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US 4,377,470 AGranted
Immobilization of vanadia deposited on catalytic materials during carbo-metallic oil conversion
AssigneeAshland Oil, Inc.
InventorsWilliam P. Hettinger, Jr., James D. Carruthers, William D. Watkins
Life of this patent
Estimating the term…
Abstract
A process is disclosed for catalytic cracking a hydrocarbon oil feed having significant vanadium content to produce lighter products. The catalyst, from the cracking step, coated with coke and vanadium in an oxidation state less than +5, is regenerated in the presence of an oxygen-containing gas at a temperature high enough to burn off a portion of the coke under conditions keeping the vanadium in an oxidation state less than +5.
Claims41
A process for converting a vanadium-containing hydrocarbon oil feed to lighter products comprising:
- contacting said oil feed under conversion conditions in a conversion zone with a cracking catalyst having a relative activity of at least about 20% to form lighter products and coke, whereby vanadium in an oxidation state less than +5 and coke are deposited on said catalyst;
- separating said lighter products from the spent catalyst carrying vanadium in an oxidation state less than +5 and coke;
- regenerating said spent catalyst by contacting it with an oxygen-containing gas under conditions whereby said coke on the spent catalyst is combusted, forming gaseous products comprising CO and CO.sub.2, said regeneration being carried out at least in part with the catalyst at a temperature greater than the melting point of vanadium in an oxidation state of +5, said regeneration further being carried out for a period of time and in the presence of sufficient oxygen so as to reduce the concentration of coke on said catalyst to a level less than about 0.15 percent by weight of the catalyst while promoting the retention of vanadium in an oxidation state less than +5;
- and
- recycling the regenerated catalyst to the conversion zone to contact fresh feed.
2 more elements
A process for converting a hydrocarbon feed containing at least about 1 ppm vanadium to lighter products comprising:
- contacting said hydrocarbon feed with a cracking catalyst having a relative activity of at least about 20% and containing at least about 5000 ppm vanadium and less than about 0.15 percent carbon, said contact being made in a progressive flow reactor for a predetermined vapor riser residence time in the range of about 0.5 to about 10 seconds at a temperature of about 900 to about 1400.degree. F. and under a pressure of about 10 to about 50 pounds per square inch absolute while causing a conversion per pass in the range of about 50 to about 90% while producing coke and laying down vanadium in an oxidation state less than +5 and coke on said catalyst;
- separating spent catalyst from the hydrocarbon products formed in said reactor;
- contacting said spent catalyst at a temperature of at least about 1275.degree. F. with an oxygen-containing gas in at least two stages, in the first stage of which said spent catalyst comprises a fluidized bed having a density from about 25 to about 50 pounds per cubic foot, the average residence time of said catalyst in said bed is from about 5 to about 30 minutes, and said oxygen-containing gas is sufficiently deficient in oxygen to produce CO and CO.sub.2 in the gases in heat exchange contact with the catalyst in a CO/CO.sub.2 ratio of at least about 0.25;
- transferring the partially regenerated catalyst to a riser regenerator wherein the partially regenerated catalyst as a dilute phase of solids and at a temperature greater than about 1275.degree. F. is contacted with a stoichiometric excess of oxygen for a period of time less than about 2 seconds so as to reduce the carbon concentration on said catalyst to less than about 0.15 percent by weight;
- separating the resulting regenerated catalyst from the oxygen containing gases;
- collecting the separated regenerated catalyst in the presence of a reducing gas;
- and
- recycling the regenerated catalyst containing at least about 5000 ppm vanadium by weight to the progressive flow reactor for contact with fresh feed.
5 more elements
A process for converting a vanadium-containing hydrocarbon oil feed to lighter products comprising:
- contacting said oil feed under conversion conditions in a conversion zone with a cracked catalyst to form lighter products and coke, whereby vanadium in an oxidation state less than +5 and coke are deposited on said catalyst;
- separating said lighter products from the spent catalyst carrying vanadium in an oxidation state less than +5 and coke;
- regenerating said spent catalyst in at least two stages, in the first stage of which said spent catalyst is contacted in a dense fluidized bed with a gas containing less than a stoichiometric amount of oxygen to convert hydrogen in said coke to H.sub.2 O, and carbon in said coke to CO and CO.sub.2 so as to retain vanadium on said catalyst in an oxidation state less than +5, and in the final regeneration stage of which partially regenerated catalyst is contacted with a stoichiometric excess of oxygen for a period of time of less than about 2 seconds.
Dependencies are inferred from the claim text.