Flash chemical ionizing pyrolysis of hydrocarbons

A flash chemical ionizing pyrolysis (FCIP) process comprising the steps of:

• preparing a feed emulsion comprising (i) 100 parts by weight of an oil component comprising a liquid ionizing pyrolyzate (LIP) blend component and a feedstock oil at a weight ratio of from 1:100 to 1:1, (ii) from about 1 to 100 parts by weight of water, and (iii) from about 1 to 20 parts by weight finely divided solids comprising a mineral support and an oxide or acid addition salt of a Group 3-16 metal;
• spraying the feed emulsion in a flash pyrolysis reactor at a temperature from about 425° C. to about 600° C.;
• collecting an effluent from the reactor;
• recovering a product LIP from the effluent;
• and
• supplying a portion of the product LIP as the LIP blend component to the feed emulsion preparation step.

A hydrocarbon refinery process comprising the steps of:

• combining a liquid ionizing pyrolyzate (LIP) blend component with a feedstock oil at a weight ratio from about 1:100 to about 1:1 to form an LIP blend;
• preparing an emulsion comprising (i) a first portion of the LIP blend, (ii) water, and (iii) from finely divided solids comprising a mineral support and an oxide or acid addition salt of a Group 3-16 metal;
• spraying the emulsion in a flash pyrolysis reactor at a temperature from about 425° C. to about 600° C. and a pressure from about 1 to about 1.5 atm;
• collecting an effluent from the reactor;
• recovering a product LIP from the effluent;
• incorporating the product LIP as the LIP blend component in the LIP blend;
• and
• distilling a second portion of the LIP blend.

A hydrocarbon refinery process comprising the steps of:

• preparing a feed emulsion comprising (i) 100 parts by weight of an oil component, (ii) from about 1 to 100 parts by weight of water, and (iii) from about 1 to 20 parts by weight finely divided solids comprising a mineral support and an oxide or acid addition salt of a Group 3-16 metal;
• spraying the feed emulsion in a flash pyrolysis reactor at a temperature from about 425° C. to about 600° C.;
• collecting an effluent from the flash pyrolysis reactor;
• recovering a liquid ionizing pyrolyzate (LIP) from the effluent;
• combining the recovered LIP with a feedstock oil comprising crude oil or a petroleum fraction selected from gas oil, resid, or a combination thereof to form a pyrolyzate-feedstock blend;
• distilling, cracking, visbreaking, and/or coking a first portion of the blend;
• and
• supplying a second portion of the blend as the oil component in the feed emulsion preparation step.

A crude oil upgrading process, comprising:

• flash chemical ionizing pyrolysis of an emulsion of oil, water, mineral support, and an oxide and/or acid addition salt of a Group 3-16 metal, to obtain a liquid ionizing pyrolyzate (LIP);
• blending the LIP with a heavy oil;
• and
• thermally processing the blend at a temperature above about 100° C.