System and Method for Introducing an Additive into a Coking Process to Improve Quality and Yields of Coker Products

Abstract

Heavy gas oil components, coking process recycle, and heavier hydrocarbons in the delayed coking process are cracked in the coking vessel by injecting a catalytic additive into the vapors above the gas/liquid-solid interface in the coke drum during the coking cycle. The additive comprises cracking catalyst(s) and quenching agent(s), alone or in combination with seeding agent(s), excess reactant(s), carrier fluid(s), or any combination thereof to modify reaction kinetics to preferentially crack these components. The quenching effect of the additive can be effectively used to condense the highest boiling point compounds of the traditional recycle onto the catalyst(s), thereby focusing the catalyst exposure to these target reactants. Exemplary embodiments of the present invention can also provide methods to (1) reduce coke production, (2) reduce fuel gas production, and (3) increase liquids production.

What is claimed is: 
     
         1 . A process comprising introducing an additive comprising catalyst(s) into a coking vessel during a coking cycle of a delayed coking process such that said additive reduces the energy of activation for initiation of a catalytic reaction of a high boiling point material in said coking vessel. 
     
     
         2 . The process of  claim 1  wherein said catalyst(s) comprise cracking catalyst(s). 
     
     
         3 . The process of  claim 1  wherein said additive further comprises at least one of seeding agent(s), excess reactant(s), and carrier fluid(s). 
     
     
         4 . The process of  claim 1  wherein said additive further comprises quenching agent(s). 
     
     
         5 . The process of  claim 4  wherein said additive further comprises at least one of seeding agent(s), excess reactant(s), and carrier fluid(s). 
     
     
         6 . The process of  claim 1  wherein said additive condenses highest boiling point materials having theoretical boiling points above 800° Fahrenheit. 
     
     
         7 . The process of  claim 1  wherein said catalyst(s) comprises alumina, silica, zeolite, calcium, activated carbon, crushed pet coke, or any combination thereof. 
     
     
         8 . The process of  claim 1  wherein said catalyst(s) comprises new catalyst, FCCU equilibrium catalyst, spent catalyst, regenerated catalyst, pulverized catalyst, classified catalyst, impregnated catalysts, treated catalysts, or any combination thereof. 
     
     
         9 . The process of  claim 1  wherein said catalyst(s) has particle size characteristics such that said catalyst(s) settles below a vapor/liquid interface with continuing reactivity. 
     
     
         10 . The process of  claim 1  wherein said additive condenses said high boiling point material such that contact with components of said additive causes conversion of said high boiling point material. 
     
     
         11 . The process of  claim 10  wherein said conversion comprises cracking of said high boiling point material. 
     
     
         12 . The process of  claim 10  wherein said conversion of said high boiling point material comprises catalytic cracking, catalytic coking, thermal cracking, thermal coking, or any combination thereof. 
     
     
         13 . The process of  claim 10  wherein:
 said conversion of said high boiling point material comprises cracking said high boiling point material to lighter hydrocarbons; and 
 said lighter hydrocarbons leave the coking vessel as vapors and enter a downstream fractionator such that said lighter hydrocarbons are separated into process streams that are useful in oil refinery product blending. 
 
     
     
         14 . The process of  claim 13  wherein said lighter hydrocarbon streams comprise naphtha, gas oil, gasoline, kerosene, jet fuel, diesel fuel, heating oil, or any combination thereof. 
     
     
         15 . The process of  claim 10  wherein said conversion of said high boiling point material reduces recycle in said delayed coking process, reduces heavy components in coker gas oils, or any combination thereof. 
     
     
         16 . A process comprising introducing an additive comprising seeding agent(s) into a coking vessel during a coking cycle of a delayed coking process such that said additive enhances a reaction of a high boiling point material by providing a surface for said reaction to occur. 
     
     
         17 . The process of  claim 16  wherein said additive further comprises at least one of excess reactant(s), carrier fluid(s), catalyst(s), and quenching agent(s). 
     
     
         18 . The process of  claim 16  wherein:
 said seeding agent(s) comprises chemical element(s) or chemical compound(s) adapted to promote formation of coke by providing a surface for coking reactions and the development of coke crystalline structure; and 
 said seeding agent(s) has a physical property of a liquid droplet, a semi-solid, solid particle, or any combination thereof. 
 
     
     
         19 . The process of  claim 16  wherein said seeding agent(s) comprises carbon particles, sodium, calcium, iron, or any combination thereof. 
     
     
         20 . The process of  claim 16  wherein said seeding agent(s) comprises carbon particles that include coke, activated carbon, or any combination thereof. 
     
     
         21 . A process comprising introducing an additive comprising excess reactant(s) into a coking vessel during a coking cycle of a delayed coking process such that said additive reacts with a high boiling point material in said coking vessel. 
     
     
         22 . The process of  claim 21  wherein said excess reactant(s) comprises gas oil, FCCU slurry oil, extract from an aromatic extraction unit, coker feed, bitumen, other aromatic oil, coke, activated carbon, or any combination thereof. 
     
     
         23 . The process of  claim 21  wherein said additive further comprises at least one of seeding agent(s), carrier fluid(s), catalyst(s), and quenching agent(s). 
     
     
         24 . The process of  claim 21  wherein:
 said excess reactant(s) comprises chemical element(s) or chemical compound(s) adapted to react with heavy aromatics to form petroleum coke; and 
 said excess reactant(s) has a physical property of a liquid, a semi-solid, solid particle, or any combination thereof. 
 
     
     
         25 . The process of  claim 21  wherein said excess reactant(s) is introduced in an amount less than 15 weight percent of a coker feed in the coking vessel.