System and method of introducing an additive with a unique catalyst to a coking process

• US 9,011,672 B2
• Filed: 01/29/2013
• Issued: 04/21/2015
• Est. Priority Date: 11/17/2006
• Status: Expired due to Fees

• Current Assignee: Augusto Rodolfo Quinones, Roger G. Etter
• Original Assignee: Augusto Rodolfo Quinones, Roger G. Etter
• Inventors: Etter, Roger G., Quinones, Augusto Rodolfo
• Primary Examiner(s): MCCAIG, BRIAN A
• Application Number:
  US13/753,167
• Publication Number:
  US 20130213859A1
• Time in Patent Office: 812 Days
• Field of Search: 208/50, 208/52, 208/53, 208131-132, 423/450, 423453-454, 423/458
• US Class Current: 208/52.R
• CPC Class Codes: C10B 57/06 containing additives
• CPC Class Codes: C10G 1/00 Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal mechanical winning of oil from oil-shales, oil-sand, or the like B03B
• CPC Class Codes: C10G 2400/20 C2-C4 olefins
• CPC Class Codes: C10G 29/00 Refining of hydrocarbon oils, in the absence of hydrogen, with other chemicals
• CPC Class Codes: C10G 51/04 including only thermal and catalytic cracking steps
• CPC Class Codes: C10G 9/005 Coking (in order to produce liquid products mainly)

Abstract

Gas oil components, coking process recycle, and heavier hydrocarbons are cracked or coked in the coking vessel by injecting an additive into the vapors of traditional coking processes in the coking vessel. The additive contains catalyst(s), seeding agent(s), excess reactant(s), quenching agent(s), carrier(s), or any combination thereof to modify reaction kinetics to preferentially crack or coke these components. Modifications of the catalysts in the additive improve performance for certain desired outcomes. One exemplary embodiment of the present invention uses the olefin production capabilities from newly developed catalysts to increase the production of light olefins (e.g. ethylene, propylenes, butylenes, pentenes) for alkylation process unit feed, the production of oxygenates, and petrochemical feedstocks, such as plastics manufacture. Another exemplary embodiment of the present invention is the use of the olefin production from newly developed catalysts to improve the coker naphtha quality. A third exemplary embodiment of the present invention uses the cracking characteristics of newly developed catalysts to optimize the production of light gas oils, naphtha, and gases from the coking process.

Claims

1. A process comprising introducing an additive including catalyst(s) into a coking vessel during a coking cycle of a delayed coking process wherein said catalyst(s) is adapted to increase a production of olefins in said coking process.

2. The process of claim 1 wherein said additive is added to vapors above a coking vapor-liquid/solid interface in said coking vessel.

3. The process of claim 1 wherein said additive is added to said coking process by pressurized injection.

4. The process of claim 1 wherein said additive comprises said catalyst(s) in combination with seeding agent.

5. The process of claim 1 wherein said additive comprises said catalyst(s) in combination with excess reactant.

6. The process of claim 1 wherein said additive comprises said catalyst(s) in combination with quenching agent.

7. The process of claim 1 wherein said additive comprises said catalyst(s) in combination with carrier fluid.

8. The process of claim 1 wherein said additive comprises said catalyst(s) in combination with at least three selected from the group consisting of seeding agent, excess reactant, quenching agent, and carrier fluid.

9. The process of claim 1 wherein said catalyst(s) substantially increases a proportion of an olefin in gases separated from said coking process.

10. The process of claim 1 wherein said olefins are selected from a group consisting of ethylenes, propylenes, butylenes, pentenes, or any combination thereof.

11. The process of claim 1 wherein said catalyst(s) substantially increases a proportion of olefins in a naphtha boiling point range.

12. The process of claim 1 wherein said olefins have boiling points in a range between 180 and 400 degrees Fahrenheit.

13. The process of claim 1 wherein said catalyst(s) is adapted to optimize a production of heavy coker gas oil.

14. The process of claim 1 wherein said catalyst(s) is adapted to optimize a production of light coker gas oil.

15. The process of claim 1 wherein said catalyst(s) is adapted to optimize a production of naphtha.

16. The process of claim 1 wherein said catalyst(s) is adapted to optimize a production of gases.

17. The process of claim 1 wherein said catalyst(s) is selected from the group consisting of Fluid Catalytic Cracking (FCC) catalysts, active matrix catalysts, zeolite catalysts, FCC equilibrium catalysts, hydroprocessing catalysts, hydrocracking catalysts, new catalysts, spent catalysts, regenerated catalysts, multifunctionalcatalysts, bimodal catalysts, pulverized catalysts, classified catalysts, impregnatedcatalysts, treated catalysts, or any combination thereof.