CA1214422A - Multi-zone process and reactor for cracking heavy hydrocarbon feeds - Google Patents

Multi-zone process and reactor for cracking heavy hydrocarbon feeds

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Publication number
CA1214422A
CA1214422A CA000408838A CA408838A CA1214422A CA 1214422 A CA1214422 A CA 1214422A CA 000408838 A CA000408838 A CA 000408838A CA 408838 A CA408838 A CA 408838A CA 1214422 A CA1214422 A CA 1214422A
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Canada
Prior art keywords
zone
refractory
conduit
gas
reactor
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CA000408838A
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French (fr)
Inventor
John D. Milligan
Marvin S. Rakow
Michael Calderon
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HRI Inc
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HRI Inc
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    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10GCRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G9/00Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils
    • C10G9/28Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils with preheated moving solid material
    • C10G9/32Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils with preheated moving solid material according to the "fluidised-bed" technique
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J8/00Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
    • B01J8/18Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles
    • B01J8/24Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles according to "fluidised-bed" technique
    • B01J8/26Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles according to "fluidised-bed" technique with two or more fluidised beds, e.g. reactor and regeneration installations
    • B01J8/28Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles according to "fluidised-bed" technique with two or more fluidised beds, e.g. reactor and regeneration installations the one above the other
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2208/00Processes carried out in the presence of solid particles; Reactors therefor
    • B01J2208/00008Controlling the process
    • B01J2208/00017Controlling the temperature
    • B01J2208/00477Controlling the temperature by thermal insulation means
    • B01J2208/00495Controlling the temperature by thermal insulation means using insulating materials or refractories

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • General Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)
  • Devices And Processes Conducted In The Presence Of Fluids And Solid Particles (AREA)
  • Hydrogen, Water And Hydrids (AREA)

Abstract

ABSTRACT

A multiple-zone fluidized bed conversion process and apparatus for producing light distillate liquid and fuel gas products from heavy hydrocarbon feedstocks. The feedstock is introduced into an upper fluidized bed cracking zone maintained at a temperature of 900-1400°F for cracking reactions, and resulting tars and coke are deposited on and within a particulate carrier material therein. The carrier material descends through a stripping zone to remove tars and then into a lower fluidized bed gasification zone, which is maintained at a temperature of 1700--2000°F by 02-containing gas and steam introduced therein to gasify the coke and produce a reducing gas. The stripping zone contains coarse packing material which is supported by a refractory annular-shaped grid. The decoked hot particulate carrier is recirculated by a transport gas upwardly through a central refractory-lined conduit to the upper bed. Such recycle of the carrier solids is controlled by a refractory-lined gas-cooled valve.

Description

~ 12~7 MULTI-ZONE PROCESS AND REACTOR FO~ CRACKING H~A~Y
HYDROCARBON FEEDS

BACKGROUND OF INVE~TION
.

Thi~ invention pertains to an improved multiple zone fluidi~ed bed cracking process for ~onversion of heavy hydrocarbon feeds to produce lighter hydrocarbon liquids and fuel gas. It pertain~ particularly to such conver~ion pro-cess and apparatus utilizi~g multiple zo~es of a fluidized bed of par~iculate carrier mat~rial to facilitate cracking the feed i~ the upper zone and gasification of tars and coke deposited on and within the carrier in a lower refractory lined gasification zone.

Con~iderable work has previously been done for the multi-stage gasificatiorl of heavy oil feeds in fluidized beds, some proce~es u~ing a partic~late carrier material for depoQition of carbon, and ~or the~ multiple-~tage ga~ification of coal.
Some typlcal pertinent patent~ include U. $. Patent 2, 8S1~ 943 to Finneran, and UO S. Paterlt 2, 885, 343 to Woebc~;e di~clos~
th~ u3e of a c:irculating particulate carrier for co3ce laydown from crude and . re~idual oil f~ed~tock~ . Also, U- S . Patent
2,875,150 to Schuman and U.S. Patent 3,202,603 toKeith disclose a multiple-bed hydro-gasificatio~l proce~s for residual oils and tar eeds using a particulate carri~r material for hydrocracking the heavy oil feed to produce gas and liquid fraction~. But no di~closure is made regarding important proc~s3 steps and con~truction fea~ures required or a multi-zone reactor ve~sel of commercial scal~.

There has thus been an unfulfill~d need for a practical conversion and gasification proce~ for heavy hydrooarbon feeds such as residual oi~ to produce distillable liquids a-nd fuel gas, and which would also effectively gasify tars and coke evolved from the feed within the same reactor vessel and produce clean fuel gas and liquid products, and provide a reactor design suitable for commercial-scale operations.

^ SUMMAR _ F INVE~TI0~

The present invention provides a multi-zone reaction process and apparatus for cracking and conversion of heavy hydrocarbon feeds, such as crude oil and residua feedstocks and mixture~ of such oils with coal, to produce light2r lower boiling hydrocar~on liquid and gaseous products. The invention utilizes a multi-zone reactor vessel having an upper cracking or conversion zone and a lower gasification or combustion zone, ~eparated by an intermediate stripping zon~
which contains a par~i~ula~e packing ma~erial of sufficent voidage to permit downward passage o par~iculate carrier material~ The upper and lower ZOlleS as well as the stripping zone contain a bed o~ particulate carrier material, which is continuously circulated through the three zones.

Becaus~ of the high temperatures required in the gasifi cation and stripping zone6, such as 1400-2000F, these zones are entirely lined with refractory materials so as to effec-tively limit temperature of th~ metal walls to safe levels, and thus avoid undesirable ~loss of ~trength and also prevent corrosion and erosion of the ba e metals. The reactor design is adapted to utilize the inh~rent high temperature strength of thPse refractory material for structural purposes in unique and advantageous ways. The coarse packing material used in the intermediate stripping zone is supported by an annular shaped apertured refractory grid member, whic'n preferably has an arch-shaped cross section. This grid is in turn supported at its outer and inner circular edges by the refractory lining structuresof the annular-shaped lower gasification chamber or zone.

~ he hot particulate carrier material is recirculated from the lower gasification or combustion zone upwardly to the upper cracking or conversion zone through a vertical transfer conduit. This conduit comprises a tube of temperature-resiStan~ metal which is refractory-lined to pre-vent arosion by the upflowiny particle~. The conduit metal tub~ is supported entirely from the inner refractory lining or column of the annular-shaped gasification chamber.
Furthermore, the lower end of the refractory-lined eentral conduit is reduced in diameter and provides the refractory-coated seating ~urface for a control valve, which controls the recirculation rate of the particulate carrier solids from the lower gasification zone or ~hamb~r upward to the cracki~g or co~verion zone. Al o, the control valve has a plug member which is refractory-coated to provide erosion protection and long service life. The recirculation of particulate solids is facilitated by a transport ga~ which is passed upwardly through the valve plug a embly to a point above the valve eat. Also, the valve pluy i5 cooled effectively by the upflowing gas tream, which is pre~erably steam or a process gas stream provided at a t~ature not exceedin~ about 750~F.

DESC~IPTION OF DRAWI~GS

Figure 1 is a cross-sectional view of the overall multi-zone reactor configuration showing internal detaila of the reactor assembly, including support details for the refrac-tory lining and grid.

Figure 2 is an isometric view of two typical sectors of the annular~shaped apertured refractory grid structure.

Figure 3 is a cross-sec~ional view showing configuration of the solids recirculation control valve assembly and conduit.

DESCRIPTIO~ OF P~EFERRED EMBODIMENT5 ., As shown in Figure 1, a feedstxeam of heavy petroleum crude or residuum oil a~ 10, such as obtained from previous distillation step~a I i~ pressurized at 12, and preh ated as required at 13, 3uch as to 250-Ç00F t~mperature. The pr~-heated stream is introduced through a suitable sparger device 14a into the upper prLmary cracking zone 14 of multi-zone reactor 16. Zone 14 contains a fluidized bed 15 of a particulate solid carrier material 17, which is maintained at a temperatur2 within the range of 900-1400F so that the heavy hydrocarbon feed material is further heated and ther-mally cracked therein. Reactor pres~ure is usually main-tained withi~ t~e range of 200-800 p5ig, although higher pressures could be used. The bed 15 i5 fluidized by upflowing reducing g~ses produced in a lower zone. Some coke produced in ~he cracXing reaction is deposited on and wi~hin the carrier material 17. The resulting product gas along with som~ fine par~icles of carrier material are pas3ed upwardly through a cyclone separator 30 and the gas exits from the reactor.

The majority of the par~iculate carrier material in zone 14, usually containing 3-25 W % coke deposits and heavy liquid hydrocarbons, descends through the adjacent inter-mediate packed stripping zone 18 where some liquids ar2 stripped from the particles by upflowing gases. The ~tripped dry solids then descend to the lower gasification zone 20 containing fluidized bed 21, which is maintained at a temperature within the range of 1700-2000F. Here char and coke deposited on and within the carrier material are gasified in the presence of an oxygen conta.ining gas and steam introduced into the bed 21 at nozzLe 22 through distrihutor 23. 5Ome tars formed in the upper fluidized bed 15 ~nd deposited on and within the carrier material 17 may be ca~ried to the lower bed 21, where the tars are gasified and removed, from the carrier. Some tars may undergo secondary cracking to lighter liquid and gaseous hydrocarbons in the stripping zone 18.

The selection of a 3uitable particulate carrier materi 1 17 wi~h respect to its absorptive characteristic~ a~d pore distribution i~ ~uch a to collect substantially all tars, char and coke ~rom cracXed pxoducts evolved in the upper zone 14 and bed 15~ After gasification o~ tar~, char and coke in the lower fluidized bed 21, the particulate carrier material 17 i recirculated to the upper bed with the aid of a tran~port gas supplied a~ 24, such as steam or product recycle gas, an~ pa~s~d through vertical transer conduit 28 and control valve a3sembly 50~

The lower gasification zone 20 is mads annular-shape~ and is lined with a refractory material provided on its outer wall 25, in the lower head 16b, and inner wall 26, such as "Greencast" No. 94 obtainable from A.P. Green Co. The inner refractory wall 26 is made cylindrical-shaped and is preferably supported from the refractory material lining provided in the ~eactor lower head 16b.

Multiple opening~ 27 are provided in the lower end of inner refractory wall 26 for pas3age of the solid carrier particles 17 from the gaslfication chamber 20 to the lower end of transfer conduit 2S. These op~nings 27 are preferably provided with tubular liners 27a, composed of a hard refrac- -~
tory material which is more resi~tant to abrasion and erosion by the flowing solid particles 17 than refractory structure 26. Alternatively, multiple passages 27 can be provided in the solid refractory material in lower head 16~.. In any event, it i~ e~ential that the inl~t to pas~ages 27 be located at a point below the distributor 23 for introducing the oxygen-containing yas into fluidized bed 20, to prevent any oxygen-containing ga~ being pas~ed into ths vertical conduit 28~ which i~ preferably ~entrally located in the reactor.

Flow control of the particulate carrier material 1 flowing into transfer conduit 28 at it5 bottom end is pro-vided by control valve assembly 50O The carrier material is ~u~pended and lLfted to 1~pp~r bed 15 by the transport gas supplied at connection 24. The upp~r end of ~o~duit 28 ter-minates within fluidized b~d 15- Some of the carrier material may be carried by 'che eiEfluenl: gas from zone 14 to
3,~ an internal cyclon~ separator system 30, which serv~s to trap the ma jority of par~iculate carrier material a~d re~urn it to cracking zone 14. Makeup carrier material may be added to *Trademark 6 the reactor as needed, usually through a pressure-lock hopper system 31. Spent carrier material may be similarly withdra~n at conduit 32.

The intermediate stripping zone 18 contains a coarse solid packing material 19 having size a-t least about 10 times greater than the particula~e carrier material and provides qufficient voidage to permit downward passage of the particulate solids. Packing material 19 may comprise ceramic Raschig rings, saddles, or similar materials and shapes, This packing 19 is supported by an annular-shaped apertured grid structure 34. To limit pressure drop across the inter-mediate stripping section 18, and to facilitate the downward flow o~ particulate solids 17 therethrough, the packing material 19 can have a relatively coarse size, such as 0.5~2.0 inch effective diameter. The apertures 34a provided in grid 34 for gas and so~ids flow are sized to prevent any downflow o packing 19 and can likewise be made relatively large and have various shape~ such as circular, square, elongated and uch, as is generally shown in Figure 2.

Depending on the feedsto~k used, i.e., heavy oil or oil-coal ~lurry, gas and liquid products, along with the minor amount of small particle size unconverted coke and a larger portion of smaLl particle size ash, leave the reactor as stream 37 and pass to an external cyclone solids separation system 38. This separation step remove~ any remaining coke and ash particles from the product gas stream a~ a dispo~aL

tr~am 39. The resulting cyclone effluent stream 40 is then otherwise usually quenched at 41, such as by an oil streamJ or~cooled to reduce it~ temperature and limit or prevent further unde-sired reactions. The cooled gas and liquid~ are then separated using conventional fractionation means at 44 to il ~4~
provide a product gas stream 45, light liquid stream 46, and heavier liquid fraction 47. If desired, a por~ion 4~ o~ th~
heavy fraction can be recycled to the cracking zone 14 for further reaction.

With further reference to annular-shaped apertured grid 34 which supports the coarse packing 19 in stripping section 18, it is made of a strong refractory material suitable for withstanding extended temperature~ of about 2000F, such as "Cerox 600" obtainable from C-E ~efractories, Inc. The grid 1` has an arch-shaped cross-section so as to remain tight and in compres~ion to prevent any loss of packing 19 from above, even if a crack should develop in the grid. The grid is composed of multiple sectors 35, two of which are typically shown i~ Figure 2. Th use of such radial sectors permits the grid to be installed through a manway opening, such as manway 33 located at the top of the reactor. These sectors 35 rest on outer and inner circular shoulder surfac~ 25a and 26a respectively in the refractory lining 25 and wall 26. The sectors 35 are held in place mainly by the weight o the .~ coarse p~cXing 19 located immediately above, and for which they provide support. The apertuxes 34a are ~ized to pr~vent the packing material 19 from passing therethrough, and can be made any shape such as circular, square, or elongated. If de ired, the upper surface of grid sectors 35 can be made dLmpled ~o ~s to prevent pieces of packing material 19 from obstructing the grid openings 34a.

Following combu~tion in lower ga3ification zone 20 of the coXe deposited on the particulate carrier material 17, the hot decoked carrier solids are passed radially inwardly -:- throu~h openings 27 and control valve 50, and are thereby transferred from gasifica~ion zone 20 t~rough updraf~ conduit *Trademark 8 r~ ' ., 28 by use of the transport gas supplied at 24. This conduit 28 is preferably centrally located in reactor 16, and comprises a pressure-tight. heat-resistant metal tube 29 which h~s re~ractory lining 29a, which prevents metal erosion by the upflowing particulate carrier solids 17. A suitable refractory lining material is RESCO CAST No. AA-22, produced by RE5C0 ~roducts, Inc., which is placed within tube 29.
Updraft conduit assembly 28 i~ rigidly attached to and supported from the upper end of inner refractory lining or column 26, and is preferably attached to the refractory column 26 at point 28a, such as by bolts 28b which ar~ cast into refractory wall 26.

Figure 3 shows a cross-sectional view of control valve assembly 50, comprising refractory-coated v~lve seat 51 and cooled valve plug 54 ~hich controls recycle of the hot decoked particulate solids 17 from the lower combustion zone 20 to the upper cracking zone 14. The central conduit 28 is reduced in diameter at its lower end 28b sufficient to pro-vide the valve sea~ member 51. If desired, seat element 51 can be made removable from condui~ end 28b, such as by bolted 1ange joint S2, for purpose of repair or replacement as needed.

Valve plug assembly 54 comprises metal tube 55 which has an enlargement portion 56 located intermediate the tube ends, and serves as the valve plug tructure mating with seat memb~r 51. Th2 upper por~ion of tube 55 and enlargement 56 are coated with re~ractory material 57. The enlaryement 56 contains horizontal plate element S8, and also contains multiple openings 58a in plate 58 and openings 55a in tube ~,~ 55, which serve to divert the upward flow of transport gas through the openings to effectively cool the metal portions ~4~

of the plug assembly 54. Also, the tube 55 and its re~rac-tory coating 57 extend above seating surface 51 by distance at least equal o the inner diameter of seat 51, and preferably by 1.5-10 times that diameter. Refrac~ory material 59 is also provided around tube 55 below enlarge-ment 56 to prevent tube erosion by the solids 17 flowing radially inwaxdly. The gas flowing upward through tube ;5 and its extension 55b facili~ates recirculation of the hot carrier solids 17 upwardly through valve seat 51 and conduit 28.
The transport gas used for suspending and transferring the hot particulate solids 17 upwardly through conduit 28 is introduced at opening 24 and passes upwardly through tube 55 at a velocity of a~ least about 6 ft/sec. and preferably at 10-40 ft/sec. This gas flow also serves to cool the valve plug 54. Thi5 transport and cooling gas is preferably a process gas 3tream, such a~ steam or recycled product fuel gas having initial temperature not exceeding about 750F.
Packing gland 60 is provided around tube 5S to prevent transport gas bypacsing the tube and also to prsvent par-ticulate carrier solids 17 from entering gas flow passageway G2 around tube 55. The packing gland 60 is covered by refractory plate 64 for erosion protection~ The val~e plug assembly 54 i moved axially as needed using a suitahle actuator device (not ~hown) to control the upward flow of particulate solids 17, by actuator rod ~6, which i~ connected to tube 55 by radial bracket 67 and i5 pressure sealed by lo~er packing gland 68. The entire valve plug assembly 54 is removable from the lower e~d of central conduit ~8 and valve ~eat 51 by disconnecting bolted flange 70 and removing the assembly downwardly for inspection or repair.

During start~up of the multi-zone reactor 16 from cold or near ambie~t conditions, the central conduit 28 is heated and expands in a downward direction. Plug assembly ~4 i3 likewise withdrawn by the actuator devic~ (not shown) to prevent any excessive compressive force being developed bet-ween the valve plug 54 and seat surface 51. The transport gas supplied at 24 flows upwardly through tube 55 to facili-tate the recirculation of particulate carrier solids 17 from the lower gasification zone 20 to the upper cracking zone 14.

Although we have disclosed certain preferred embodiments of our invention, it is recognized that modifications can be made thereto and that some features can be employed without others, all within the spirit and scope of the invention which is defined solely by the following claims.

. .

Claims (18)

We claim:
1. A process for conversion of a heavy hydrocarbon feedstock to produce lighter hydrocarbon liquids and fuel gases, comprising:

(a) introducing the feedstock into a pressurized upper fluidized bed cracking zone maintained at a tem-perature within the range of 900-1400°F, said zone containing a fluidized bed of particulate carrier material which is f1uidized by upflowing reducing gases passing therethrough;

(b) passing the carrier material containing coke deposits downwardly through an intermediate stripping zone into a lower fluidized bed gasification zone to gasify the coke deposits from the carrier material therein;

(c) injecting an oxygen-containing gas and steam into the lower gasification zone for reaction with said coke deposited on and within the carrier material and to maintain a temperature within the range of 1700-2000°F for coke gasification and to produce the reducing gases;

(d) passing said reducing gases upwardly successively .
through said stripping zone and through said fluidized bed in the upper cracking zone to fluidize the bed:

(e) passing the resulting hot decoked particulate carrier material from the lower gasification zone radially inward through passageways to the lower end of a vertical transfer conduit at a point below the oxygen-containing gas injection point, and recycling said solids upwardly through a control valve and the conduit into the upper cracking zone at a controlled rate using a transport gas flowing in said conduit at velocity sufficient to carry said solids;

(f) separating the resultant product gases from said particulate matter above the upper cracking zone and returning said separated particulate matter to the reaction zone for further use; and (g) withdrawing effluent gas and distillable liquid pro-ducts from said upper cracking zone.
2. A process according to Claim 1, wherein the recycle of decoked particulate carrier solids to the upper cracking zone is controlled by passing the transport gas upwardly through the hollow plug portion of a control valve assembly and into said transfer conduit, And wherein the upflowing gas velocity in said conduit is at least about 6 ft/sec.
3. The process according to Claim 2, wherein the transport gas is provided at temperature not exceeding about 750°F and the control valve plug portion is cooled internally by passing the transport gas upwardly through said plug.
4. A process according to Claim 1, wherein said product gases and said particulate matter are separated externally to said reaction zones, the particulate matter is recycled to the reaction vessel, and the clean effluent stream is cooled and passed to a fractionation step for recovery of gas and distillable liquid products.
5. A process according the Claim 1, wherein the feedstock includes coal particles, and includes the additional step of withdrawing particulate ash from a lower portion of aid gasification zone.
6. A process for converting heavy hydrocarbon feedstocks to produce lighter hydrocarbon liquids and fuel gases wherein the feedstock is introduced into an upper fluidized bed cracking zone maintained within temperature range of 900-1400°F, and coke is deposited on and within a particulate carrier-material which is passed downwardly through a packed stripping zone, and wherein oxygen-containing gas and steam are injected into a lower fluidized bed gasification zone to gasify coke deposited on and within a particulate carrier material and produce a reducing gas which passes upwardly to fluidize the reactor zones, wherein the improvement comprises controlling the recirculation rate of the particulate solids flowing from the lower gasification zone to the upper cracking zone by passing a transport gas upwardly through a control valve hollow plug to a point above the valve seat surface.
7. The process according to Claim 6, including the addi-tional step of cooling the solids recirculation control valve plug by passing the transport gas at temperature not exceeding about 750°F upwardly through passages in the valve plug.
8. A multi-zone reactor assembly for cracking and conversion of heavy hydrocarbon feedstocks to produce lighter liquid and gas products, comprising:

(a) a pressurizable metal reactor vessel;
(b) a conversion zone located in the reactor upper end for providing a fluidized bed reaction:

(c) means for introducing a hydrocarbon liquid feed into said conversion zone;

(d) an annular-shaped gasification chamber located in the reactor lower end for containing a fluidized bed gasification reaction;

(e) conduit means for introducing an oxygen-containing gas and steam into said lower gasification reaction zone;

(f) a stripping zone located intermediate the upper conversion zone and the lower gasification zone, said stripping zone containing a coarse-sized particulate packing material;

(g) outer refractory-lining means provided within said annular shaped lower gasification reaction zone, wherein said refractory lining is adapted to allow for differential thermal expansion between the lining and the vessel metal outer wall;

(h) an inner cylindrical shaped refractory wall which is supported from the outer refractory lining;

(i) conduit means for circulatîng a particulate carrier material from the lower gasification zone upwardly to the upper conversion zone, said conduit being refractory-lined and supported from said inner refractory wall:

(j) means for introducing a transport gas into the lower end of the said conduit, and (k) means for removing the resultant product gases from the upper portion of said reactor vessel.
9. The reactor assembly according to Claim 8, wherein the coarse packing material in the intermediate stripping zone is supported by an apertured annular-shaped grid made of refractory material and located at the upper end of the gasification reaction zone.
10. The reactor assembly according to Claim 9, wherein said grid is arch-shaped and comprises multiple radial sectors which are each supported by the refractory lining of the annular-shaped lower gasification zone, said sectors being removable from the reactor vessel.
11. The reactor assembly according to Claim 8, wherein each zone contains a particulate carrier material which is fluidized and is recirculated from said upper conversion zone downwardly through said stripping zone to said lower gasification zone, then returned upwardly through a control valve and central refractory-lined conduit to said upper reaction zone.
12. The reactor assembly according to Claim 8, wherein a refractory-lined phase separation device is provided above the conversion zone to remove particulate carrier material and return it to the reactor vessel.
13. The reactor assembly according to Claim 11, wherein the recirculated particulate carrier material passes upwardly through a refractory-lined control valve located at the lower end of the central conduit.
14. The reactor assembly according to Claim 11, wherein the control valve seating surface is formed by the lower end of the central conduit, and said conduit lower end is refractory-coated on both inner and outer sides.
15. The reactor assembly according to Claim 14, wherein the valve seating portion is made removable from said central conduit.
16. A reactor assembly according to Claim 11, wherein the solids control valve plug is coated with a refractory material and has internal flow passages for cooling said plug by the upflowing transport gas.
17. The reactor assembly of Claim 16, wherein said valve plug refractory coating extends above the plug surface by a distance at least equal to the valve seat inner diameter.
18. A multi-zone reactor assembly for cracking and conversion of heavy hydrocarbon feedstocks to produce lighter liquid and gas products, comprising:

(a) a pressurizable metal reactor vessel;

(b) a conversion zone located in the reactor upper end and containing a particulate carrier material for providing a fluidized bed reaction;
(c) means for introducing a hydrocarbon liquid feed into said conversion zone;

(d) an annular-shaped gasification chamber located in the reactor lower end and containing a particulate carrier material for providing a fluidized bed gasi-fication reaction;

(e) conduit means for introducing an oxygen-containing gas and steam into said lower gasification reaction zon;

(f) a stripping zone located intermediate the upper con-version zone and the lower gasification zone, said stripping zone containing a coarse-sized particulate packing material supported by an apertured annular-shaped grid made of refractory material and located at the upper end of the gasification reaction zone;

(g) outer refractory-lining means provided within said annular-shaped lower gasification reaction zone, wherein aid refractory lining is adapted to allow for differential thermal expansion between the lining and the vessel metal outer wall;

(h) an inner cylindrical-shaped refractory wall which is supported from the outer refractory lining;

(i) conduit means for circulating a particulate carrier material from the lower gasification zone upwardly to the upper conversion zone, said conduit being refractory-lined and supported from said inner refractory wall and having a control valve located at the lower end of said conduit;

(j) means for introducing a transport gas into the lower end of the said conduit; and (k) means for removing the resultant product gases from the upper portion of said reactor vessel.
CA000408838A 1981-08-06 1982-08-05 Multi-zone process and reactor for cracking heavy hydrocarbon feeds Expired CA1214422A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US29056081A 1981-08-06 1981-08-06
US290,560 1981-08-06

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JP (1) JPS5834890A (en)
BE (1) BE894032A (en)
CA (1) CA1214422A (en)
DE (1) DE3227977A1 (en)
FR (1) FR2511026A1 (en)
GB (1) GB2103103B (en)
MX (1) MX162180A (en)
NL (1) NL8203071A (en)
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CA2017116C (en) * 1990-03-26 1996-11-12 James Francis Mosby Catalytic cracking with quenching
US5626741A (en) * 1990-03-26 1997-05-06 Amoco Corporation Catalytic cracking with quenching
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MX162180A (en) 1991-04-05
JPS5834890A (en) 1983-03-01
ZA825691B (en) 1983-07-27
BE894032A (en) 1982-12-01
FR2511026A1 (en) 1983-02-11
GB2103103A (en) 1983-02-16
NL8203071A (en) 1983-03-01
DE3227977A1 (en) 1983-02-24

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