System for thermal and catalytic cracking of crude oil

An oil refinery system of catalytic cracking processes in said system for heavy products of previous oil distillation for fine fractions comprising:

• (a) a tubular furnace for heating of initial product up to temperatures corresponding to heavy fractions boiling in the range of 300-500 C;
• and for obtaining of more narrow fractional composition of catalytic products, a furnace for providing a heating of initial product to the temperatures in a sufficiently narrow range distinguished by intensity of heat exchange inside a furnace;
• and, in this case, a necessity for utilization of several furnaces for successive heating of initial components is eliminated;
• (b) a vortex vapor generator with a catalyst layer moving in a boiling layer of a liquid;
• (c) a system of a catalyst introduction and extraction into and from a boiling layer of a vortex vapor generator, i.e. a catalyst circulation system;
• (d) a catalyst regeneration system, which can consist of already existing equipment;
• (e) a vortex vapor condensers of catalyst products and pumps transporting condensate into corresponding reservoirs.

A vortex separator utilizing inertia forces of rotating liquid for separation of not purified crude oil from water and other heavy admixtures comprising:

• (a) a tangential introduction of crude oil into cylindrical chamber of a vortex separator;
• (b) a collector of purified oil;
• (c) a chamber for water collection connected with a separator's cylindrical chamber through holes;
• (d) a tube for extraction of gases in a backside of vortex separator through a tube, which diameter is less than a gas vortex diameter;
• (e) a tangential tube for extraction of purified oil;
• (f) a tube for water extraction;
• and
• (g) a separation efficiency of oil from water can be enhanced by repeating of a process in another vortex separator.

A vortex vapor separator utilizing inertia forces of rotating liquid for increase of oil vapor intensity output due to increase of up floating bubbles developed in a vortex vapor generator volume in a field of accelerating forces comprising:

• (a) a tangential introduction of oil purified from water and preliminary heated in a furnace, or a heat exchanger at elevated pressure exceeding a saturated vapor pressure of oil most light fraction at given temperature;
• (b) in a vortex vapor generator volume with increase of a radius a pressure of a liquid falls down, and at preservation of rotating liquid temperature it leads to a situation, when at a certain definite radius the condition of equality of pressure in a liquid and pressure of a dry saturated vapor of a light fraction is realized, and this condition determines a volumetric boiling in liquid with development of microbubbles filled with vapors of light fraction, up floating to a chamber axis under influence of pressure gradient;
• (c) a tube for extraction of gases developed in a result of up floating bubbles;
• and at said tube a subsonic, or critical (sonic) regime of light fractions vapor flow is established;
• a critical flow regime from the vortex vapor generator provides a way for prevention a propagation of disturbances, or oscillations into the vortex vapor generator during condensation of vapors in a vortex vapor condenser;
• (d) by reducing pressure at a vortex vapor generator exit, it is possible to change conditions for boiling in a vortex of the vortex vapor generator, so that pressure in a vortex can be varied;
• in this case, it is possible to separate fractions with boiling points which are close at pressure 1 atm, and different at-lower pressure.

A catalytic reactor utilizing inertia forces with catalyst in a boiling layer in a rotating liquid comprising:

• (a) a vortex vapor generator chamber with catalyst and supplied liquid (oil heavy residue) where a catalytic reaction takes place;
• (b) a collector, through which heavy products of oil thermal cracking and a catalyst are supplied;
• an alternative way for supply of heavy products and catalyst is through a tangential introduction into a vortex vapor generator chamber;
• (c) a swirler, where said products and a catalyst acquire a circumferential speed, and catalysts particles occupy a certain layer in a chamber according to supplied liquid speed, pressure, temperature, and catalysts mass and area;
• (d) a vortex vapor generator's chamber with a catalyst, where a swirler location is determined by conditions for development of a boiling layer, i.e. by temperature, pressure and speed of supplied liquid;
• (e) a blade constrictor for extraction of a catalyst from vortex catalytic vapor for decrease of a vapor and liquid mixture speed and for increase of pressure in an output collector, from where a mixture of oil fractions with solid particles is directed into a catalytic regenerator through an output tube;
• (f) a tube for returning a regenerated catalyst from a catalyst regenerator;
• (g) a tube through which liquid residuals of catalytic cracking collected in a peripheral area of catalytic reactor are extracted;
• (h) a central tube with holes in its walls, through which light fractions of cracking products concentrated in a gas vortex are removed;
• (i) a metal grid of an output tube external wall serving for prevention of small size catalyst particles removal with flow of light fractions.

An oil refinery system for separating crude oil from a mixture of said crude oil and water and dissolved heavy admixtures, and then separating said oil into fractions of different boiling points, said system comprising:

• (a) a supply of said mixture of oil, water, and heavy admixtures;
• (b) first vortex separator means for separating said oil from said water and said heavy admixtures, wherein said vortex separator means comprises a cylindrical chamber with a tangentially located inlet port for receiving said mixture under pressure;
• (c) first collector means for collecting a purified oil which is separated from said water in said vortex separator means;
• (d) second collector means for collecting said water after it has been separated from said crude oil in said vortex separator means;
• (e) heating means for heating said crude oil to an elevated temperature to reduce the viscosity of said crude oil;
• (f) vortex vapor generator means for separating said purified oil into fractions of different boiling points;
• wherein said vortex vapor generator means comprises a cylindrical chamber including a tangentially located inlet port for receiving said oil under pressure;
• (g) first collector means for collecting fractions of said oil having a boiling point below said elevated temperature;
• and
• (h) second collector means for fractions of said oil having a boiling point above said elevated temperature.

An oil refinery system for catalytically cracking heavy fractions of oil into light fractions, said system comprising:

• (a) heating means for heating said heavy residues of oil to an elevated temperature;
• said heavy residues are heated at lower heating temperatures with a vaporization taking place in a boiling layer with a catalyst (catalytic reactor);
• where obtained light fractions are separated, and remained heavier residues heated to higher temperature and sent into a next consecutive reactor, or a chain of reactors;
• (b) vortex vapor generator means comprising a cylindrical chamber with a tangentially located inlet port, or a collector with a swirler for receiving said heavy fractions of oil under pressure;
• wherein said vortex vapor generator means includes a particulate catalyst;
• and
• (c) vortex vapor condenser means for receiving said light fractions from said vortex vapor generator means and condensing said lighter fractions.