CA2285489A1 - A novel process for catalytic cracking of fuel oil by new catalyst - Google Patents

Abstract

The invention consists of a method of catalytic cracking of fuel oil using a catalyst comprised of Mg, Al, Si, P, S, Cl, K, Ca, Ti, Fe, Cu, Zn, Mo, Sn, Pb and a mixture of hydrocarbon gas such as methane, ethane, propane, and butane in a heated environment allows the cracking of heavy hydrocarbons in fuel oil at a low temperature and economical cost.

Description

A NOVEL PROCESS FOR CATALYTIC CRACKING OF
FUEL OIL BY NEW CATALYST
Background of the Invention 1. Field of Invention This invention relates to a new catalyst and new process condition for catalytic cracking of vacuum bottom product, fuel oil, containing heavy hydrocarbons to lighter cuts. The major products are: gasoline, kerosene, gasoil and Tube oil.

2. Description of prior Art A new catalyst was developed to crack heavy hydrocarbon chains and reform them into useful products and cuts using new process condition not similar to the invented ones. The innovated process condition herewith described is not similar to the invented and conventional processes.
Summary of the invention Conventionally long chain hydrocarbons may be broken down into short chain hydrocarbons by two methods:
1- Thermal cracking 2- Catalytic carcking in the vicinity of hydrogen gas.
The later method called hydrocracking. In this new method, a catalyst from one hand and a single or mixture of hydrocarbon gas such as methane, ethane, propane and Butane from the other hand in a heated media are used. Hydrocarbons gases play an important role in breaking down the hydrocarbon chains as following. First, lowers the process temperature (320°C) than the conventional Methods (500-900°C). Secondly, prevents from producing very short chain hydrocarbons. Thirdly, carries cracked hydrocarbon out of the reactor and, therefore stops the cracking reaction as mentioned in the second role.
The new catalyst used in this process, consists of pieces of alloys found in the used Tube-oil embedded on graphite. The Analysis of catalyst is as following:

Name Element Percentage Mangenes Mg 0.26 Aluminium AI 0.044 Silicon Si 0.125 Phosphorate P 0.76 Sulfur S

chloring CI 0.0014 Patassium K 0.018 calcium Ca 1.56 Titanium Ti 0.0023 Iron Fe 0.28 Coppeer Cu 0.018 Zine Zn 1.16 Molybdenum Mo 0.0013 Tin Sn 0.002 Lead Pb 0.23 Heavy hydrocarbons in fi~el oil consists of complex chain forms and stn.icture with a variety in their bonds such as Esters, Acids, Aromatics and Polymers.
Therefore, such alloys play an important role in breaking a specific compound in fiael oil and hence the cracking phenomena occurs conveniently at low temperature of 320°C.
Manufacturing of catalyst from used lube-oil, on the other hand, leads to an economically feasible process.
In conclusion, one can break down any type of heavy hydrocarbon using, this catalyst, heat and a hydrocarbon gas. By changing the process pressure, temperature and/or gas flow one can vary the ratio of the broken chain to the feed. In negative pressure (gases), the product rate increases at the same temperature. Ultra heavy hydrocarbons such as bitumen properties may change by passing through this catalyst bed. For example, the produced bitumen resists against ultera violet ray and doesn't crack during service life. In an experiment, the resistance of bitumen against heat and oxygen was measured and the softening point observed to be increased up to 300°C.
Examples Although the following examples do not limit the application, only some of fields and depth of this invention are revealed.
I. Fuel oil at 320°C was sent to a reactor in which the catalyst is held. A hydrocarbon gas or a mixture of gases is sent to the reactor , too. The products exit from the top of the reactor. In the separator, the gas may be separated and recycled to the reactor.
The liquid from the separator was analyzed and found to be mostly, gasoline, kerosene and gasoil. (Appendix 1). As mentioned before, the ratio of the product could vary by the pressure and gas Ilow rate. Changing the pressure, causes a variation in the temperature.
2. In a second trial a used Tube-oil was placed in the reactor similar to example one.
The results is similar to that of in example 1.

3. Bitumen was tested according to the procedure mentioned in example one. The product was placed in the reactor, however, the pressure was changed. This lead to a polymerization and production of a new bitumen with a better properties.

Claims (9)

1. Using the new catalyst, one can crack the long chain hydrocarbons at elevated temperatures.

2. The hydrocarbon gases (any formula and chain length) control the cracking process.
Gas flow rate may decrease the cracking temperature. One can control the size of the hydrocarbon chain by gas flow rate and reactor pressure.

3. The produced chain in this method are saturated and linear.

4. The amount of ultra short chain hydrocarbon (gas) are very small, while conventional processes produce a higher ratio of gas to naphta.

5. To saturate the products, hydrogen gas is not necessary.

6. Bitumen with better properties and higher resistance against oxygen, heat and UV-ray may be produced. This bitumen doesn't crack during service.

7. The residue from the reactor has enough sulfur and carbon as well as metals to be a suitable substitute for fillers in the rubber.

8. The residue from the fuel oil, bitumen, and lube oil and oxidized bitumen, and acidic sludge (produced from the refining of used tube oil) may be used as catalyst in producing a new fuel with octane number enhances by alcohol.

9. Using this process, one can convert bitumen to insulator for gas or oil tubes, roofs, building base, and metallic structures, and etc.