Enhanced Catalytic Reactions in a Coking Process to Improve Process Operation and Economics

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 may comprise 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 may 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 may also provide systems and 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) alone or in combination with seeding agent(s), excess reactant(s), quenching agent(s), carrier fluid(s), or any combination thereof into a coking vessel of a delayed coking process during a coking cycle; and   excess reactant(s) containing hydrogen into a coker feed, into a transfer line between a coker heater and a coke drum, into the coking vessel of the delayed coking process, or any combination thereof;   
       wherein said excess reactant(s) promote cracking of heavy hydrocarbons. 
     
     
         2 . A process of  claim 1  wherein said excess reactant(s) containing hydrogen comprise gaseous hydrogen, chemical compounds that release reactive hydrogen at higher temperatures, Lewis Acids, Bronstead Acids, or any combination thereof. 
     
     
         3 . A process of  claim 2  wherein said reactant(s) containing hydrogen provide a 0.5:1 to 3:1 molar ratio of reactive hydrogen to coker feed. 
     
     
         4 . A process of  claim 2  wherein said reactant(s) containing hydrogen provide hydrogen to the targeted reaction zones at a rate of 30 to 600 Standard Cubic Feet per barrel of coker feed. 
     
     
         5 . A process of  claim 1  wherein said reactant(s) containing hydrogen promote catalytic cracking, thermal cracking, or any combination thereof. 
     
     
         6 . A process of  claim 1  wherein said additive is added to vapors above a vapor-liquid interface in said coking vessel. 
     
     
         7 . A process of  claim 1  wherein said additive is added to said coking process by pressurized injection. 
     
     
         8 . A process of  claim 1  wherein components of said additive are combined by mixing that provides a sufficient level of blending said components prior to addition to said coking vessel of said coking process. 
     
     
         9 . A process of  claim 1  wherein a temperature of said additive is regulated by temperature control that provides a predetermined temperature level of said additive mixture prior to addition to said coking vessel of said coking process. 
     
     
         10 . A process of  claim 1  wherein said catalyst lowers an energy required for cracking reactions, coking reactions, or any combination thereof. 
     
     
         11 . A process of  claim 1  wherein said catalyst is a catalyst that provides propagation of carbon based free radicals that facilitate cracking and coking reactions. 
     
     
         12 . A process of  claim 1  wherein said catalyst comprises alumina, silica, zeolite, calcium, activated carbon, crushed pet coke, or any combination thereof. 
     
     
         13 . A process of  claim 1  wherein said catalyst comprises new catalyst, FCCU equilibrium catalyst, spent catalyst, regenerated catalyst, pulverized catalyst, classified catalyst, impregnated catalysts, treated catalysts, or any combination thereof. 
     
     
         14 . A process of  claim 1 , wherein said catalyst has particle size characteristics to prevent entrainment in vapors, to achieve fluidization in the coking vessel and increase residence time in said vapors, or any combination thereof. 
     
     
         15 . A process of  claim 1  further comprising cracking of heavy hydrocarbons in said coking vessel to lighter hydrocarbons that leave the coking vessel as vapors and enter a downstream fractionator where said lighter hydrocarbons are separated into process streams that are useful in oil refinery product blending. 
     
     
         16 . A process of  claim 15  wherein said lighter hydrocarbon streams comprise naphtha, gas oil, gasoline, kerosene, jet fuel, diesel fuel, heating oil, or any combination thereof. 
     
     
         17 . A process comprising introducing:
 an additive by pressurized injection into a coking vessel of a delayed coking process during a coking cycle to promote cracking of heavy hydrocarbons, wherein said additive comprises cracking catalyst(s), alone or in combination with seeding agent(s), excess reactant(s), quenching agent(s), carrier fluid(s), or any combination thereof; and   excess reactant(s) containing hydrogen into a coker feed, into a transfer line between a coker heater and a coke drum, into a coking vessel of a delayed coking process, or any combination thereof;   wherein said hydrogen from said excess reactant(s) promote cracking of heavy hydrocarbons.