Catalytic cracking of whole crude oil

Abstract

An effective, economical catalytic cracking process is provided to produce quality gasoline and other hydrocarbons from whole crude oil. The catalytic cracking process is operable and particularly useful during maintenance or shutdown of associated pipestills, vacuum tower, and/or atmospheric tower.

Description

BACKGROUND OF THE INVENTION

This invention pertains to refining of petroleum and, more particularly, to catalytic cracking of oil.

Catalytic cracking of oil is an important refinery process which is used to produce gasoline and other hydrocarbons. During catalytic cracking, the feedstock, which is generally a cut or fraction of crude oil, is cracked in a reactor under catalytic cracking temperatures and pressures in the presence of a catalytic to produce more valuable, lower molecular weight hydrocarbons. Gas oil is usually used as the feedstock in catalytic cracking. Gas oil feedstocks typically contain from 55% to 80% gas oil by volume having a boiling range from 650.degree. F. to 1000.degree. F. and less than 1% RAMS carbon by weight. Gas oil feedstocks also typically contain less than 5% by volume naphtha and lighter hydrocarbons having a boiling temperature below 430.degree. F., from 10% to 30% by volume diesel and kerosene having a boiling range from 430.degree. F. to 650.degree. F., and less than 10% by volume resid having a boiling temperature above 1000.degree. F.

In conventional catalytic cracking, whole crude oil is separated in a primary pipestill (crude oil unit) or atmospheric tower into fractions of 200.degree. F. and lighter material, naphtha, diesel oil, atmospheric gas oil, and atmospheric bottoms. The atmospheric bottoms are heated in a furnace and separated in a secondary pipestill or vacuum tower into fractions of vacuum naphtha, light vacuum gas oil, heavy vacuum gas oil, and resid. The atmospheric gas oil from the atmospheric tower and the light and heavy gas oils from the vacuum tower and subsequently pumped into the catalytic cracker as a blended composite gas oil feedstock, where it is contacted with fine solid catalyst particles under cracking conditions to crack the gas oil. During cracking, the catalyst becomes coked and deactivated and has to be regenerated in a regeneration vessel. Fresh catalyst is conventionally replaced in the catalytic cracker at a rate of 0.25 pounds per barrel of reactor feed.

Catalytic cracking is an important source of gasoline. From time to time, however, it is necessary to shut down the catalytic cracking unit for days, weeks, or even months to clean, unplug, maintain, uncoke, revamp, and/or repair the pipestill (crude unit) vacuum tower and/or atmospheric tower. When the crude unit is down for maintenance or repair, there is no gas oil feed for the catalytic cracking unit. The catalytic cracking unit would normally be shutdown if gas oil cannot be obtained from another source. Such shutdown deprives the refinery and the consumer of substantial amounts of gasoline. It is also very expensive. Revamp costs and revenue loss to the refinery during shutdown can add up to millions of dollars. Shutdown of the catalytic cracker was, heretofore, required when the pipestills (crude unit), vacuum tower, and/or atmospheric tower were taken offstream for maintenance, revamp, or other work since there was no longer any production of gas oil feedstock from the pipestills (crude unit) and towers. It was generally believed that the catalytic cracking unit could not be operated nor the required heat balance maintained when using unrefined whole crude oil as the feedstock.

Typifying some to the many prior art catalytic cracking units, regenerators, and other refinery equipment and processes are those shown in U.S. Patents: 2,382,382; 2,398,739; 2,398,759; 2,414,002; 2,425,849; 2,436,927; 2,884,303; 2,981,676; 2,985,584; 3,004,926; 3,039,953; 3,351,548; 3,364,136; 3,513,087; 3,563,911; 3,661,800; 3,838,036; 3,844,973; 3,909,392; 4,331,533; 4,332,674; 4,341,623; 4,341,660; 4,332,674; and 4,695,370.

It is, therefore, desirable to provide an improved catalytic cracking process which is operable when the upstream pipestills (crude unit) or towers are taken off line for revamp, maintenance, or to shutdown permanently to consolidate operations.

SUMMARY OF THE INVENTION

An effective catalytic cracking process is provided to produce gasoline and other hydrocarbons. The novel catalytic cracking process is efficient, economical, and safe. It provides an excellent source of good quality gasoline to consumers and is very profitable for the refinery. Advantageously, the novel process is fully operable and is particularly useful when the upstream pipestills (crude unit) or towers are shut down and/or taken off line for revamp, repair, cleaning, decoking, maintenance, etc.

To this end, the novel cataytic cracking process comprises feeding petroleum to a catalytic cracking unit without previously fractionating the petroleum in a pipestill (crude unit), atmospheric tower, or vacuum tower. The petroleum can comprise: raw, uncut, whole crude oil; flashed crude oil; or petroleum containing less than about 50% gas by volume. In the catalytic cracking unit, the petroleum is cracked in the presence of a catalyst in a riser reactor and/or a fluidized bed reactor to more valuable, lower molecular weight hydrocarbons. For enhanced demetallization (removal of metals) of the oil, fresh catalyst can be fed and replaced in the regenerator at an increased rate of up to about 2 pounds per barrel of reactor feed. Coked catalyst is conveyed to a regenerator where it is regenerated and then recycled to the reactor. In order to enhance the environment and minimize pollution, carbon monoxide emitted during regeneration is essentially completely combusted in the regenerator.

Preferably, the composition of the petroleum feed comprises by volume: (a) less than about 35% hydrocarbons comprising naphtha and light hydrocarbons having a boiling temperature less than about 430.degree. F.; preferably less than 400.degree. F.; (b) from about 20% to about 50% hydrocarbons comprising diesel oil and kerosene having a boiling temperature ranging from greater than about 430.degree. F. to less than about 650.degree. F.; (c) from about 20% to less than about 50% hydrocarbons comprising gas oil having a boiling tempreature ranging from greater than about 650.degree. F. to less than about 1000.degree. F.; (d) less than about 20% hydrocarbons comprising resid having a boiling temperature greater than about 1000.degree. F.; and (e) preferably less than 2% RAMS carbon by weight in the petroleum feed. Most perferably, a low resid crude is used with the RAMS carbon content of the resid ranging from about 0.5% to about 10% by weight.

One particularly useful petroleum feedstock is Trinidad crude from the Island of Trinidad. Other useful petroleum feedstocks can comprise: Brass River crude from Nigeria, HIPS crude from Galveston Bay, Texas, Florence Canal crude from Louisiana, St. Gabriel crude from Louisiana, and Louisiana Light crude from Louisiana.

As used in this patent application, the abbreviation "FCCU" means fluid catalytic cracking unit.

A more detailed explanation of the invention is provided in the following description and appended claims, taken in conjunction with the accompanying drawing.

BRIEF DESCRIPTION OF THE DRAWING

The FIGURE is a schematic flow diagram of a catalytic cracking process in accordance with principles of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Unrefined, raw, whole crude oil or petroleum, is pumped by a pump 10 from tankage, such as an above ground storage tank 12 at about 75.degree. F. to about 80.degree. F., through pipelines 14-17. The whole crude oil comprises by volume: (a) less than about 35% hydrocarbons comprising naphtha and light hydrocarbons having a boiling temperature less than about 430.degree. F., preferably less than 400.degree. F.; (b) from about 20% to about 50% hydrocarbons comprising diesel oil and kerosene having a boiling temperature ranging from greater than about 430.degree. F. to less than about 650.degree. F.; (c) from about 20% to less than about 50% hydrocarbons comprising gas oil having a boiling temperature ranging from greater than about 650.degree. F. to less than about 1000.degree. F.; (d) less than about 20% hydrocarbons comprising resid having a boiling temperature greater than about 1000.degree. F.; and (e) preferably less than 2% RAMS carbon by weight in the whole crude oil. Most preferably, a low resid crude is used with the RAMS carbon content of the resid ranging from about 0.5% to about 10% by weight. For best results, the preferred petroleum (whole crude oil) is Trinidad crude.

Decanted oil can be injected, fed, mixed, or blended with the whole crude oil in line 14 through decanted oil line 18 and/or 19, via valves 20 and 21, to raise the temperature of the regenerator 22 in the fluid catalytic cracking unit (FCCU) 24 so as to enhance the complete combustion of carbon monoxide in the regenerator 22. Decanted oil can be obtained from a separate FCCU or from the decanted oil ouput line 26 of the main fractionator 30, downstream of the subject FCCU 24. In some circumstances it may be desirable to inject, feed, mix, or blend, the decanted oil with the reactor charge or crude oil anywhere before reaching the reactor.

Valve 32 can be provided to regulate the flow of oil through line 17. Water can be passed through water lines 34-37 and injected, fed, and dispersed into oil line 17 downstream of valve 32. The flow rate of the water can be regulated or stopped by one or more water control valves 38 and 40.

The oil in line 17 is partially preheated to about 125.degree. F. in a heat exchanger 42. The partially preheated oil from heat exchanger 42 in line 44 is passed through exchanger lines 46 and 48 to parallel heat exchangers 50 and 52 where the oil is further partially preheated to about 220.degree. F. The partially preheated oil from heat exchangers 50 and 52 in exchanger effluent line 54-56 is passed through an oil flow valve 58 to line 60. Water from water lines 34 and 35 can be passed through water lines 62 and 64 via water flow valve 66 to be injected, fed, and dispersed into the oil in oil line 60. Hydrochloric acid or other acids from a tank 68 can be pumped by pH control pump 70 through acid lines 72 and 74 into the water in lines 35 and 62 to maintain and control the pH of the water injected into the oil. The oil and water in line 76 are mixed by a mix valve 78 and passed through mixed oil and water line 80 into a desalter 82. About 5% to about 10% water by volume can be added to the oil. In the desalter 82, the oil is desalted and the water removed. The removed water is discharged through water discharge line 84.

The desalted oil from the desalter 82 in line 86 is passed through line 88, via a valve 90, into a heat exchanger 92 where it is preheated to about 315.degree. F. The preheated oil from heat exchanger 92 in exchanger effluent line 94 is passed into another heat exchanger 96 where it is further preheated to about 372.degree. F. The preheated oil from heat exchanger 96 is passed from line 98 to a furnace 100 where it is heated to about 520.degree. F. The heated oil from the furnace 100 is passed through oil lines 102-104, via heated oil flow valve 106, into a flash drum 108.

In the flash drum 108, the oil is flashed so a substantial portion of the naphtha and light ends (light hydrocarbons) having a boiling temperature below 430.degree. F. are vaporized and removed through an overhead flash line 110. About 20% to about 30% by volume of Trinidad crude can be flashed. The flashed vapors in overhead flash line 110 are passed through a flash vapor line 112, via a valve 114, to the main fractionator 30.

The remaining flashed liquid oil (flashed bottoms) in the flash drum 108 is discharged from the bottom portion of the flash drum 108 through liquid line 116 and pumped by pump 118 through lines 120-122, via liquid flow control valve 124, into the catalytic cracking reactor 126 of the FCCU 24. The reactor charge (reactor feed) comprising flashed liquid oil (flashed) bottoms fed to the reactor 126 comprises by volume: (a) from about 0.1% to about 20% hydrocarbons comprising naphtha and light hydrocarbons having a boiling temperature less than about 430.degree. F., preferably less than about 400.degree. F.; (b) from about 20% to about 50% hydrocarbons comprising diesel oil and kerosene having a boiling temperature ranging from greater than about 430.degree. F. to less than about 650.degree. F.; (c) from about 30% to about 70%, preferably less than 50%, hydrocarbons comprising gas oil having a boiling temperature ranging from greater than about 650.degree. F. to less than about 1000.degree. F.; (d) less than about 20% hydrocarbons comprising resid having a boiling temperature greater than 1000.degree. F.; and (e) preferably from about 0.5% to about 10% by weight RAMS carbon in the resid.

In some circumstances, it may be desirable to bypass the flash drum 108 and feed whole crude oil through bypass lines 128 and 130 and oil line 122, via bypass regulator valve 132 into the FCCU 24. Bypass valve 132 can be opened for bypass operations or can be closed if feed is flashed in the flash drum 108.

The fluid catalytic cracking unit (FCCU) 24 includes a catalytic cracking (FCC) reactor 126, a stripper section 128, and a regenerator 22. The catalytic cracking reactor 126 preferably comprises a riser reactor. In some circumstances it may be desirable to use a fluid bed reactor or a fluidized catalytic cracking reactor. Fresh replacement catalyst (makeup catalyst) is fed through fresh catalyst line 134 into the regenerator 22 at a replacement rate of about 0.25 to about 2.0, preferably less than about 0.5, pounds per barrel to reactor feed (flashed bottoms) to control the effects of contaminant metals in the reactor feed. In the catalytic cracking reactor 126, the oil is contacted, mixed, and fluidized with the fresh catalyst and regenerated catalyst from regenerated catalyst line 136 at catalytic cracking temperatures and pressures to catalytically crack and volatilize the oil feed into more valuable, lower molecular weight hydrocarbons. The temperatures in the reactor 126 can range from about 900.degree. F. to about 1025.degree. F. at a pressure from about 5 psig to about 50 psig. The circulation rate (weight hourly space velocity) of the cracking catalyst in the reactor can range from about 5 to about 200 WHSV. The velocity of the oil vapors in the riser reactor can range from about 5 ft/sec to about 100 ft/sec.

Suitable cracking catalysts include, but are not limited to, those containing silica and/or alumina, including the acidic type. The cracking catalyst may contain other refractory metal oxides such as magnesia or zirconia. Preferred cracking catalysts are those containing crystalline aluminosilicates, zeolites, or molecular sieves in an amount sufficient to materially increase the cracking activity of the catalyst, e.g., between about 1 and about 25% by weight. The crystalline aluminosilicates can have silica-to-alumina mole ratios of at least about 2:1, such as from about 2 to about 12:1. The crystalline aluminosilicates are usually available or made in sodium form and this component is preferably reduced, for instance, to less than about 4 or even less than about 1% by weight through exchange with hydrogen ions, hydrogen-precursors such as ammonium ions, or polyvalent metal ions. Suitable polyvalent metals include calcium, strontium, barium, and the rare earth metals such as cerium, lanthanum, neodymium, and/or naturally-occuring mixtures of the rare earth metals. Such crystalline materials are able to maintain their pore structure under the high temperature conditions of catalyst manufacture, hydrocarbon processing, and catalyst regeneration. The crystalline aluminosilicates often have a uniform pore structure of exceedingly small size with the cross-sectional diameter of the pores being in a size range of about 6 to about 20 angstroms, preferably about 10 to about 15 angstroms. Silica-alumina based cracking catalysts having a major proportion of silica, e.g., about 60 to about 90 weight percent silica and about 10 to about 40 weight percent alumina, are suitable for admixture with the crystalline aluminosilicate or for use as such as the cracking catalyst. Other cracking catalysts and pore sizes can be used. The cracking catalyst can also contain or comprise a carbon monoxide (CO) burning promoter or catalyst, such as a platinum catalyst to enhance the combustion of carbon monoxide in the dense phase in the regenerator 22.

The catalytically cracked hydrocarbon vapors (volitilized oil) from the catalytic cracking reactor 126 are passed through an overhead product line 138 into the FCC main fractionator 30. In the main fractionator 30, the oil vapors and flashed vapors are fractionated (separated) into: (a) light hydrocarbons having a boiling temperature less than about 430.degree. F., (b) light catalytic cycle oil (LCCO), and decanted oil (DCO). The light hydrocarbons are withdrawn from the fractionator 30 through an overhead line 140 and fed to a separator drum 142. In the separator drum 142, the light hydrocarbons are separated into (1) wet gas and (2) C.sub.3 to 430-.degree. F. light hydrocarbon material comprising propane, propylene, butane, butylene, and naphtha. The wet gas is withdrawn from the separator drum 142 through a wet gas line 144 and further processed in a vapor recovery unit (VRU). The C.sub.3 to 430-.degree. F. material is withdrawn from the separator drum 142 through a line 146 and passed to the vapor recovery unit (VRU) for further processing. LCCO is withdrawn from the fractionator 30 through an LCCO line 148 for further refining, processing, or marketing. DCO is withdrawn from the fractionator 30 through one or more DCO lines 26 for further use. Slurry recycle comprising DCO can be pumped from the bottom portion of the fractionator 30 by pump 150 through a slurry line 26 for recycle to the reactor 126. The remainder of the DCO is conveyed through line 28 for further use in the refinery.

Spent deactivated (used) coked catalyst is discharged from the catalytic cracking reactor 126 and stripped of volatilizable hydrocarbons in the stripper section 128 with a stripping gas, such as with light hydrocarbon gases or steam. The stripped coked catalyst is passed from the stripper 128 through spent catalyst line 146 into the regenerator 22. Air is injected through air injector line 148 into the regenerator 22 at a rate of about 0.2 ft/sec to about 4 ft/sec. Preferably, excess air is injected in the regenerator 22 to completely convert the coke on the catalyst to carbon dioxide and steam. The excess air can be from about 2.5% to about 25% greater than the stoichiometric amount of air necessary for the complete conversion of coke to carbon dioxide and steam.

In the regenerator 22, the coke on catalyst is combusted in the presence of air so that the catalyst contains less than about 0.1% coke by weight. The coked catalyst is contained in the lower dense phase section of the regenerator 22, below an upper dilute phase section of the regenerator 22. Carbon monoxide can be combusted in both the dense phase and the dilute phase although combustion of carbon monoxide predominantly occurs in the dense phase with promoted burning, i.e., the use of a CO burning promoter. The temperature in the dense phase can range from about 1150.degree. F. to about 1400.degree. F. The temperature in dilute phase can range from about 1200.degree. F. to about 1510.degree. F. The stack gas (combustion gases) exiting the regenerator 22 through overhead flue line 150 preferably contains less than about 0.2% CO by volume (2000 ppm). The major portion of the heat of combustion of carbon monoxide is preferably absorbed by the catalyst and transferred with the regenerated catalyst through a regenerated catalyst line 136 into the catalytic cracking reactor 126.

In a catalytic cracker (reactor) 126, some non-volatile carbonaceous material, or coke, is deposited on the catalyst particles. Coke comprises highly condensed aromatic hydrocarbons which generally contain 4-10 wt. % hydrogen. As coke builds up on the catalyst, the activity of the catalyst for cracking and the selectivity of the catalyst for producing gasoline blending stock diminish. The catalyst particles can recover a major proportion of their original capabilities by removal of most of the coke from the catalyst by a suitable regeneration process.

Catalyst regeneration is accomplished by burning the coke deposits from the catalyst surface with an oxygen-containing gas such as air. The burning of coke deposits from the catalyst requires a large volume of oxygen or air. Oxidation of coke may be characterized in a simplified manner as the oxidation of carbon and may be represented by the following chemical equations:

a. C+O.sub.2 .fwdarw.CO.sub.2 b. 2C+O.sub.2 .fwdarw.2CO c. 2CO+O.sub.2 .fwdarw.2CO.sub.2 Reactions (a) and (b) both occur at typical catalyst regeneration conditions wherein the catalyst temperature may range from about 1050.degree. F. to about 1300.degree. F. and are exemplary of gas-solid chemical interactions when regenerating catalyst at temperatures within this range. The effect of any increase in temperature is reflected in an increased rate of combustion of carbon and a more complete removal of carbon, or coke, from the catalyst particles. As the increased rate of combustion is accompanied by an increased evolution of heat whenever sufficient oxygen is present, the gas phase reaction (c) may occur. This latter reaction is initiated and propagated by free radicals. Further combustion of CO to CO.sub.2 is an attractive source of heat energy because reaction (c) is highly exothermic.

EXAMPLES

The following examples serve to give specific illustration of the practice of this invention but are not intended in any way to limit the scope of this invention.

Whole crude oil consisting of Trinidad crude was fed, processed, and refined in a catalyst cracking process and system substantially similar to the process flow diagram of the Figure. Specifically, 51 days of test runs were conducted starting on Mar. 29, 1987 at FCCU No. 2 at the Amoco Oil Company Refinery at Texas City, Texas. The test runs produced unexpected surprisingly good results, since it was heretofore believed that Trinidad crude could not be catalytically cracked without prior fractionation of the Trinidad crude or similar light crude in a pipestill(s), vacuum tower, and/or atmospheric tower. The extent, amount, and quality of the products produced by the test runs were unexpected. Furthermore, the test runs later became a commercial success when the products produced during the tests runs were eventually sold for about a $5 million net profit. Such profit was mainly attributable to the unique process arrangement and sequence shown in the Figure and recited in the claims.

EXAMPLE 1

Totals for the test runs were as follows:

______________________________________ VolumeFeed BSD .degree.API Lb/Hr Wt. %______________________________________Trinidad 31,800 32.3 400,345 98.5FCCU No. 3 DCO 370 -3.3 6,015 1.5 Total 32,170 Total 406,360______________________________________ VolumeProducts BSD .degree.API Use______________________________________Absorber Offgas 220 22.6 MW fuel MSCFHPropane-Propylene 5 42.7 MW fuel MSCFHPropane-Propylene 2,600 144.5 alkylation feedButane-Butylene 3,910 109.5 alkylation feedLight CatalyticNaphtha 4,020 76.6 blendingHeavy CatalyticNaphtha 12,810 49.3 reformer feedLight CatalyticCycle Oil (LCCO) 10,190 26.4 fuel oilDecanted Oil (DCO) 280 -1.1 recycle, fuelCoke______________________________________Products Lb/Hr Wt % Use______________________________________Absorber Offgas 13,230 3.26 fuelPropane-Propylene 540 0.13 fuelPropane-Propylene 19,370 4.77 alkylation feedButane-Butylene 33,450 8.23 alkylation feedLight CatalyticNaphtha 39,830 9.80 blendingHeavy CatalyticNaphtha 146,070 35.95 reformer feedLight CatalyticCycle Oil (LCCO) 133,050 32.74 fuel oilDecanted Oil (DCO) 4,440 1.09 recycle, fuelCoke 16,380 4.03Total 406,360 100.00______________________________________

EXAMPLE 2

During the test runs on Apr. 13, 1987, the Trinidad whole crude had: an actual API gravity of 32.7.degree., a molecular weight of 231.98, an observed refractive index of 1.4612, and an average boiling point of 571.4.degree. F. The Trinidad crude comprised by weight: 0.22% RAMS carbon, 0.25% sulfur, and 0.0230 total nitrogen. The Trinidad whole crude had the following characteristics at a normal pressure of 760 mm.

______________________________________True Boiling Point % Crude Vaporized.degree.F. (Boiled)______________________________________400 24.73430 28.78450 31.96475 36.43500 40.85525 45.08550 49.32575 53.44600 57.54625 61.27650 64.43675 67.59700 70.65725 73.37750 76.09800 81.01850 84.60900 88.20950 91.001000 93.001100 96.321200 98.95______________________________________

EXAMPLE 3

During the test runs on Apr. 13, 1987, the flashed bottoms which were fed to the catalytic cracker had: an actual API gravity of 29.degree., a molecular weight of 290.94, an observed refractive index of 1.4702, and an average boiling point of 678.2.degree. F. The flashed bottoms comprised by weight: 0.35% RAMS carbon, 0.37% sulfur, 0.0370 total nitrogen. The flashed bottoms had the following characteristics at a normal pressure of 760 mm.

______________________________________ % FlashedTrue Boiling Point Bottoms Vaporized.degree.F. (Boiled)______________________________________400 11.36430 15.06450 17.53475 20.68500 24.11525 27.53550 31.40575 36.40600 41.27625 45.82650 50.34675 54.58700 58.81725 62.50750 65.97800 72.36850 77.98900 81.95950 85.001000 88.051100 95.211200 98.63______________________________________

EXAMPLE 4

During the test runs on Apr. 15, 1987, the Trinidad whole crude had: an actual API gravity of 33.degree., a molecular weight of 224, and an average boiling point of 571.63.degree. F. The Trinidad crude had the following characteristics at a normal pressure of 760 mm.

______________________________________True Boiling Point % Crude Vaporized.degree.F. (Boiled)______________________________________400 18.38430 21.80450 24.62475 28.14500 32.21525 36.88550 41.55575 46.23600 50.81625 55.04650 59.27675 63.50700 67.73725 72.30750 77.28800 84.81850 90.65900 93.64950 95.701000 96.981100 99.541200 100.00______________________________________

EXAMPLE 5

During the test runs on Apr. 15, 1987, the flash drum bottoms (flashed bottoms) which were fed to the FCCU had: an actual API gravity of 29.3.degree., a molecular weight of 265, and an average boiling point of 685.59.degree. F. The flashed bottoms comprised by weight: 0.3% RAMS carbon and 0.25% total nitrogen. The flashed bottoms had the following characteristics at a normal pressure of 760 mm.

______________________________________ % FlashedTrue Boiling Point Bottoms Vaporized.degree.F. (Boiled)______________________________________400 8.69430 9.46450 9.96475 13.36500 16.91525 20.69550 26.01575 31.25600 36.25625 41.24650 46.23675 50.99700 55.06725 59.13750 63.20800 71.30850 79.27900 84.83950 90.341000 98.471100 100.001200 100.00______________________________________

EXAMPLE 6

During the test runs on Apr. 28, 1987, the Trinidad whole crude had an API gravity of 32.9.degree. and a RAMS carbon content of 0.31% by weight. The initial boiling point was 143.degree. F. The whole crude had the following characteristics:

______________________________________True Boiling Point % Crude Vaporized.degree.F. (Boiled)______________________________________335 10420 20485 30531 40578 50629 60684 70699 75.5______________________________________

EXAMPLE 7

During the test runs from Mar. 29, 1987 to May 18, 1987, 1.62 MM barrels of Trinidad crude were processed at a throughput rate of 31.8 MBCD. The catalytic cracking reactor charge rate averaged 23.8 MBCD, and 24.6% flashed off and processed with a riser. The volume recovery was 105.78%, and the weight balance was 99.3%. Gasoline production was 16.7 MBCD. Light catalytic naphtha production was 23.8%. Heavy catalytic naphtha production was 76.2%.

EXAMPLES 8-357

The feed rates, products, and other data taken for the tests run from Mar. 30, 1987 to May 19, 1987 were as follows:

__________________________________________________________________________ Propane Fresh Propylene Propane Butane Lt CatDate Feed to-Fuel Propylene Butylene Gasoline1987 B/D SCFH B/D FR-313 B/D__________________________________________________________________________0330 25947 6.7 2895 3010 61580331 29560 0.0 2538 3475 50740401 29338 6.2 2255 3331 47490402 29448 0.0 2617 3196 48280403 29900 0.0 2467 3675 41500404 29524 4.0 2282 3632 36220405 29570 0.5 2454 3706 36000406 28989 0.0 2363 4046 36300407 29378 0.0 2562 3658 42800408 34000 0.0 2432 4315 50980409 33378 0.4 2525 4127 46000410 33308 0.0 2707 3687 53910411 32405 1.4 2672 3588 54570412 32733 4.1 2660 4851 51230413 33361 10.3 2638 3754 51000414 33454 19.3 2663 3901 51540415 33034 9.5 2702 3984 50430416 32146 6.8 2690 4124 36380417 32004 4.5 2579 3868 32340418 31780 4.8 2263 3919 26500419 32404 0.7 2643 3729 26230420 32043 0.0 2724 4000 34660421 32930 0.0 2559 4372 40310422 32910 3.8 2565 4164 47460423 33243 0.0 2708 3843 44330424 33425 0.1 2828 3889 32160425 31915 0.3 2512 4319 29010426 29173 0.6 2314 4822 22880427 33780 0.6 2800 4528 27840428 33860 0.5 2873 3878 36910429 34522 0.4 2817 3945 36790430 33453 0.9 2487 4366 35270501 33365 1.1 2637 4304 39840502 33290 3.4 2776 4245 49320503 32936 0.0 2574 4228 50520504 32990 0.5 2764 3784 52800505 32964 1.9 3076 3581 54730506 33181 2.7 2751 3669 47510507 32930 4.7 2727 4006 40390508 33459 0.1 2494 4255 29990509 33232 0.0 2497 4287 23650510 33959 0.2 3130 3301 26290511 17116 45.7 1353 3434 18290512 27848 10.4 1940 3209 34000513 32513 0.0 2555 3782 29600514 32691 0.3 2691 4167 29500515 32650 0.1 2817 4071 30350516 33122 6.7 3032 3700 25300517 32932 11.0 2815 3633 31260518 33500 11.2 2529 3610 49420519 30158 19.7 2324 3888 5150Average 31799 4.0 2594 3899 3988__________________________________________________________________________ DCO from Heavy Cat DCO another ReactorDate Gasoline HCCO LCCO Recycle FCCU Charge1987 B/D B/D B/D B/D B/D B/D__________________________________________________________________________0330 7209 98 7502 0 125 150000331 10950 0 8667 0 300 240000401 11300 0 9009 0 335 220000402 11290 0 9193 0 0 220000403 12012 0 8910 0 0 225000404 12365 0 8500 0 0 225000405 12299 0 8661 0 0 225000406 11776 0 8342 0 0 225000407 11342 0 8999 0 0 220000408 12780 0 10400 0 0 220000409 12710 0 10500 0 0 250000410 12078 0 11231 0 420 252000411 11777 0 10631 316 400 250000412 11274 0 10851 245 500 245000413 12207 0 11330 288 730 247900414 12100 0 11466 439 745 250000415 11872 0 11091 401 685 243400416 12512 0 11267 338 700 237100417 12780 0 11203 261 685 243400418 12893 0 11659 227 440 240000419 13728 0 11264 343 480 242000420 13195 0 10646 311 546 240000421 12777 0 10666 405 760 255000422 12688 0 10739 304 700 255000423 12928 0 10920 185 642 254000424 13950 0 11503 160 597 250000425 13218 0 10512 301 100 253100426 12010 0 9550 275 100 261000427 13707 0 11928 482 538 255000428 13996 0 11083 338 530 253500429 14302 0 11311 375 514 254500430 13879 0 10817 262 300 255000501 13434 0 10399 319 395 250000502 12499 65 9931 418 376 246700503 12470 0 10136 311 421 250000504 12608 10 10171 308 343 250000505 12577 61 10385 199 198 252000506 13092 0 10295 150 412 252220507 13744 169 10353 156 597 253000508 14364 0 10768 294 600 252200509 15356 0 10615 263 590 252500510 15795 0 10902 386 193 84170511 9163 615 5109 696 667 143200512 11036 437 9326 393 1000 247900513 14991 0 10427 345 60 249700514 14638 6 9648 266 505 248300515 14748 0 9921 86 180 245500516 15640 0 10090 343 20 241700517 14432 0 10268 338 28 245000518 13079 0 10787 412 409 245200519 10780 0 9442 268 219 24500Average 12752 29 10183 239 374.2 23747__________________________________________________________________________ Regen Regen Flue Flue Gas Gas Reactor Regen Feed CO O2 Feed Temp PreheatDate ppm vol % deg F deg F deg F1987 AR-2 AR-1 II-1-31 II-1-12 II-1-45__________________________________________________________________________0330 613 0.6 541 1251 4140331 491 4.3 523 1257 3750401 296 5.1 532 1246 3910402 250 5.00403 250 5.00404 238 5.0 531 1249 3900405 282 5.0 531 1243 3950406 264 4.9 523 1245 3950407 283 4.2 525 1251 3920408 520 2.6 525 1253 3850409 754 1.0 520 1259 3860410 724 2.2 520 1264 3880411 597 3.1 522 1258 3800412 696 2.1 524 1266 3810413 708 2.1 523 1266 3840414 582 2.2 519 1272 3860415 445 2.7 515 1278 3820416 498 1.6 515 1279 3840417 554 1.4 515 1281 3870418 485 1.5 513 1291 3910419 439 2.0 511 1285 3880420 497 1.8 513 1286 3880421 485 1.6 513 1290 3810422 369 2.0 515 1290 3760423 252 2.5 517 1293 3780424 221 3.0 514 1291 3780425 263 2.8 517 1292 3830426 644 1.3 525 1282 4020427 443 2.1 524 1292 3800428 476 2.1 522 1283 3670429 396 2.5 521 1284 3640430 460 2.2 515 1283 3680501 526 3.0 512 1274 3640502 648 2.3 516 1264 3590503 682 1.5 516 1267 3580504 660 1.7 515 1266 3560505 787 2.9 517 1268 3580506 751 2.7 518 1259 3570507 516 3.5 513 1275 3690508 310 4.5 516 1273 3680509 315 4.3 517 1276 3670510 274 4.9 521 1277 3640511 260 5.1 498 1185 3880512 142 5.2 549 1298 4030513 351 2.8 524 1307 3840514 331 4.2 520 1285 3680515 332 5.0 520 1286 3670516 374 4.7 530 1283 3670517 475 4.6 530 1272 3640518 629 3.7 527 1276 3700519 558 1.5 550 1276 406Average 459 3.06 521 1272 379__________________________________________________________________________ Fresh Feed DCO HCCO LCCO Hvy CatDate Deg Deg Deg Deg Gasoline LCN1987 API API API API Deg API Deg API__________________________________________________________________________0330 31.8 -1.5 14.4 28.3 47 74.70331 32.3 1.2 14.4 27.7 47 74.70401 31.6 1.3 24.4 27.2 50.4 73.30402 31.6 1.3 24.4 27.2 50.4 73.30403 31.6 1.3 24.4 27.2 50.4 73.30402 32.8 2.4 24.4 26.7 50.4 73.30405 33 2.2 24.4 26.6 50.4 73.30406 32.6 0.4 24.4 24.6 49.7 74.40407 33.1 1.1 24.4 27.3 49.7 74.40408 33.1 1.1 24.4 27.3 49.7 74.40409 32.5 1.9 24.4 27.2 49.3 76.40410 32.6 -0.5 24.4 27.2 49.3 76.40411 32.9 -1 24.4 25.7 49.3 76.40412 32.7 -3.5 24.4 26.5 49.3 76.40413 33.1 -0.8 24.4 25.2 48.2 75.70414 32.3 -3 24.4 25.2 48.2 75.70415 32.8 -1.3 24.4 26.6 46.7 73.40416 27.6 -2.2 24.4 27.2 46.7 73.40417 32.8 -1.9 24.4 26.5 46.7 73.40418 32.9 -4.3 24.4 26.9 46.7 73.40419 31.6 -0.3 24.4 26.4 46.7 73.40420 34.2 -0.2 24.4 27.5 46.7 73.40421 32.5 -2.3 24.4 27.6 54.2 73.40422 32.1 -1.4 11.4 26.1 48.6 75.40423 32.6 -3.9 11.4 25.9 48.6 77.10424 32.7 -2.7 11.4 26.4 48.6 77.10425 30.7 1 11.4 26.4 48.6 77.10426 30.5 -6.3 11.4 23.1 48.6 77.10427 33 -4.1 11.4 24.2 50.6 71.40428 33.7 1.2 11.4 28 50.6 71.40492 33.4 -1.8 9.4 26 50.9 79.40430 32.9 1 9.4 26.3 50.9 79.40501 32.8 -0.8 9.4 27.1 50.9 79.40502 32 0.8 9.4 27 50.9 79.40503 34.8 1.1 9.4 27 50.9 79.40504 34 0 9.4 26.8 47.3 75.20505 32.9 -1.8 9.4 26.5 47.3 75.20506 32.7 0 9.4 26.5 48 76.70507 32.9 -3.7 9.4 27.1 48 76.70508 32.7 -2.9 9.4 26.2 48 76.70509 32.9 -3.9 9.4 25.1 48 76.70510 33.4 0.4 9.4 25.8 48 76.70511 32 -0.2 9.4 27.6 47.2 83.80512 27.4 -1.8 9.4 27.6 47.2 83.80513 32.3 -1.6 18.2 25.6 51.7 87.10514 32.9 -4.7 18.2 25.7 51.7 87.10515 33 -4.2 18.2 24.6 51.7 87.10516 32.8 -2.8 18.2 25.8 51.7 850517 32.8 -2.8 18.2 25.8 51.7 850518 32.8 -2.8 18.2 25.8 51.7 78.80519 36.4 0.5 18.2 26.8 51.7 78.8Average 32.3 -1.1 17.3 26.4 49.3 76.9__________________________________________________________________________ Heavy LightDate LCCO LCCO Catalytic Naphtha Catalytic Naphtha1987 90% FBP 90% FBP RVP__________________________________________________________________________0330 513 562 344 413 18.60331 554 624 342 398 17.60401 561 616 340 402 15.30402 572 624 345 396 12.80403 592 652 352 392 15.90404 583 642 350 388 15.90405 570 633 329 371 15.90406 574 630 340 415 12.90407 579 632 349 409 13.30408 592 637 343 383 13.80409 590 635 344 375 15.10410 630 668 340 406 130411 604 670 356 400 13.10412 596 664 336 404 11.90413 600 654 341 381 15.30414 676 673 350 400 12.30415 592 654 342 386 15.30416 627 695 331 367 120417 596 662 338 374 13.50418 600 664 339 367 15.70419 575 633 352 389 15.90420 643 690 350 389 15.90421 576 639 347 387 11.20422 598 665 347 388 10.80423 600 673 349 395 13.40424 655 672 343 380 15.60425 607 636 352 420 15.60426 632 688 342 395 16.10427 603 682 326 384 13.70428 591 643 347 406 13.70429 618 676 361 472 13.10430 607 676 347 379 12.60501 595 652 338 395 12.30502 576 626 339 375 11.90503 595 650 339 399 11.10504 590 640 348 402 11.80505 598 660 348 4100506 601 667 355 382 120507 587 648 340 382 150508 619 676 345 389 14.50509 630 682 344 397 160510 610 667 348 385 16.40511 397 652 341 381 16.305120513 613 676 341 411 21.40514 601 696 331 360 20.70515 616 682 340 411 20.70516 609 665 349 376 20.70517 660 704 370 440 10.70518 587 646 352 411 14.90519 603 663 376 420 20.6Average 596 656 345 395 14.8__________________________________________________________________________ Feed Feed LCCO DCO NaphthaDate Sulfur RAMS Flash Sulfur in LCCO1987 wt % wt % .degree.F. wt % vol %__________________________________________________________________________0330 0.3 0.13 152 13.140331 0.29 0.13 158 1.37 18.470401 0.33 0.26 158 1.38 18.880402 0.28 168 13.930403 18.980404 0.31 0.26 153 1.38 140405 0.32 0.31 153 1.22 17.750406 0.31 0.31 160 1.22 16.870407 0.3 0.31 157 1.22 17.360408 0.27 0.35 13.310409 0.27 0.35 171 1.16 20.690410 0.27 0.35 171 1.16 17.740411 0.58 0.35 164 1.16 16.940412 0.58 0.35 161 1.25 18.620413 0.28 0.35 165 1.25 190414 0.3 0.35 166 1.25 19.430415 0.25 0.21 161 1.17 24.110416 0.25 0.21 141 1.17 17.210417 0.26 0.21 156 1.17 21.040418 0.28 0.21 154 1.17 22.660419 0.28 0.33 157 1.35 24.420420 0.29 0.33 165 1.35 17.90421 0.27 0.33 166 1.35 21.540422 0.26 0.23 166 1.27 21.520423 0.29 0.23 160 1.27 23.80424 0.29 0.23 156 1.27 19.660425 0.3 0.23 154 1.27 12.070426 0.37 0.25 166 1.27 16.970427 0.29 0.25 158 1.27 21.710428 0.29 0.25 156 1.27 18.640429 0.29 0.25 160 1.27 16.750430 0.22 0.25 158 1.27 21.940501 0.25 0.25 154 1.27 18.080502 0.27 0.25 157 1.27 17.130503 0.25 0.3 151 1.35 21.260504 0.22 0.3 157 1.35 20.760505 18.160506 16.870507 19.750508 18.80509 18.80510 16.30511 21.440512 20.840513 0.28 0.26 19.870514 19.870515 0.28 162 1.32 19.410516 0.29 151 1.32 17.940517 0.28 138 1.27 19.220518 0.35 138 1.27 190519 0.34 156 1.27 18.7Average 0.30 0.27 158 1.27__________________________________________________________________________Propane-Propylene toDate Fuel Butane-Butylene1987 Wt % Vol % Wt % Vol % Wt %__________________________________________________________________________0330 0.23 11.16 6.45 11.60 7.910331 0.00 8.59 4.98 11.76 8.040401 0.18 7.68 4.44 11.35 7.730402 0.00 8.89 5.33 10.85 8.600403 0.00 8.25 4.95 12.29 9.740404 0.12 7.73 4.70 12.30 8.450405 0.02 8.30 4.90 12.53 8.670406 0.00 8.15 4.80 13.96 9.630407 0.0 8.72 5.15 12.45 8.630408 0.00 7.15 4.22 12.69 8.790409 0.01 7.56 4.45 12.37 8.550410 0.00 8.13 4.71 11.07 7.550411 0.04 8.25 4.79 11.07 7.560412 0.11 8.13 4.73 14.82 10.150413 0.27 7.91 4.58 11.25 7.670414 0.50 7.96 4.58 11.66 7.900415 0.25 8.18 4.81 12.06 8.120416 0.18 8.37 4.76 12.83 8.360417 0.12 8.06 4.74 12.09 8.130418 0.13 7.12 4.23 12.33 8.380419 0.02 8.16 4.70 11.51 7.780420 0.00 8.50 4.96 12.48 8.550421 0.00 7.77 4.45 13.28 8.930422 0.10 7.80 4.55 12.65 8.480423 0.00 8.14 4.78 11.56 7.790424 0.00 8.46 4.98 11.64 7.860425 0.01 7.87 4.53 13.53 9.200426 0.02 7.93 4.56 16.53 11.230427 0.02 8.29 4.76 13.40 9.100428 0.01 8.49 4.90 11.45 7.820429 0.01 8.16 4.86 11.43 7.760430 0.03 7.43 4.45 13.05 8.910501 0.03 7.90 4.55 12.90 8.740502 0.09 8.34 4.78 12.75 8.610503 0.00 7.81 4.54 12.84 8.810504 0.01 8.38 4.86 11.47 7.860505 0.05 9.33 5.41 10.86 7.440506 0.07 8.29 4.86 11.06 7.510507 0.13 8.28 4.82 12.16 8.210508 0.00 7.45 4.34 12.72 8.580509 0.00 7.51 4.37 12.90 8.710510 0.00 9.22 5.61 9.72 4.110511 2.35 7.90 4.58 20.06 8.070512 0.32 6.97 3.94 11.52 4.530513 0.00 7.86 4.32 11.63 7.450514 0.01 8.23 4.76 12.75 8.570515 0.00 8.63 5.05 12.47 8.500516 0.18 9.15 5.39 11.17 7.650517 0.30 8.55 5.03 11.03 7.550518 0.29 7.55 4.34 10.78 7.300519 0.58 7.70 4.56 12.89 8.98__________________________________________________________________________Date Lt Cat Gasoline Hvy Cat Gasoline 1987 Vol % Wt % Vol % Wt %__________________________________________________________________________0330 23.73 18.80 27.78 25.420331 17.17 13.64 37.04 33.990401 16.19 12.9 38.52 34.50402 16.40 13.1 38.34 34.40403 13.88 11.1 40.17 36.00404 12.27 9.8 41.8 37.80405 12.17 9.8 41.59 37.60406 12.52 10.0 40.62 36.80407 14.57 11.6 38.61 35.10408 14.99 12.0 37.59 34.10409 13.78 10.9 38.08 34.50410 16.18 12.6 36.26 32.40411 16.84 13.1 36.34 32.50412 15.65 12.1 34.44 30770413 15.29 11.8 36.59 32.60414 15.41 11.8 36.17 32.10415 15.27 11.9 35.94 32.30416 11.32 8.6 38.92 33.80417 10.10 7.9 39.93 35.80418 8.34 6.6 40.57 36.80419 8.10 6.3 42.37 38.10420 10.82 8.6 41.18 37.50421 12.24 9.5 38.80 33.30422 14.42 11.1 38.55 34.10423 13.33 10.2 38.89 34.60424 9.62 7.4 41.74 37.20425 9.09 7.0 41.42 37.20426 7.84 6.1 41.17 36.90427 8.24 6.5 40.58 35.90428 10.90 8.7 41.33 36.80429 10.66 8.2 41.43 36.80430 10.54 8.1 41.49 37.00501 11.94 9.2 40.26 35.70502 14.81 11.3 37.55 33.20503 15.34 11.9 37.86 34.00504 16.01 12.6 38.22 34.90505 16.60 13.1 38.15 34.80506 14.32 11.1 39.46 35.50507 12.26 9.5 41.74 37.40508 8.96 6.9 42.93 38.40509 7.12 5.5 46.21 41.40510 7.74 6.1 46.51 42.40511 10.68 7.7 53.53 46.70512 12.21 8.6 39.63 33.80513 9.11 6.4 46.11 38.60514 9.02 6.7 44.78 39.40515 9.30 6.9 45.17 40.30516 7.64 5.8 47.22 42.30517 9.49 7.2 43.82 39.30518 14.75 11.3 39.04 34.50519 17.08 13.5 35.75 32.5__________________________________________________________________________Date LCCO LCCO HCCO HCCO Decanted Oil1987 Vol % Wt % Vol % Wt % Vol % Wt %__________________________________________________________________________0330 28.91 29.55 0.38 0.42 0.00 0.000331 29.32 30.17 0.00 0.00 0.00 0.000401 30.71 31.6 0.00 0.00 0.00 0.000402 31.22 32.1 0.00 0.00 0.00 0.000403 29.80 30.6 0.00 0.00 0.00 0.000404 28.79 29.9 0.00 0.00 0.00 0.000405 29.29 30.5 0.00 0.00 0.00 0.000406 28.78 30.3 0.00 0.00 0.00 0.000407 30.63 31.8 0.00 0.00 0.00 0.000408 30.59 31.7 0.00 0.00 0.00 0.000409 31.46 32.5 0.00 0.00 0.00 0.000410 33.72 34.3 0.00 0.00 0.00 0.000411 32.81 33.8 0.00 0.00 0.97 1.210412 33.15 33.8 0.00 0.00 0.75 0.940413 33.96 34.7 0.00 0.00 0.86 1.060414 34.27 34.8 0.00 0.00 1.31 1.630415 33.57 34.0 0.00 0.00 1.21 1.490416 35.05 34.2 0.00 0.00 1.05 1.260417 35.00 35.4 0.00 0.00 0.82 1.010418 36.69 37.4 0.00 0.00 0.72 0.910419 34.76 35.3 0.00 0.00 1.06 1.290420 33.22 33.9 0.00 0.00 0.97 1.200421 32.39 32.4 0.00 0.00 1.23 1.520422 32.63 33.0 0.00 0.00 0.92 1.130423 32.85 33.4 0.00 0.00 0.56 0.700424 34.41 35.0 0.00 0.00 0.48 0.600425 32.94 33.7 0.00 0.00 0.94 1.150426 32.74 34.2 0.00 0.00 0.94 1.210427 35.31 36.6 0.00 0.00 1.43 1.810428 32.73 33.3 0.00 0.00 1.00 1.220429 32.76 33.7 0.00 0.00 1.09 1.360430 32.33 33.3 0.00 0.00 0.78 0.960501 31.17 31.8 0.00 0.00 0.96 1.190502 29.83 30.4 0.19 0.22 1.25 1.530503 30.77 31.8 0.00 0.00 0.94 1.160504 30.83 31.8 0.03 0.04 0.93 1.160505 31.50 32.5 0.18 0.21 0.60 0.760506 31.03 31.8 0.00 0.00 0.45 0.550507 31.44 31.8 0.51 0.59 0.47 0.600508 32.18 32.8 0.00 0.00 0.88 1.100509 31.94 32.8 0.00 0.00 0.79 1.000510 32.10 33.4 0.00 0.00 1.14 1.410511 29.85 29.3 3.60 3.98 4.07 4.830512 33.49 32.0 1.57 1.69 1.41 1.660513 32.07 31.3 0.00 0.00 1.06 1.250514 29.51 30.3 0.02 0.02 0.81 1.030515 30.39 31.8 0.0 0.00 0.26 0.340516 30.46 31.8 0.00 0.00 1.04 1.320517 31.18 32.5 0.00 0.00 1.03 1.310518 32.20 33.1 0.00 0.00 1.23 1.550519 31.31 32.9 0.00 0.00 0.89 1.12__________________________________________________________________________Date Regen Total Air Coke Burn Coke1987 SCFH lb/hr Wt %__________________________________________________________________________0330 3273640 16832 5.140331 3285700 13996 3.760401 3256780 13168 3.550402 3188480 12995 3.490403 3201780 13049 3.450404 3156080 12855 3.470405 3160880 12861 3.470406 3147740 12919 3.550407 3148440 13443 3.650408 3221640 15030 3.530409 3185420 16096 3.830410 3243520 15444 3.630411 3236900 14734 3.570412 3250500 15556 3.710413 3261240 15603 3.630414 3274580 15573 3.600415 3276320 15240 3.580416 3210660 15729 3.680417 3338440 16579 4.020418 3228340 15906 3.920419 3308900 15959 3.820420 3311200 16134 3.960421 3425760 16798 3.940422 3235520 15571 3.660423 3456740 16191 3.780424 3414380 15620 3.640425 3425300 15846 3.890426 3062300 15271 4.090427 3309740 15830 3.660428 3358260 16066 3.730429 3381200 15824 3.600430 3429500 16333 3.850501 3395280 17120 4.030502 3325800 17320 4.070503 3296800 17884 4.310504 3292020 17710 4.250505 3308060 16722 4.010506 3356300 17123 4.050507 3513240 17172 4.060508 3491840 16147 3.760509 3476840 16254 3.810510 3102360 13978 3.270511 3206520 14272 6.300512 3308320 14653 3.880513 3160660 16027 3.670514 3406840 15977 3.820515 3278620 14710 3.570516 3261480 14886 3.580517 3286340 15150 3.660518 3236680 15697 3.680519 3245480 17648 4.72__________________________________________________________________________ Total ConvertedDate Gasoline Barrels Total Products1987 B/D B/D B/D lb/hr vol % wt %__________________________________________________________________________0330 13367 17128 26872 320013 103.6 97.70331 16024 20139 30704 362631 103.9 97.40401 16049 19594 30643 362142 104.4 97.60402 16118 18898 31124 369966 105.7 99.40403 16162 20275 31214 372781 104.4 98.60404 15987 19778 30400 360207 103.0 97.20405 15899 20072 30720 361991 103.9 97.60406 15406 19743 30157 356165 104.0 97.80407 15622 19462 30841 363068 105.0 98.60408 17878 21979 35025 411669 103.0 96.60409 17310 22275 34462 408789 103.2 97.40410 17469 20990 35093 416222 105.4 97.90411 17234 20211 34441 409904 106.3 99.30412 16397 20632 35005 417006 106.9 99.50413 17307 20741 35316 426958 105.9 99.40414 17254 20551 35723 432944 106.8 100.00415 16915 21276 35094 421607 106.2 99.10416 16150 19258 34568 416605 107.5 97.40417 16014 19861 33925 411527 106.0 99.70418 15543 19454 33611 411071 105.8 101.30419 16351 20596 34330 416807 105.9 99.90420 16661 19975 34341 413336 107.2 101.50421 16808 21232 34809 413253 105.7 97.00422 17434 21267 35207 425925 107.0 100.00423 17361 21902 35016 426571 105.3 99.60424 17166 20890 35546 431039 106.3 100.40425 16119 19189 33763 409443 105.8 100.50426 14298 18233 31259 384769 107.2 103.10427 16491 20686 36229 443603 107.2 102.60428 17687 21386 35860 431825 105.9 100.20429 17981 21466 36430 439814 105.5 100.00430 17406 21846 35337 426705 105.6 100.60501 17418 21581 35077 419518 105.1 98.70502 17431 21673 34866 414844 104.7 97.40503 17522 21880 34770 415321 105.6 100.10504 17888 21820 34926 420638 105.9 101.00505 18050 21286 35352 424052 107.2 101.80506 17843 21570 34707 418308 104.6 98.80507 17783 24149 35193 425006 106.9 100.50508 17363 21409 35174 426911 105.1 99.30509 17721 21389 35382 431540 106.5 101.20510 18424 21278 36143 426546 106.4 99.70511 10992 22281 2670060512 14436 16898 29785 354140 107.0 93.90513 17951 20913 35061 421863 107.8 96.60514 17588 22021 34365 410009 105.1 98.00515 17783 21874 34678 411592 106.2 99.80516 18170 21624 35335 420672 106.7 101.10517 17558 21423 34611 413877 105.1 100.00518 18021 21300 35359 423672 105.5 99.20519 15930 19566 31851 384495 105.6 102.8Average 16740 20638 33686 404046 105.7 99.3__________________________________________________________________________ Through- putDate Conv Ratio Energy Index1987 vol % (TPR) MBTU/bbl__________________________________________________________________________0330 66.0 1.14 3620331 68.1 1.12 3030401 66.8 1.10 2890402 64.2 1.10 2810403 67.8 1.09 2770404 67.0 1.10 2810405 67.9 1.08 2770406 68.1 1.09 2810407 66.2 1.09 2870408 64.6 1.08 2720409 66.7 1.11 2900410 63.0 1.09 2840411 62.4 1.06 2820412 63.0 1.07 2840413 62.2 1.06 2800414 61.4 1.06 2830415 64.4 1.06 2840416 59.9 1.06 2920417 62.1 1.07 3010418 61.2 1.08 2940419 63.6 1.08 2930420 62.3 1.08 2990421 64.5 1.08 3000422 64.6 1.07 2890423 65.9 1.06 2950424 62.5 1.06 2870425 60.1 1.07 3010426 62.5 1.06 3160427 61.2 1.0 2860428 63.2 1.07 2890429 62.2 1.06 2810430 65.3 1.07 2890501 64.7 1.06 3020502 65.1 1.11 3040503 66.4 1.07 3140504 66.1 1.13 3130505 64.6 1.09 3020506 65.0 1.07 3120507 65.0 1.07 3120508 64.0 1.06 3000509 64.4 1.06 2980510 62.7 1.07 2720511 1.07 5450512 60.7 1.12 3130513 64.3 1.08 2960514 67.4 1.04 2970515 67.0 1.05 2810516 65.3 1.06 2810517 65.1 1.04 2870518 63.6 1.07 2900519 64.9 1.08 342Average 64.3 1.08 299__________________________________________________________________________

Among the many advantages of the novel catalytic cracking process are:

1. Outstanding ability to refine petroleum and produce gasoline without the use of a pipestill(s), atmospheric tower, and/or vacuum tower. 2. Superior processing of whole crude oil. 3. Excellent production of gasoline and other hydrocarbons. 4. Enhanced catalytic cracking of petroleum. 5. Good throughput. 6. Cost effective. 7. Convenient. 8. Safe. 9. Efficient. 10. Effective.

Although embodiments of the invention have been shown and described, it is to be understood that various modifications, additions, and substitutions, as well as rearrangements of process steps, can be made by those skilled in the art without departing from the novel spirit and scope of this invention.

Claims

1. A catalyst cracking process, comprising the steps of:

substantially desalting petroleum comprising crude oil;

flashing and separating said desalted crude oil in a flash drum into a flashed overhead stream and a flashed bottom stream;

feeding said flashed bottom stream to a catalytic cracking unit comprising a regenerator and at least one catalytic cracking reactor selected from the group consisting of a riser reactor and a fluidized bed reactor, in the absence of previously fractionating said petroleum in a fractionator selected from the group consisting of a pipestill, crude unit, an atmospheric tower, and a vacuum tower;

substantially cracking said flashed bottom stream in said catalytic cracking reactor in the presence of a cracking catalyst to form a cracked effluent stream;

passing said cracked effluent stream from said catalytic cracking reactor and said flashed overhead stream from said flash drum in a fractionator;

fractionating said cracked effluent stream from said catalytic cracking reactor and said flashed overhead stream from said flash drum in said fractionator;

regenerating said catalyst in a regenerator; and recycling said regenerated catalyst to said catalytic cracking reactor.

2. A catalytic cracking process in accordance with claim 1 wherein said petroleum contains less than 50% gas oil by volume.

3. A catalytic cracking process in accordance with claim 1 wherein said petroleum comprises whole crude oil.

4. A catalytic cracking process in accordance with claim 1 including substantially combusting carbon monoxide in said regenerator during said regeneration.

5. A catalytic cracking process in accordance with claim 4 wherein catalyst includes a promoter for enhancing said combustion of carbon monoxide in said regenerator.

6. A catalytic cracking process, comprising the steps of:

flashing and separating substantially desalted petroleum into an overhead flashed stream and flashed bottoms;

substantially cracking said flashed bottoms comprising a reactor charge in a catalytic cracking reactor in the presence of a cracking catalytic to produce cracked effluent comprising more valuable, lower molecular weight hydrocarbons;

said reactor charge comprising by volume

from about 0.1% to about 20% hydrocarbons comprising naphtha and light hydrocarbons having a boiling temperature less than about 430.degree. F.,

from about 20% to about 50% hydrocarbons comprising diesel oil and kerosene having a boiling temperature ranging from greater than about 430.degree. F. to less than about 650.degree. F.,

from about 20% to less than about 50% hydrocarbons comprising gas oil having a boiling temperature ranging from greater than about 650.degree. F. to less than about 1000.degree. F. and

less than about 20% hydrocarbons comprising resid having a boiling temperature greater than about 1000.degree. F.;

passing and fractionating said cracked effluent and said overhead flashed stream in a fractionator;

regenerating said catalyst in a regenerator; and conveying said regenerated catalyst to said reactor.

7. A catalytic cracking process in accordance with claim 6 wherein said resid has a RAMS carbon content ranging from about 0.5% to about 10% by weight.

8. A catalyst cracking process, comprising:

pumping whole crude oil from a storage tank through a series of heat exchangers;

said whole crude oil comprising by volume less than about 35% naphtha and lighter hydrocarbons having a boiling temperature less than about 430.degree. F.,

from about 20% to about 50% diesel oil and kerosene having a boiling temperature ranging from more than about 430.degree. F. to less than about 650.degree. F.,

from about 20% to less than about 50% gas oil having a boiling temperarture ranging from more than about 650.degree. F. to less than about 1000.degree. F.,

from about 0.1% to less than about 20% resid having a boiling temperature more than about 1000.degree. F. and a RAMS carbon content from about 0.5% to about 10% by weight;

injecting water into said whole crude oil;

mixing said whole crude oil and said water;

substantially desalting said whole crude oil;

heating salt desalted crude oil in a furnace;

passing said heated crude oil to a flash drum;

substantially flashing, separating and removing a substantial portion of said naphtha and light hydrocarbons from said whole crude oil in said flash drum leaving flashed crude oil liquid comprising reactor charge;

passing said removed naphtha and light hydrocarbons to a fractionator;

pumping said flashed crude oil liquid to a fluid catalytic cracking unit comprising a regenerator and a catalytic cracking reactor selected from the group consisting of a riser reactor and a fluidized bed reactor;

substantially catalytically cracking and volatilizing said flashed crude oil liquid in said catalytic cracking reactor in the presence of a cracking catalyst to produce mor valuable, lower molecular weight hydrocarbons leaving substantially deactivated, coked catalyst;

stripping volatile hydrocarbons from said coked catalyst;

feeding said stripped coked catalyst to said regenerator;

injecting a sufficient amount of air into said regenerator to fluidize said catalyst in said regenerator;

regenerating and substantially combusting said coked catalyst in said regenerator to produce regenerated cracking catalyst containing less than about 0.1% coke by weight;

feeding and recycling said regenerated cracking catalyst to said catalytic cracking reactor;

passing said cracked volatilized crude oil from said catalytic cracking reactor to a fractionator;

fractionating and separating said cracked volatilized crude oil from said catalytic cracking reactor and said flash naphtha and said light hydrocarbons from said flash drum in said fractionator to produce a stream of light hydrocarbons, a stream of light catalytic cycle oil, and at least one stream of decanted oil;

conveying said light hydrocarbons from said fractionator to a separator drum; and

separating said light hydrocarbons in said separator drum to produce a stream of wet gas and a stream of material comprising propane, propylene, butane, butylene, and naphtha.

9. A catalyst cracking process in accordance with claim 8 including injecting decanted oil into whole crude oil before said whole crude oil enters said reactor.

10. A catalytic cracking process in accordance with claim 9 wherein at least some of said decanted oil from said stream of decanted oil is injected into said reactor charge.

11. A catalytic cracking process in accordance with claim 8 wherein excess air is injected into said regenerator to substantially completely convert said combusted coke to carbon dioxide and steam.

12. A catalytic cracking process in accordance with claim 11 wherein said catalyst comprises a promoter for enhancing the complete combustion of carbon monoxide in said regenerator.

13. A catalyst cracking process in accordance with claim 8 wherein said whole crude oil contains less than about 2% RAMS carbon by weight.

14. A catalytic cracking process in accordance with claim 8 wherein said whole crude oil comprises at least one oil selected from the group consisting of Trinidad crude, Brass River crude, HIPS crude, Florence Canal crude, St. Gabriel crude, and Louisiana Light crude.

15. A catalytic cracking process in accordance with claim 14 wherein said catalytic cracking reactor comprises a riser reactor.

16. A catalytic cracking process in accordance with claim 15 wherein said fresh catalyst is fed to said regenerator at a replacement rate of at least about 0.25 pounds of catalyst per barrel of reactor charge.

17. A catalyst cracking process in accordance with claim 16 wherein said fresh catalyst is fed to said regenerator at a replacement rate greater than about 0.25 to less than about 2.0 pounds per barrel of reactor charge to substantially control the effects of contaminant metals in said reactor charge.