Claims
- 1. A process for converting the residue from partially distilling a hydrocarbonaceous material to lighter products, comprising:
- I. providing a distillation bottoms oil containing 650.degree. F.+ material, said 650.degree. F.+ material being characterized by a carbon residue on pyrolysis of at least about 1 and by containing at least about 4 parts per million of Nickel Equivalents of heavy metal(s);
- II. bringing said converter feed together with cracking catalyst bearing substantially more than 600 ppm Nickel Equivalents of heavy metal to form a stream comprising a suspension of said catalyst in said feed and causing the resultant stream to flow through a progressive flow type reactor having an elongated reaction chamber which is at least in part vertical or inclined for a 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 at least about 6 by weight based on fresh feed, and laying down coke on the catalyst in amounts in the range of about 0.3 to about 3% by weight;
- III. separating said catalyst from the resultant cracking products;
- IV. stripping said separated catalyst;
- V. regenerating said metals-bearing, coked catalyst by burning the coke in a two-stage regeneration zone with oxygen-containing combustion-supporting gas while forming combustion product gases comprising CO and/or CO.sub.2 and a sulfur oxide, maintaining the CO:CO.sub.2 molar ratio of the combustion product gases formed from the burning of at least the major weight portion of the coke at a level of at least about 0.25 while such gases are in heat exchange contact with the catalyst, burning sufficient coke to reduce the weight of carbon on catalyst to about 0.1% or less while limiting the amount of combustion-supporting gas supplied to the regeneration operation as a whole to less than the stochiometric amount which would be required to burn all of the carbon in the coke to CO.sub.2, to burn all of the H.sub.2 in the coke to H.sub.2 O and to burn any other combustibles which may be present in the coke to their respective combustion products, and restricting the combined free oxygen mole % of all gases resulting from the entire, completed combustion of coke in said two-stage regeneration zone to zero or an amount substantially less than 2%; and
- VI. recycling the regenerated catalyst to the reactor for contact with fresh feed.
- 2. A process for economically converting carbo-metallic oils to lighter products, comprising:
- I. providing a converter feed containing 650.degree. F.+ material, said 650.degree. F.+ material being characterized by a carbon residue on pyrolysis of at least about 1 and by containing at least about 4 parts per million of Nickel Equivalents of heavy metal(s);
- II. bringing said converter feed together with cracking catalyst bearing substantially more than 600 ppm Nickel Equivalents of heavy metal to form a stream comprising a suspension of said catalyst in said feed and causing the resultant stream to flow through a progressive flow type reactor having an elongated reaction chamber which is at least in part vertical or inclined for a vapor residence time in said elongated reaction chamber in the range of about 0.5 to about 10 seconds at a reaction chamber outlet temperature of about 900.degree. to about 1400.degree. F. and under a pressure of 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 of at least about 6% by weight based on fresh feed, and laying down coke on the catalyst in amounts in the range of about 0.3 to about 3% by weight;
- III. separating said catalyst from the resultant cracking products;
- IV. stripping said separated catalyst;
- V. regenerating said metals-bearing, coked catalyst by burning the coke in a plurality of regeneration zones with oxygen-containing combustion-supporting gas in at least a first stage of regeneration and at least a subsequent stage of regeneration while forming combustion product gases comprising CO and CO.sub.2, maintaining the CO:CO.sub.2 molar ratio of the combustion product gases formed from the burning of at least the major weight portion of the coke in one or more of said plurality of regeneration zones at a level of at least about 0.25 while such gases are in heat exchange contact with the catalyst, burning sufficient coke in at least one of said plurality of regeneration zones to reduce the weight of carbon on catalyst to about 0.1% or less while limiting the combined total amount of combustion-supporting gas supplied to all of said plurality of regeneration zones to less than the stoichiometric amount which would be required to burn all of the carbon in the coke to CO.sub.2, to burn all of the H.sub.2 in the coke to H.sub.2 O and to burn any other combustibles which may be present in the coke to their respective combustion products, and restricting the combined mole percentage of free oxygen in all gases resulting from the entire, completed combustion of coke in said regeneration zones to an amount substantially less than 2%; and
- VI. recycling the regenerated catalyst to the reactor for contact with fresh feed.
- 3. A process according to claim 2 in which said catalyst regenerating step reduces the carbon on the catalyst to about 0.1% by weight or less.
- 4. A process according to claim 2 wherein the catalyst is regenerated to a carbon content of about 0.5% or less.
- 5. A process according to claim 2 wherein the catalyst is regenerated to a carbon content of about 0.025% or less.
- 6. A process according to claim 2 wherein the catalyst is regenerated to a carbon content of about 0.01% or less.
- 7. A process according to claim 2 wherein the CO:CO.sub.2 molar ratio of the combustion product gases formed from the burning of at least the major portion of the coke is maintained at a level of at least about 0.3 while such gases are in heat exchange contact with the catalyst.
- 8. A process according to claim 2 wherein the CO:CO.sub.2 molar ratio of the combustion product gases formed from the burning of at least the major portion of the coke is maintained at a level of at least about 1 while such gases are in heat exchange contact with the catalyst.
- 9. A process according to claim 2 wherein the CO:CO.sub.2 molar ratio of the combustion product gases formed from the burning of at least the major portion of the coke is maintained at a level of at least about 1.5 while such gases are in heat exchange contact with the catalyst.
- 10. A process according to claim 2 in which catalyst is ballistically separated from the stream of hydrocarbons formed by vaporized feed and resultant cracking products in the elongated reaction chamber by projecting catalyst particles in a direction established by said elongated reaction chamber or an extension thereof, and causing said products to make an abrupt change of direction relative to the direction in which said catalyst particles are projected.
- 11. A process according to claim 2 in which said separating of catalyst from product vapors includes abruptly separating catalyst from product vapors at the downstream end of said elongated reaction chamber, discharging the catalyst thus separated into a catalyst collection chamber, and preventing at least about 50% by volume of the total feed and product vapors which have passed through said elongated reaction chamber from having further contact with the thus separated catalyst in said catalyst collection chamber.
- 12. A process according to claim 11 in which said percentage of vapors prevented from further contact with catalyst in the catalyst collection chamber is at least about 80%.
- 13. A process according to claim 11 in which said percentage of vapors prevented from further contact with catalyst in the catalyst collection chamber is at least about 90%.
- 14. A process according to claim 11 wherein substantially all of said vapors are prevented from further contact with catalyst in the catalyst collection chamber.
- 15. A process according to claim 2 wherein said stripping is conducted at a temperature of about 1,025.degree. F. or higher.
- 16. A process according to claim 2 in which said reaction chamber outlet temperature is in the range of about 900.degree. to about 1,200.degree. F. and in which said resultant stream flows through said reactor at a lineal velocity of at least about 55 feet per second.
- 17. A process according to claim 2 wherein said regenerated catalyst is stripped with an inert gas prior to being recycled to the reactor for contact with fresh feed.
- 18. A process according to claim 2 in which said reaction chamber outlet temperature is greater than about 900.degree. F. and less than about 1,200.degree. F.
- 19. A process according to claim 2 wherein said reactor comprises a riser and said resultant stream flows through said riser at a lineal velocity of at least about 55 feet per second.
- 20. A process according to claim 2 wherein said reactor comprises a riser and said resultant stream flows through said riser at a lineal velocity of at least about 75 feet per second.
- 21. A process according to claim 2 wherein the concentration of cracking catalyst in said resultant stream is maintained below about 5 pounds per cubic foot.
- 22. A process according to claim 2 in which said cracking catalyst bears an accumulation of at least about 2,000 ppm combined of nickel and vanadium expressed as weight of metal(s) on regenerated equilibrium catalyst.
- 23. A process according to claim 2 wherein said converter feed contains up to about 200 ppm combined of nickel and vanadium.
- 24. A process for economically converting carbo-metallic oils to lighter products, comprising:
- I. providing a converter feed containing 650.degree. F.+ material and at least about 10% by volume of material which will not boil below about 1000.degree. F., said 650.degree. F.+ material being characterized by a carbon residue on pyrolysis of at least about 2 and by containing at least about 4 parts per million of Nickel Equivalents of heavy metal(s);
- II. bringing said converter feed together with cracking catalyst bearing substantially more than 600 ppm Nickel Equivalents of heavy metal to form a stream comprising a suspension of said catalyst in said feed and causing the resultant stream to flow through a progressive flow type reactor having an elongated reaction chamber which is at least in part vertical or inclined for a vapor residence time in said elongated reaction chamber in the range of about 0.5 to about 10 seconds at a reaction chamber outlet temperature of about 900.degree. to about 1200.degree. F. and under a pressure of 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 of at least about 6% by weight based on fresh feed, and laying down coke on the catalyst in amounts of at least about 0.3% by weight;
- III. separating said catalyst from the resultant cracking products;
- IV. stripping said separated catalyst;
- V. regenerating said metals-bearing, coked catalyst by burning at least a major portion of the coke with oxygen-containing combustion-supporting gas in at least a first regeneration zone while forming combustion product gases comprising CO and CO.sub.2, maintaining the CO:CO.sub.2 molar ratio of the combustion product gases formed from the burning of said major weight portion of the coke at a level of at least about 0.25 while such gases are in heat exchange contact with the catalyst, and burning sufficient coke with oxygen-containing combustion-supporting gas in at least a second regeneration zone to reduce the weight of carbon on catalyst to about 0.25% or less; and
- VI. recycling the regenerated catalyst to the reactor at a temperature of at least about 1,275.degree. F. for contact with fresh feed.
- 25. A process for economically converting carbo-metallic oils to lighter products, comprising:
- I. providing a converter feed containing 650.degree. F.+ material, said 650.degree. F.+ material being characterized by a carbon residue on pyrolysis of at least about 1 and by containing at least about 4 ppm by weight of Nickel Equivalents of heavy metal(s);
- II. bringing said converter feed together with cracking catalyst having an equilibrium microactivity test conversion activity level of at least about 40 volume percent and bearing an accumulation of at least about 3,000 ppm by weight of Nickel Equivalents of heavy metal(s), expressed as metal(s) on regenerated equilibrium catalyst, and with additional material in a weight ratio to feed of up to about 0.4 including H.sub.2 O in a weight ratio to feed of at least about 0.04 to form a stream comprising a suspension of said catalyst in said feed and additional material wherein the ratio of the partial pressure of the additional material relative to the partial pressure of the feed is in the range of about 0.25 to about 4, and causing the resultant stream to flow at a lineal velocity of at least about 25 feet per second through a progressive flow type reactor having an elongated reaction chamber which is at least in part vertical or inclined for a vapor residence time in the range of about 0.5 to about 6 seconds at a reaction chamber outlet temperature of about 900.degree. to about 1,400.degree. F. and under a total pressure of about 10 to about 50 pounds per square inch absolute sufficient for causing a conversion per pass in the range of about 60% to about 90%, while producing at least about 6% coke by weight based on fresh feed and laying down coke on the catalyst in amounts of at least about 0.3% by weight;
- III. separating catalyst from product vapors at the downstream end of said elongated reaction chamber;
- IV. stripping said separated catalyst;
- V. regenerating said metals-bearing, coked catalyst in a plurality of regeneration zones by burning a major portion of the coke with oxygen-containing combustion-supporting gas in at least a first stage of regenerating while forming combustion product gases comprising CO and CO.sub.2 and maintaining the CO:CO.sub.2 molar ratio of the combustion product gases formed from the burning of said major weight portion of the coke at a level of at least about 0.25 while such gases are in heat exchange contact with the catalyst, and by burning sufficient coke in at least a subsequent stage of regeneration to reduce the weight of carbon on the catalyst to about 0.25% or less; and
- VI. recycling the regenerated catalyst to the reactor for contact with fresh feed.
- 26. A process according to either claims 24 or 25 in which the combined total amount of combustion-supporting gas supplied to all of said plurality of regeneration zones is less than the stoichiometric amount which would be required to burn all of the carbon in the coke to CO.sub.2, to burn all of the hydrogen in the coke to H.sub.2 O and to burn any other combustibles which may be present in the coke to their respective combustion products, and restricting the combined mole percentage of free oxygen in all gases resulting from the entire, completed combustion of coke in said regeneration zones to an amount substantially less than 2%.
- 27. The process according to claim 25 in which at least a portion of said H.sub.2 O is liquid water when brought together with said converter feed.
- 28. A process according to claim 25 in which a portion of said H.sub.2 O is steam and another portion of said H.sub.2 O is liquid water when brought together with said converter feed.
- 29. A process according to claim 25 in which the weight ratio of total H.sub.2 O relative to feed is in the range of about 0.04 to about 0.4.
- 30. A process according to either of claims 27 or 28 in which the weight ratio of liquid water to feed is in the range of about 0.04 to about 0.15.
- 31. A process according to either of claims 27 or 28 in which the total amount of liquid water added to the feed is in the range of about 1% to about 25% by weight of said 650.degree. F.+ material.
- 32. A process according to claim 25 in which the water and converter feed are mixed in an atomizing nozzle and sprayed into contact with the catalyst.
- 33. A process according to claim 28 in which the weight ratio of liquid water relative to steam is in the range of about 0.2 to about 5.
- 34. A process according to claim 25 wherein said H.sub.2 O is brought into contact with said converter feed in the form of liquid water in a weight ratio relative to converter feed in the range of 0.04 to about 0.15 and in the form of steam in a weight ratio relative to converter feed in the range of about 0.01 to about 0.25, the total H.sub.2 O thus supplied not exceeding a weight ratio of about 0.3 relative to converter feed.
- 35. A process according to claim 25 in which at least a portion of said water is recycle water from a product stream of a previously converted hydrocarbon feed.
- 36. A process according to claim 25 in which said water contains at least 120 ppm by weight of hydrogen sulfide, and in which said conversion per pass comprises a yield of C.sub.5 -430.degree. F. gasoline representing at least about 44% by volume of the total amount of fresh feed.
- 37. A process according to claim 25 in which said water contains more than 1,000 ppm hydrogen sulfide.
- 38. A process according to claim 25 wherein said H.sub.2 O is brought into contact with said converter feed prior to, substantially simultaneously with, and/or subsequent to formation of said stream in the form of steam and/or liquid water, and the total water thus supplied does not exceed a weight ratio of about 0.3 relative to converter feed.
- 39. A process according to any of claims 2, 3, 24 or 25 in which regeneration of said catalyst is accomplished in a two-stage regeneration operation in which the product flue gas of a second regeneration stage passes upwardly through a dense fluid bed of catalyst in a first regeneration stage and CO rich flue gas is recovered from said first stage of regeneration.
- 40. A process according to claim 39 in which said second stage of catalyst regeneration is accomplished at a higher temperature than said first stage of regeneration.
- 41. A process according to claim 2 wherein said accumulation of heavy metal(s) on said catalyst is at least about 4,000 ppm by weight of Nickel Equivalents expressed as metal(s) on regenerated equilibrium catalyst.
- 42. A process according to claim 2 wherein said accumulation of heavy metal(s) on said catalyst is at least about 5,000 ppm by weight of Nickel Equivalents expressed as metal(s) on regenerated equilibrium catalyst.
- 43. A process according to claim 2 wherein said carbon residue corresponds with a Ramsbottom carbon value of at least about 1.
- 44. A process according to claim 2 wherein said converter feed as a whole is characterized by a carbon residue on pyrolysis of at least about 1.4.
- 45. A process according to claim 25 wherein the total amount of water added to the feed is in the range of about 5% to about 15% by weight of said carbonaceous portion of the feed, and said water contains more than 1,000 ppm hydrogen sulfide.
- 46. A process according to claim 25 wherein said water contains less than 25 ppm sodium.
- 47. A process according to claim 2 wherein the conversion catalyst is a cracking catalyst containing zeolite.
- 48. A process according to claim 2 wherein the feed as a whole contains at least about 2 ppm by weight of nickel.
- 49. A process according to claim 2 wherein said 650.degree. F.+ material has a carbon residue on pyrolysis of at least about 4.
- 50. A process according to claim 2 wherein said carbon residue corresponds with a Ramsbottom carbon value in the range of about 2 to about 12.
- 51. A process according to claim 2 wherein said carbon residue corresponds with a Ramsbottom carbon value in the range of about 4 to about 8.
- 52. A process according to claim 2 in which said converter feed as a whole is characterized by carbon residue on pyrolysis of at least about 2.
- 53. A process according to claim 2 in which said converter feed as a whole is characterized by carbon residue on pyrolysis of at least about 4.
- 54. A process according to claim 2 wherein the carbon residue of the feed as a whole corresponds with a Ramsbottom carbon value of at least about 1.
- 55. A process according to claim 2 wherein the carbon residue of the feed as a whole corresponds with a Ramsbottom carbon value in the range of about 2 to about 12.
- 56. A process according to claim 2 in which the Ramsbottom carbon value of the feed as a whole is in the range of about 4 to about 8.
- 57. A process according to claim 2 wherein the carbon residue of the converter feed as a whole corresponds with a Ramsbottom carbon value not exceeding about 12.
- 58. A process according to claim 2 in which said converter feed is at a temperature of about 500.degree. F. or less when it is brought together with said cracking catalyst.
- 59. A process according to claim 2 in which said converter feed comprises at least about 85% by volume of said 650.degree. F.+ material.
- 60. A process according to claim 2 in which said converter feed comprises substantially 100% by volume of said 650.degree. F.+ material.
- 61. A process according to claim 2 in which the 650.degree. F.+ material includes at least about 10% by volume of material which will not boil below about 1,000.degree. F.
- 62. A process according to claim 2 in which the 650.degree. F.+ material includes at least about 15% by volume of material which will not boil below about 1,000.degree. F.
- 63. A process according to claim 2 in which the 650.degree. F.+ material includes at least about 20% by volume of material which will not boil below about 1,000.degree. F.
- 64. A process according to claim 2 in which the 650.degree. F.+ material includes at least about 10% by volume of material which will not boil below about 1,025.degree. F.
- 65. A process according to claim 2 in which the 650.degree. F.+ material includes at least about 15% by volume of material which will not boil below about 1,025.degree. F.
- 66. A process according to claim 2 in which the 650.degree. F.+ material includes at least about 20% by volume of material which will not boil below about 1,025.degree. F.
- 67. A process according to claim 2 wherein at least about 85% by volume of the feed is oil which has not previously been contacted with cracking catalyst under cracking conditions.
- 68. A process according to claim 2 wherein at least about 90% by volume of the converter feed is oil which has not previously been contacted with cracking catalyst under cracking conditions.
- 69. A process according to claim 2 wherein said feed is processed in a substantially once-through or single pass mode with no substantial amount of recycled oil in the feed.
- 70. A process according to claim 2 wherein said feed comprises about 15% or less by volume of recycled oil.
- 71. A process according to claim 2 wherein said converter feed comprises about 10% or less by volume of recycled oil.
- 72. A process according to claim 2 wherein said converter feed comprises at least about 0.8% by weight of sulfur.
- 73. A process according to claim 2 wherein said converter feed comprises at least about 10% by volume of material which will not boil below about 1,000.degree. F., and has an average composition characterized by:
- (a) an atomic hydrogen to carbon ratio in the range of about 1.2 to about 1.9; and
- (b) by containing one or more of the following:
- (i) at least about 0.3% by weight of sulfur;
- (ii) at least about 0.05% by weight of nitrogen; and
- (iii) at least about 0.05% of pentane insolubles.
- 74. A process according to claim 73 wherein said sulfur is at least about 0.8% by weight.
- 75. A process according to claim 2 in which said converter feed has had substantially no hydrotreatment.
- 76. A process according to claim 2 in which the equilibrium microactivity test conversion level of said catalyst is at least about 60 volume percent.
- 77. A process according to claim 2 wherein said catalyst as introduced into the process has a microactivity of at least about 60 volume percent.
- 78. A process according to claim 2 wherein there is an accumulation of heavy metal(s) on said catalyst in the range of about 3,000 ppm to about 70,000 ppm by weight of Nickel Equivalents expressed as metal(s) on regenerated equilibrium catalyst.
- 79. A process according to claim 2 wherein there is an accumulation of heavy metal(s) on said catalyst of at least about 5,000 ppm by weight of Nickel Equivalents expressed as metal(s) on regenerated equilibrium catalyst.
- 80. A process according to claim 2 wherein there is an accumulation of heavy metal(s) on said catalyst in the range of about 5,000 ppm to about 30,000 ppm by weight of Nickel Equivalents expressed as metal(s) on regenerated equilibrium catalyst.
- 81. A process according to claim 2 wherein catalyst is added to the process at a rate in the range of about 0.1 to about 5 pounds of catalyst per barrel of feed.
- 82. A process according to claim 2 wherein replacement catalyst is added to the process at a rate in the range of about 0.1 to about 3 pounds per barrel of feed.
- 83. A process according to claim 2 wherein replacement catalyst is added to the process at a rate in the range of about 0.15 to about 2 pounds per barrel of feed.
- 84. A process according to claim 2 wherein replacement catalyst is added to the process at a rate in the range of about 0.2 to about 1.5 pounds per barrel of feed.
- 85. A process according to claim 2 wherein said catalyst is characterized by a pore structure for absorbing hydrocarbon molecules and by reactive sites within or adjacent the pores.
- 86. A process according to claim 2 wherein said catalyst is a molecular sieve catalyst.
- 87. A process according to claim 86 wherein said catalyst is a zeolite-containing catalyst.
- 88. A process according to claim 87 wherein said zeolite-containing catalyst includes at least about 5% by weight of sieve.
- 89. The process of claim 86 in which said catalyst is a fluid cracking catalyst suitable for production of gasoline from vacuum gas oil.
- 90. A process according to claim 2 wherein said catalyst is equilibrium cracking catalyst which has previously been used in a fluid catalytic cracking unit in which said catalyst was used for the cracking of feed characterized by a carbon residue on pyrolysis of less than 1 and by containing less than about 4 ppm by weight of Nickel Equivalents expressed as heavy metal(s).
- 91. A process according to claim 2 wherein said catalyst has a particle size in the range of about 5 to about 150 microns.
- 92. A process according to claim 2 wherein additional material other than catalyst, converter feed and resultant products is introduced into said stream and the total amount of said additional material present in said reaction zone is in a weight ratio of up to about 0.4 relative to converter feed.
- 93. A process according to claim 92 wherein the total amount of additional material other than catalyst, converter feed and resultant products which is present in said reaction zone is in a weight ratio in the range of about 0.04 to about 0.4 relative to converter feed.
- 94. A process according to claim 92 wherein the total amount of additional material other than catalyst, converter feed and resultant products which is present in said reaction zone is in a weight ratio in the range of about 0.04 to about 0.3 relative to converter feed.
- 95. A process according to claim 92 wherein the total amount of additional material other than catalyst, converter feed and resultant products which is present in said reaction zone is in a weight ratio in the range of about 0.05 to about 0.25 relative to converter feed.
- 96. A process according to claim 92 wherein said additional material includes at least one of the following: nitrogen, other inert gases, recycled gas, and hydrogen donors.
- 97. A process according to claim 92 in which said additional material includes water and the ratio of the partial pressure of said additional material, including H.sub.2 O, relative to the partial pressure of the feed in said resultant stream is in the range of about 0.4 to about 2.3.
- 98. A process according to claim 92 in which said additional material includes water and the ratio of the partial pressure of said additional material, including H.sub.2 O, relative to the partial pressure of the feed in said resultant stream is in the range of about 0.25 to about 4.0.
- 99. A process according to claim 92 wherein the partial pressure of said additional material relative to that of the feed is in the range of about 0.7 to about 1.7.
- 100. A process according to claim 2 in which said reaction chamber outlet temperature is in the range of about 900.degree. to about 1,300.degree. F.
- 101. A process according to claim 2 in which said reaction chamber outlet temperature is in the range of about 900.degree. to about 1,200.degree. F.
- 102. A process according to claim 2 in which said resultant stream flows through said reactor under a pressure of about 15 to about 35 pounds per square inch absolute.
- 103. A process according to claim 92 wherein the feed partial or total pressure is in the range of about 3 to about 10 psia.
- 104. A process according to claim 92 wherein the feed partial or total pressure is in the range of about 7 to about 25 psia.
- 105. A process according to claim 92 wherein the feed partial or total pressure is in the range of about 10 to about 17 psia.
- 106. A process according to claim 2 wherein said conversion per pass is at least about 70%.
- 107. A process according to claim 2 wherein said conversion per pass is in the range of about 70% to about 85%.
- 108. A process according to claim 2 in which said coke is produced in amounts in the range of about 6 to about 14% by weight based on fresh feed.
- 109. A process according to claim 24 wherein the coke laydown on the catalyst is in the range of about 0.5% to about 3%.
- 110. A process according to claim 2 wherein the coke laydown on the catalyst is in the range of about 1% to about 2%.
- 111. A process according to claim 2 in which the residence time of the feed and product vapors is in the range of about 0.5 to about 3 seconds.
- 112. A process according to claim 2 in which said vapor residence time is less than about 2 seconds.
- 113. A process according to claim 2 wherein said residence time of the converter feed and product vapors is in the range of about 1.0 to about 3.0 seconds.
- 114. A process according to claim 2 wherein said residence time of the converter feed and product vapors is in the range of about 1.0 to about 2.5 seconds.
- 115. A process according to claim 2 wherein said residence time of the converter feed and product vapors is in the range of about 1.5 to about 2.5 seconds.
- 116. A process according to claim 2 wherein the ratio of average catalyst residence time to vapor residence time is in the range of about 1 to about 5.
- 117. A process according to claim 2 wherein the ratio of average catalyst residence time to vapor residence time is in the range of about 1 to about 4.
- 118. A process according to claim 2 wherein the ratio of average catalyst residence time to vapor residence time is in the range of about 1.2 to about 3.
- 119. A process according to claim 2 wherein the ratio of average catalyst residence time to vapor residence time is in the range of about 1.2 to about 2.
- 120. A process according to claim 2 wherein said catalyst is contacted with said converter feed in said elongated reaction zone in a weight ratio of catalyst to converter feed in the range of about 3 to about 18.
- 121. A process according to claim 2 in which said catalyst is maintained in contact with said converter feed in said elongated reaction zone in a weight ratio of catalyst to converter feed in the range of about 4 to about 12.
- 122. A process according to claim 2 in which said catalyst is maintained in contact with said converter feed in said elongated reaction zone in a weight ratio of catalyst to converter feed in the range of about 5 to about 10.
- 123. A process according to claim 2 in which said catalyst is maintained in contact with said converter feed in said elongated reaction zone in a weight ratio of catalyst to converter feed in the range of about 6 to about 10.
- 124. A process according to claim 2 in which said catalyst is maintained in contact with said converter feed in said elongated reaction zone in a weight ratio of catalyst to converter feed in the range of about 6 to about 8.
- 125. A process according to claim 2 wherein said catalyst and converter feed are brought together in sufficient amounts so that the weight ratio of said catalyst to converter feed in said elongated reaction chamber is at least about 6.
- 126. A process according to claim 2 wherein said reactor is a riser type reactor.
- 127. A process according to claim 2 wherein said reactor is a vented riser type reactor.
- 128. The process of either claim 25 or 98 in which said water contains less than 25 ppm sodium, and at least about 2,000 ppm combined of nickel and vanadium is deposited on the catalyst.
- 129. A process according to either claim 25 or 98 wherein the ratio of the partial pressure of said additional material, including water, relative to the partial pressure of the feed in said resultant stream is at least about 0.8 and said vapor residence time is about 2.5 seconds or less.
- 130. A process according to either claim 25 or 98 wherein the ratio of the partial pressure of said additional material, including water, relative to the partial pressure of the feed in said resultant stream is at least about 1 and said vapor residence time is about 2 seconds or less.
- 131. A process according to either claim 25 or 98 wherein said water contains from 500 to 5,000 ppm hydrogen sulfide.
- 132. A process according to claim 2 wherein said regeneration is conducted at a temperature in the range of about 1,100.degree. F. to about 1,600.degree. F.
- 133. A process according to claim 2 wherein said regeneration is conducted at a temperature in the range of about 1,200.degree. F. to about 1,500.degree. F.
- 134. A process according to claim 2 wherein said regeneration is conducted at a temperature in the range of about 1,275.degree. F. to about 1,500.degree. F.
- 135. A process according to either claim 24 or 25 wherein sufficient coke is burned during regeneration to reduce the weight of carbon on catalyst to about 0.1% or less while limiting the amount of combustion-supporting gas supplied to the regeneration operation as a whole to less than the stoichiometric amount which would be required to burn all of the carbon in the coke to CO.sub.2, to burn all of the hydrogen in the coke to H.sub.2 O and to burn any other combustibles which may be present in the coke to their respective combustion products, and restricting the total free oxygen mole percent of all gases resulting from the entire, complete combustion of coke in said regeneration operation to an amount substantially less than 2%.
- 136. A process according to either claim 24 or 25 wherein sufficient coke is burned during regeneration to reduce the weight of carbon on catalyst to about 0.05% or less while limiting the amount of combustion-supporting gas supplied to the regeneration operation as a whole to less than the stoichiometric amount which would be required to burn all of the carbon in the coke to CO.sub.2, to burn all of the hydrogen in the coke to H.sub.2 O and to burn any other combustibles which may be present in the coke to their respective combustion products, and restricting the total free oxygen mole percent of all gases resulting from the entire, complete combustion of coke in said regeneration operation to an amount substantially less than 0.2%.
RELATED APPLICATIONS
This is a division of application Ser. No. 094,091 filed Nov. 14, 1979 (now U.S. Pat. No. 4,299,687) and a continuation-in-part of Ser. No. 228,393 filed Jan. 26, 1981.
US Referenced Citations (46)
Foreign Referenced Citations (1)
Number |
Date |
Country |
2001545 |
Feb 1979 |
GBX |
Non-Patent Literature Citations (2)
Entry |
Shankland & Schmitkons, "Determination of Activity and Selectivity of Cracking Catalyst", Proc. API 27, (III), 1947, pp. 57-77. |
AM-79-37-Charles L. Hemler; Charles W. Strother; Bill E. McKay; and George D. Myers; "Catalytic Conversion of Residual Stocks", Mar. 25-27, 1979; pertinent pp.: 1-14 (entire paper). |
Divisions (1)
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Number |
Date |
Country |
Parent |
94091 |
Nov 1979 |
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