Combined thermal and catalytic treatment of heavy petroleum in a slurry phase counterflow reactor

Abstract

A slurry phase reactor is designed to treat extra heavy petroleum crude in a combination of thermal-zone and catalytic-zone in a counterflow system where liquid feed is added to the top and hydrogen at the bottom. Feed enters the gas-phase thermal zone, where it passes to a liquid-phase thermal zone. In the liquid-phase thermal zone, the hydrocarbon is thermally cracked and the unreacted liquid is further passed to a catalytic-zone below in communication with the thermal-zone. Catalyst can be added or removed as required in a continuous mode without shutting down the system. The heat generated inside the catalytic cracking zone is distributed to the entire reactor as the gaseous product flows upward. Feed is brought to the reaction conditions by the heat recovered from the gas-phase zone. Reaction temperature could be controlled by feed temperature.

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         14 . A slurry phase counter flow reactor for combined thermal and catalytic treatment of heavy petroleum, which reactor comprises: 
 a reactor vessel having a gas-phase thermal reaction zone, a liquid phase thermal reaction zone, and a catalytic reaction zone;    a feedstock inlet in communication with said gas-phase thermal reaction zone;    a hydrogen-containing gas inlet in communication with said catalytic reaction zone;    an unconverted liquid and solid recovery outlet in communication with said catalytic reaction zone; and;    a hydrogen-containing gas and gaseous hydrocarbon product outlet in communication with said gas-phase thermal reaction zone.    
     
     
         15 . A slurry phase counter flow reactor for combined thermal and catalytic treatment petroleum as set forth in  claim 14  including a catalyst addition system.  
     
     
         16 . A slurry phase counter flow reactor for combined thermal and catalytic treatment of heavy petroleum as set forth in  claim 15  wherein said catalyst addition system includes an inlet in communication with said liquid bottom product recovery outlet, a pump, a buffer tank, and an outlet, in communication with said catalytic reaction zone of said reactor.  
     
     
         17 . A slurry phase counter flow reactor for combined thermal and catalytic treatment of heavy petroleum as set forth in  claim 14  wherein said hydrogen-containing gas is substantially hydrogen.  
     
     
         18 . A slurry phase counter flow reactor for combined thermal and catalytic treatment of heavy petroleum as set forth in  claim 14  wherein said hydrogen-containing gas is hot.