Flash chemical ionizing pyrolysis of hydrocarbons
First Claim
1. A hydrocarbon conversion process, comprising the steps of:
- emulsifying water and an oil component with finely divided solids comprising a mineral support and an oxide and/or acid addition salt of a Group 3-16 metal;
introducing the emulsion into a flash chemical ionizing pyrolysis (FCIP) reactor maintained at a temperature greater than about 400°
C. up to about 600°
C. and a pressure up to about 1.5 atm to form a chemical ionizing pyrolyzate effluent;
condensing a liquid ionizing pyrolyzate (LIP) from the effluent;
combining a feedstock oil with the LIP to form a pyrolyzate-feedstock blend; and
thermally processing the blend at a temperature above about 100°
C.
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Abstract
Flash chemical ionizing pyrolysis (FCIP) at 450° C.-600° C. forms liquid ionizing pyrolyzate (LIP) that can be blended in oil feedstock for thermal processes to promote conversion of heavier hydrocarbons to reduce resid/coke yields and/or increase yields of liquid hydrocarbons and isomerates. A front-end refinery process modifies crude oil with LIP for distillation to reduce resid/coke yields and/or increase liquid oil yields. A downstream process modifies a heavy oil stream such as resid with LIP and the LIP-modified stream can be thermally processed to reduce resid/coke yields and/or increase liquid oil yields. FCIP of the LIP blends also improves quality and/or yields of the liquid pyrolyzate product. Finely divided FCIP solids can contain FeCl3 supported on NaCl-treated calcium bentonite. A process for preparing the FCIP solids treats iron with HCl and HNO3 to form acidified FeCl3 of limited solubility, loads the FeCl3 on NaCl-treated bentonite, and heat-treats the material at 400° C.-425° C.
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Citations
22 Claims
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1. A hydrocarbon conversion process, comprising the steps of:
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emulsifying water and an oil component with finely divided solids comprising a mineral support and an oxide and/or acid addition salt of a Group 3-16 metal; introducing the emulsion into a flash chemical ionizing pyrolysis (FCIP) reactor maintained at a temperature greater than about 400°
C. up to about 600°
C. and a pressure up to about 1.5 atm to form a chemical ionizing pyrolyzate effluent;condensing a liquid ionizing pyrolyzate (LIP) from the effluent; combining a feedstock oil with the LIP to form a pyrolyzate-feedstock blend; and thermally processing the blend at a temperature above about 100°
C. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
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14. A flash chemical ionizing pyrolysis (FCIP) process comprising the steps of:
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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.
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15. A hydrocarbon refinery process comprising the steps of:
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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. - View Dependent Claims (16, 17)
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18. A hydrocarbon refinery process comprising the steps of:
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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. - View Dependent Claims (19, 20, 21)
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22. A crude oil upgrading process, comprising:
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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.
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Specification