Oxygen addition to a coking zone and sludge addition with oxygen addition

• US 5,041,207 A
• Filed: 12/15/1988
• Issued: 08/20/1991
• Est. Priority Date: 12/04/1986
• Status: Expired due to Fees

• Current Assignee: Amoco Corporation (BP PLC)
• Original Assignee: Amoco Corporation (BP PLC)
• Inventors: Sorrentino, Ciro D., Harrington, Joseph A., Ginsburgh, Irwin, Goyal, Shri K., Venardos, Dean G.
• Primary Examiner(s): Davis, Curtis R.
• Application Number:
  US07/285,110
• Time in Patent Office: 978 Days
• Field of Search: 208/48 R, 208/50, 208/131, 208/127, 201/2.5, 201/25, 201/36
• US Class Current: 208/131
• CPC Class Codes: C10B 55/00 Coking mineral oils, bitumen, tar, and the like or mixtures thereof with solid carbonaceous material cracking oils C10G
• CPC Class Codes: C10B 55/02 with solid materials
• CPC Class Codes: C10B 57/06 containing additives
• CPC Class Codes: C10B 57/12 Applying additives during coking
• CPC Class Codes: C10G 9/005 Coking (in order to produce liquid products mainly)

Abstract

A process is disclosed wherein at least two separate gaseous oxygen streams are passed into a coker transfer line to effect oxidation of a portion of the feed passing through the transfer line. Another aspect of the process is disclosed wherein gaseous oxygen is passed into a coking process and sludge is also passed into the coking process.

Claims

1. In a delayed coking process wherein a heavy hydrocarbon feed is passed through a furnace to heat the feed, the heated feed is thereafter passed through a transfer line comprising a conduit and into a coking drum at coking conditions to effect the production of coke and lighter liquid hydrocarbon products, wherein an improvement comprises introducing into said feed which is passing through the transfer line at a temperature in the range of from about 870°

F. to about 950°

F. at least one gaseous stream comprising oxygen, at conditions to effect combustion of a portion of the feed in said transfer line to form products of combustion comprising carbon monoxide and carbon dioxide and wherein substantially all combustion of the feed and substantially complete consumption of said oxygen occur in the transfer line.

2. The process of claim 1 further characterized in that said gaseous stream comprises oxygen in combination with inert gas.

3. The process of claim 2 further characterized in that said gaseous streams comprise oxygen, inert gas and a combustible gas.

4. The process of claim 1 further characterized in that said gaseous streams comprise oxygen, inert gas, and a combustible gas.

5. In a delayed coking process wherein a heavy hydrocarbon feed is passed through a furnace to heat the feed, the heated feed is thereafter passed through a transfer line comprising a conduit and into a coking drum at coking conditions to effect the production of coke and lighter liquid hydrocarbon products, wherein an improvement comprises introducing into the feed which is passing through the transfer line at a temperature in excess of 850°

F. at least one gaseous stream comprising oxygen at conditions to effect combustion of a portion of the feed in said transfer line to form products of combustion comprising carbon monoxide and carbon dioxide, wherein substantially all combustion of the feed and substantially complete consumption of said oxygen occur in the transfer line.

6. The process of claim 5 further characterized in that said gaseous stream comprises oxygen, inert gas, and a combustible gas.

7. The process of claim 5 further characterized in that said gaseous stream is introduced into the heavy hydrocarbon passing through the transfer line at conditions to effect countercurrent contact of said gaseous stream with the feed passing through the transfer line.

35. The process of claim 5 further characterized in that the feed temperature is in the range of from about 850°

F. to about 970°

F.

36. The process of claim 5 further characterized in that the feed temperature is in the range of from about 870°

F. to about 950°

F.

8. A coking process wherein a heavy hydrocarbon feed comprising residual oil is passed into a coking zone at coking conditions including a feed temperature in excess of 850°

F., to effect production of solid coke and vapor products from the feed which comprises;

(1) contacting the feed or liquid derived from the feed with at least one gaseous stream comprising oxygen at conditions to effect combustion of a portion of the feed or liquid derived from the feed to form products of combustion comprising carbon monoxide and carbon dioxide and, (2) adding sludge to the coking zone at thermal treatment conditions to effect contact of at least a portion of the sludge with at least a portion of said feed, liquid derived from the feed or vapor products.

9. The process of claim 8 further characterized in that said gaseous stream effects combustion of a portion of the feed.

10. The process of claim 9 further characterized in that said gaseous stream effects combustion of a portion of the liquid derived from the feed.

11. The process of claim 10 further characterized in that the liquid derived from feed includes at least partially thermally converted feed.

12. The process of claim 9 further characterized in that the feed is passed through a furnace to be heated, thereafter passed through a transfer line and into the coking zone.

13. The process of claim 12 further characterized in that said gaseous stream contacts the feed passing through the transfer line to effect combustion of a portion of the feed in the transfer line.

14. The process of claim 8 further characterized in that said coking zone comprises a delayed coker.

15. The process of claim 8 further characterized in that said,, sludge comprises water and organic material.

16. The process of claim 8 further characterized in that said coking zone comprises a delayed coking drum having an upper section containing vapor products and a lower section containing solid coke, wherein said feed passes into said lower section of the coking drum, vapor products are removed from the coking drum from said upper section and sludge passes into the upper section of the coking drum.

17. The process of claim 8 further characterized in that the sludge is added to the coking zone as a stream separate from the feed and contacts the vapor products in the coking zone.

18. The process of claim 9 further characterized in that said coking zone comprises a delayed coking drum having an upper section containing vapor products and a lower section containing solid coke, wherein said feed passes into said lower section of the coking drum, vapor products are removed from the coking drum from said upper section and sludge passes into the upper section of the coking drum.

19. The process of claim 9 further characterized in that the sludge is added to the coking zone as a stream separate from the feed and contacts the vapor products in the coking zone.

20. The process of claim 8 further characterized in that at least a portion of said feed boils in the range of from about 850°

up to about 1250°

F. or higher;

said coking conditions include a feed temperature of from about 870°

to about 950°

F., a coking zone pressure of from about atmospheric to about 250 psig, and a coking zone vapor residence time of from about a few seconds up to ten or more minutes; and

a sludge addition rate of from about 0.01 to about 10 percent by weight, based on the feed addition rate to the coking zone.

21. A coking process wherein a heavy hydrocarbon feed comprising residual oil is passed through a furnace to heat the feed, the heated feed is thereafter passed through a transfer line at a feed temperature above 850°

F. and into a coking zone at coking conditions, to effect production of solid coke and vapor products from said feed which comprises;

(1) introducing into the feed passing through the transfer line a gaseous stream comprising oxygen at combustion conditions to effect combustion of a portion of the feed in the transfer line to form products of combustion comprising carbon monoxide and carbon dioxide and, (2) adding sludge to the coking zone at thermal treatment conditions to effect contact of at least a portion of the sludge with at least a portion of the vapor products.

22. the process of claim 21 further characterized in that said coking zone comprises a delayed coker.

23. The process of claim 21 further characterized in that said sludge comprises water and organic material.

24. The process of claim 21 further characterized in that said sludge comprises liquid water and liquid hydrocarbon oil.

25. The process of claim 21 further characterized in that said sludge comprises water, hydrocarbon oil and solid material.

26. The process of claim 21 further characterized in that said coking zone comprises a delayed coking drum having an upper section containing vapor products and a lower section containing solid coke, wherein said feed passes into said lower section of the coking drum, vapor products are removed from the coking drum from said upper section and sludge passes into the upper section of the coking drum.

27. The process of claim 21 further characterized in that the sludge is added to the coking zone as a stream separate from the feed and contacts the vapor products in the coking zone.

28. The process of claim 21 further characterized in that at least a portion of said feed boils in the range of from about 850°

up to about 1250°

F. or higher;

said coking conditions include a feed temperature of from above 850°

up to about 970°

F., a coking zone pressure of from about atmospheric to about 250 psig, and a coking zone vapor residence time of from about a few seconds up to ten or more minutes; and

a sludge addition rate of from about 0.01 to about 10 percent by weight, based on the feed addition rate to the coking zone.

29. A delayed coking process having an elongated vertically positioned coke drum containing an upper section and a lower section, wherein a residual feed is passed through a furnace to be heated, the heated feed at a temperature above 850°

F. is thereafter passed through a transfer line comprising a conduit and into a lower section of the coke drum, at coking conditions to effect production of solid coke and wherein solid coke is contained in the lower section and vapor product is contained in the upper section, and wherein vapor product is removed from the coke drum through a vapor outlet connected to said upper section, wherein;

(1) a gaseous stream comprising oxygen is introduced into feed passing through the transfer line at conditions to effect combustion of a portion of the feed in the transfer line to form products of combustion comprising carbon monoxide and carbon dioxide and wherein substantially all combustion of the feed occurs in transfer line, and (2) sludge comprising liquid water, hydrocarbons, and solid materials is added to the upper section of the coke drum at thermal treatment conditions to effect contact of said sludge with vapor product in said upper section and vaporization of at least a portion of the sludge.

30. The process of claim 29 further characterized in the substantially complete consumption of said oxygen occurs in the transfer line.

31. The process of claim 29 further characterized in that said feed comprises heavy residual hydrocarbons, at least a portion of which, boils in the range of from about 850°

up to about 1250°

F. or higher;

said coking conditions include a feed temperature of from above 850°

F. up to about 970°

F., a coking zone pressure of from about atmospheric to about 250 psig, and a coking zone vapor residence time of from about a few second up to ten or more minutes; and

a sludge addition rate of from about 0.01 to about 10 percent by weight, based on the feed addition rage to the coking zone.

32. A delayed coking process having an elongated vertically positioned coke drum containing an upper section and a lower section, wherein a residual feed, at least a portion of which boils in the range of from about 850°

F. up to about 1250°

F., is passed through a furnace to be heated, the heated feed is thereafter passed through a transfer line comprising a conduit and into a lower section of the coke drum at coking conditions including a feed temperature of from about 870°

F. up to about 950°

F., a coke drum pressure of from about atmospheric to about 250 psig, and a coke drum vapor residence time of from about a few seconds up to about ten minutes to effect production of solid coke and vapor product and wherein solid coke is contained in said lower section, and vapor product, which is contained in said upper section, is removed from the coke drum through a vapor outlet connection to said upper section, wherein;

(1) a gaseous stream comprising oxygen is introduced into feed passing through the transfer line at conditions to effect combustion of a portion of the feedstock in the transfer line to form products of combustion comprising a carbon monoxide and carbon dioxide, and wherein substantially all of the combustion of the feed occurs in the transfer line, and substantially complete consumption of the oxygen occurs in the transfer line, and (2) sludge, comprising liquid water, hydrocarbons, and inorganic solids is added to said upper section of the coke drum at thermal treatment conditions including a sludge addition rate of from about 0.01 to about 10 percent by weight based on the feed addition rate to the coking drum to effect contact of said sludge with vapor product in the upper section and vaporization of at least a portion of the sludge.

33. The process of claim 32 further characterized in that said sludge is added at a rate of from about 0.01 to about 1.5 percent by weight, based on the feed addition rate to the coking drum.

34. The process of claim 32 further characterized in that said sludge comprises from about 1 to about 20 percent, by weight, of inorganic solids, from about 1 to about 20 percent, by weight, of liquid hydrocarbons and from about 98 down to about 60 percent, by weight, of liquid water.