same time, applying a fixed magnitude of direct-current voltage parallel to the flow of the heavy petroleum oil being introduced into the furnace. More effective prevention of occurrence of coking can be obtained by having a specific inorganic substance incorporated in the heavy petroleum oil before the oil is subjected to the magnetic field or to simultaneous application of the magnetic field and voltage.

Abstract: A method of obtaining a refined oil product from low-grade oils containing a relatively large amount of water and/or sludge, which comprises the steps of introducing a low-grade oil directly into a fluidized bed type cracking furnace and subjecting it to thermal cracking therein, introducing the resulting efflux from said cracking furnace into a fractionation column and therein separating it into an overhead light vapor component which is removed from the top of said column and a heavy component which is recovered from the bottom of said column, cooling the overhead light vapor component and then feeding it into a gas-liquid separator to divide it into a vapor-phase stream and a liquidphase stream, and circulating a part of said liquid-phase stream to the top of the fractionation column as reflux while recovering the balance of the liquid-phase stream as the refined oil product.

Abstract: In producing cracked gas and cracked oil by thermally cracking a heavy hydrocarbon within a reactor in which a granular solid, steam and oxygen form a fluidized bed or moving bed, a process which is characterized in that the heavy hydrocarbon is supplied to the upper portion of the reactor and part of the granular solid is discharged from the bottom of the reactor and thereafter fed again to the upper portion of the reactor, to thereby maintain the upper portion at a temperature of not higher than 550.degree.C.