Sludge addition to a coking process
First Claim
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1. A process for upgrading sludge comprising the steps of:
- A. passing a feedstock comprising residual oil into a coking zone containing a low velocity vapor phase having a superficial vapor velocity of not more than about 10 feet per second, at coking conditions during a coke production cycle, to produce solid coke and vapor products; and
B. injecting a separate sludge stream into said low velocity vapor phase in the substantial absence of solid coke and coking foam produced from said feedstock, and contacting said sludge with vapor products at thermal treatment conditions to effect vaporization of at least a portion of the sludge.
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Abstract
The present invention relates to a process and apparatus for injecting sludge into the vapor phase of a coking process to vaporize the sludge while minimizing the carryover of solids and coke to downstream equipment. The process and apparatus are applicable to use in both fluid and delayed coking operations and are useful on various sludges which can be found in refineries or petrochemical plants.
16 Citations
32 Claims
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1. A process for upgrading sludge comprising the steps of:
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A. passing a feedstock comprising residual oil into a coking zone containing a low velocity vapor phase having a superficial vapor velocity of not more than about 10 feet per second, at coking conditions during a coke production cycle, to produce solid coke and vapor products; and B. injecting a separate sludge stream into said low velocity vapor phase in the substantial absence of solid coke and coking foam produced from said feedstock, and contacting said sludge with vapor products at thermal treatment conditions to effect vaporization of at least a portion of the sludge. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
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17. A process for upgrading sludge comprising the steps of:
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A. passing a feedstock comprising residual oil into a delayed coking process comprising an elongated, vertically positioned coke drum containing an upper vapor phase and a lower phase containing solid coke, wherein said upper phase contains an upper high velocity vapor phase and an upper low velocity vapor phase, said upper low velocity vapor phase having a superficial vapor velocity of not more than about 1 foot per second and located below said upper high velocity vapor phase and above said lower phase wherein said feedstock is injected into said coke drum at coking conditions during a coke production cycle to produce coke and vapor products; and B. injecting a separate sludge stream into said coke drum through a drop tube terminating in said upper low velocity vapor phase, in the substantial absence of solid coke and coking foam produced from said feedstock, to contact said sludge with vapor products at thermal treatment conditions to effect vaporization of at least a portion of the sludge. - View Dependent Claims (18, 19, 20, 21)
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22. A process for upgrading sludge comprising the steps of:
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A. passing a feedstock comprising heavy hydrocarbon boiling in the range of from about 850°
F. up to about 1250°
F. at a feedstock temperature of from about 850°
F. to about 970°
F. to a delayed coking process comprising an elongated, vertically positioned coke drum at coking conditions during a coke production cycle wherein said coke drum contains an upper vapor phase and a lower phase containing solid coke, wherein said upper phase contains an upper high velocity vapor phase and an upper low velocity vapor phase, said upper low velocity vapor phase having a superficial vapor velocity of between about 0.3 and 0.6 feet per second located below said upper high velocity vapor phase and above said lower phase, to produce coke and vapor products from said feedstock; andB. injecting a separate sludge stream into said coke drum through a drop tube terminating in said upper low velocity vapor phase and in the substantial absence of solid coke and coking foam produced from said feedstock, contacting said sludge with vapor products at thermal treatment conditions to effect vaporization of at least a portion of the sludge and conversion of at least a portion of the sludge to coke. - View Dependent Claims (23, 24, 26, 27, 29, 30)
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25. An apparatus for the upgrading of sludge comprising:
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A. a cylindrical, vertically positioned delayed coking drum with an outwardly convex top and a downwardly converging frusto conical bottom wherein said drum contains an upper section containing an outlet nozzle and a lower section for containing solid coke at drum operating capacity, wherein said upper section contains an upper high velocity vapor section positioned within the outwardly convex top of the drum and an upper low velocity vapor section positioned below said upper high velocity section and above said lower section for processing a feedstock comprising residual oil and producing solid coke and vapor products; and B. a sludge injection drop tube communicating with said coking drum and terminating in said upper low-velocity vapor section, said drop tube aligned parallel to the vertical wall of said vertically positioned drum, for injection of a sludge stream into said coke drum to effect vaporization of at least a portion of the sludge.
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28. An apparatus for the upgrading of sludge comprising:
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A. a cylindrical, vertically positioned delayed coking drum with an outwardly convex top and a downwardly converging frusto conical bottom wherein said drum contains an upper section containing an outlet nozzle and a lower section for containing solid coke at drum operating capacity, wherein said upper section contains an upper high velocity vapor section positioned within the outwardly convex top of the drum and an upper low velocity vapor section positioned below said upper high velocity section and above said lower section for processing a feedstock comprising residual oil and producing solid coke and vapor products; and B. a sludge injection drop tube communicating with said coking drum and terminating in said upper low-velocity vapor phase not less than 5 feet above said lower section, for injection of a sludge stream into said coking drum at a drop tube liquid velocity of not less than 1 foot per second, said drop tube aligned parallel to the vertical wall of said vertically positioned drum, to effect vaporization of at least a portion of the sludge. - View Dependent Claims (31, 32)
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Specification