Fluid coking for proppant material production

A method comprising:

• providing a fluid coker reactor, wherein the fluid coker reactor has a coking zone in an upper portion of the fluid coker reactor, wherein the fluid coker reactor contains a fluidized bed of solid particles into which a heavy oil feedstock is introduced, wherein the fluid coker reactor is fluidly connected to an attrition steam line supplying attrition steam;
• reacting the heavy oil feedstock in the coking zone of the fluid coker reactor to form a vapor phase and hot coke;
• stripping at least a portion of hydrocarbons that adhere to the hot coke in a stripping zone located in a lower portion of the fluid coker reactor;
• scrubbing the vapor phase from the fluid coker reactor in a scrubber;
• heating the hot coke in a heater, wherein the heater receives the hot coke from the fluid coker reactor, and wherein the heater produces a coke product;
• recycling a portion of the hot coke from the heater to the coking zone of the fluid coker reactor via a heater return line;
• removing a recycle portion from the coke product;
• and
• recycling a recycle feed comprising the recycle portion to a feed line fluidly connected to the fluid coker reactor.

A method comprising:

• providing a fluid coker reactor, wherein the fluid coker reactor has a coking zone in an upper portion of the fluid coker reactor, wherein the fluid coker reactor contains a fluidized bed of solid particles into which a heavy oil feedstock is introduced, wherein the fluid coker reactor is fluidly connected to an attrition steam line supplying attrition steam;
• reacting the heavy oil feedstock in the coking zone of the fluid coker reactor to form a vapor phase and hot coke;
• stripping at least a portion of hydrocarbons that adhere to the hot coke in a stripping zone located in a lower portion of the fluid coker reactor;
• scrubbing the vapor phase from the fluid coker reactor in a scrubber;
• heating the hot coke in a heater, wherein the heater receives the hot coke from the fluid coker reactor, and wherein the heater produces a coke product;
• recycling a portion of the hot coke from the heater to the coking zone of the fluid coker reactor via a heater return line;
• removing a recycle portion from the coke product;
• grinding the recycle portion of the coke product in a coke grinding system to produce fine particles;
• slurrifying the fine particles in a slurry mixer, wherein slurrifying comprises mixing the fine particles with a raw petroleum resid feed to form a slurry;
• and
• providing the slurry to a feed line of the fluid coker reactor.

A system comprising:

• a fluid coker reactor, wherein the fluid coker reactor contains a fluidized bed of solid particles, and wherein the fluid coker reactor is fluidly connected to an attrition steam line supplying attrition steam;
• a coking zone, wherein the coking zone is located in an upper portion of the fluid coker reactor, and wherein coking zone is configured to react a heavy oil feedstock to form a vapor phase and hot coke;
• a stripping zone, wherein the stripping zone is located in a lower portion of the fluid coker reactor, and wherein the stripping zone is configured to strip at least a portion of hydrocarbons that adhere to the hot coke;
• a scrubber, wherein the scrubber scrubs the vapor phase from the fluid coker reactor;
• a heater, wherein the heater heats the hot coke from the fluid coker reactor, and wherein the heater produces a coke product;
• a heater return line, wherein the heater return line recycles a portion of the hot coke from the heater to the coking zone of the fluid coker reactor;
• and
• a recycle portion of the coke product, wherein the recycle portion is removed from the coke product, and wherein the recycle portion is recycled to a feed line fluidly connected to the fluid coker reactor.