US2312445A - Catalytic combination process - Google Patents

Description

March 2, 1943. R. F. RUTHRUFF CATALYTIC COMBINATION PROCESS Filed May 13, 1940 Patented Mar.- 2, 1943 UNITEDl STATES PATENT FFICE vfaalzfus oA'rALY'rIo COMBINATION PROCESS F1 Ruthrutr", chicago, n1. Apucamn May i3, i940, seri-a1 No. 334,741-

' 13 olaimslkoi. 19e-49).

This invention relates to a process for the conversion ofhydrocarbon mixtures of wide boiling range into hydrocarbons'` of high utility and value boiling within the usual motor fuel range.

More particularly, this 4invention relatesto a processfor the conversion of crude oils into hydrocarbons of high utility and value boiling within the usual motor fuel range. Still more conversion of crude `oils into hydrocarbons of high utility and value boilingwithin the usual motor fuel range wherein said crude oils are separated into a pluralityof fractions, some or all of which are then subjected separately butAin cooperative combination to catalytic conversionconditions suitable for transformingv said fractions into hydrocarbons of .high u'tility and value boiling within the usual motor fuel range.

A primary object of my invention is to provide an improved unitary combination cracking process for processing hydrocarbon mixtures of wide boiling range, -for example, crude oils, whereby a maximum yield of motor fuel of superior antiknock quality is obtained.

AV further object of my invention is to vide a combination =cracking process wherein hydrocarbon mixtures of wide boiling range, for` example, crude oils, are subjected to a distilling operation to separate a plurality of fractions,

`some or all of which are subjected to separate but cooperative catalytic conversion processes so PTO.-

ao larly, this invention relates to a process for the whereby a maximum yield of motor fuel of superiorantiknock quality is produced.

' Other objects of my invention will become ap- I hydrocarbon fractions into hydrocarbons of high' utilityand value are well known in the art.

Whilev thermal conversion processes give a higher yield of gasoline .of higher quality from vcrude oilthan can be attained by simple fracof potential gasoline as gas and`tar. Because of 4 o these, and other disadvantages too numerous to mention, Within the last few years attention has been directed to the replacing of thermal conyversion'methodsv by catalytic conversion methods. For example, catalytic methods for the reforming of naphtha show Vgreat advantages overthermal conversionv processes. Operating pressures are low, ranging from alittle above atmospheric to a maximum of some 300 pounds per square inch, more or less. Operating temperatures are usually slightly lower than those employed in thermal reforming. The yieldand quality vof the catalyticallyreformed naphtha are much higher than with thermal reformed naphtha. 'Ihe catalytically reformed naphtha is rich in aromatics and accordingly hasan octane rating considerably higher than that shown Vby lany thermally reformed naphtha. Additionally, the gas formed in catalytic reforming conyields ofcatalytically Areformed naphtha arel much higher than are obtained in lthermal reas toobtain a maximum yield of motor fuelof superior antiknock quality.A

Another object of my invention is to provide a combination cracking processA wherein hydrocarbonv mixtures of wide boiling range, for example, crude oils, are subjected to a distillingversion processes are introduced into other of saidv separate catalytic conversion processes forming processes where the gas consists largely of gaseous hydrocarbons.

Similarly, the catalytic cracking of gas oil shows many advantages over thermal processes.

Operating pressures are moderate, ranging from 4gas oil are much higher than with thermal conversion processes. The gasoline from catalytic cracking of gas oil has a much higher octane number than 'thermally crackedrmaterial and due to the lower' gas yield and zero conversion of charge to liquids of higher boiling point, the

theoretical ultimate yiem gf gasoline by catalytic cracking of-gas oil-is higher than thatobtained in-thermal processes.

While catalytic viscosity breaking has been -studied to a certain extent, the results obtained' to date are. notf'such as to put the process 'on a.' l.

firm 'comercial foundation. The .reason-tor this is twofold. In theirst place, catalytic conversion Vprocesses as. applied vto hydrocarbons preferably and almost ot necessity are conduct- -ed in the vapor phase-'and reducedl crudes are hard to vaporize completely. Secondly, because of the high carbon to hydrogen' ratio of reduced crudes any catalysts usedfoul very rapidly and hence require regeneration at frequent inter- Yvals. Accordingly, in processing reduced crudes by catalytic methods, it isusually preferable vto rst convertthe reduced crude into gas oil and tar (by viscosity breaking) or into gas oil and @319194.57 v tion of'thehydrogenproducedin the 4catalytic' reformingstep and are thencatalytically :hydrogenated, the resulting products'. b eing returned .to the crude oil fractionator.` 'Ihe several gesolcoke (by coking) and then 'furtherprocess the'v gas oil thus formed in' a. .catalytic process similar' to that described in the previous paragraph.

As vfar as I am a'ware noone hasfpreviously suggested a combination process -for .the conversion of hydrocarbon mixtures of `lwide boiling range, crude oil, for example, wherein the usuall fractions treated in the now familiar lthermal combination processes of the prior `art 'are sub- "ject'ed-to separate butl cooperative catalytic conversion processes to produce .a maximum yield of motor fuel of superior antiknock quality. I have found that by employing catalytic meth-I in a combination processA for the conversion of hydrocarbon mixtures of f wide boiling range,

for example, the tower m'ay be filled with packj line fractions vare combined slredultimate product.

ing single sheet of drawings forming apart of the instant specification and wherein, the/ Ifigure is a diagrammatic illustration, partly in section and l partly in elevation, of an apparatussuitable for carrying out the"process of my invention.

Turning nowto the aforementioned ngurefhot. i

crudeI passes' through line I to the'lower portoentering fractionating towerv 2,' is heated by anysuitablefmeans (not shown), for example,

by being brought into indirect heatV exchange r'e lationship with one or more-.hot 'streams followed by passage through an ordinarypipe` still.y

for example, bubble trays I, although any-other suitable means for the purpose may be employed,

ing material such as Raschigrings. rliractionating tower 2 is also provided with suitable coolcrude' oils, for example, the various catalytic zones cooperate with one another inv a yunique l and highly beneficial manner and as a consequence, the overall results are markedly superior to those obtained by conducting the various operatins Separately;- I

Many variations arepossible in the -practice oi' my invention and accordingly it is impossible to encompass all of them in a brief :exposition thereof. However, to indicate the spirit, but not the scope, of -my invention the following brief description thereof is included:

Crude oil is fractionated to produce light naphtha, heavy naphtha, gasoil and reduced crude.

'I'he heavy naphtha is catalytically re-l formed, the resulting yreaction products are separated into gas (mostly hydrogen), catalytically reformed naphtha (largely aromatics) and a small amount of material having a higher boiling range than the charge. Preferably, hydrogen formed in the catalytic reforming reaction is in part added to the fresh heavy naphtha charge prior to entering the catalytic reforming zone. However, this recycling of a portion of the hydrogen is not essential and it is to be understood that the catalytic reforming process furnishes net hydrogen in large volumes. The reduced crude is subjected `to a oncethrough viscosity breakingl operation. under thermal` conditions. The resulting products are separated into gas, viscosity breaker gasoline, light viscosity breaker gasoil (which is added to the virgin light gas oil) and heavy viscosity breaker .gas oil. The

gas oil is also`catalytically cracked and thev ref sulting products are separated'into gas, gasoline and bottoms. The \bottoms .from heavy gas oil catalytic cracking and from light gas oil catalytic heavy viscosity breaker gas oil is catalytically ing from the final boiling ing means. Thismay take the formjof one or more closed coils (not shown) disposed inthe upper portion of the tower, through which cold to produce the de-l tion of fractionating tower 2. The crude, prior fluid, for example, cold crude, is passed. Or. cold liquid of suitable boiling point may be introduced into the tower at one or more' points to provide cooling therein as will hereinafter be more fully explained. Obviously, either or both cooling means may be employed or other suitable procedures may be resorted tofor the purpose. Fractionating tower 2 is also provided, it desired, with 4 bottom heating means.- This may take the form; for example, of anA open or closed coil l positioned `in the lower portion of the tower through which` hot fluid is passed. Specifically, iractionatingV tower 2g may be provided with an open steam coil I, steam introduced also aiding 4in stripping lower boiling components from material collecting in the bottom of the tower. Fractionating tower 2 preferably operates at atmospheric lor I slightlyA elevated pressure, f or example, in the 4neighborhood of 25 pounds persquare inch gage.

A piuralityfof streams are withdrawn from. fractionating tower 2, for example, light naphtha c may be taken overhead through line [heavyV naphtha may be taken from a trapout tray in the upper portion of the tower through line t, A gas oil may be taken from a lower positioned trapout tray through line 1 while reduced crude bottoms may be removed by means of line 8. ,In

general the light naphtha may be taken to repre sent those portions of the crude boiling upto l about 150 to 300- F. Heavy naphtha may be taken to represent material boiling from the final boiling point 0f the iight naphtha up to about 350 to 500 F. Gas oil represents material boil-l i point of the heavy naphtha up to 850 to '150 1"., while the still higher boiling portions of hated as reduced crude bottoms.

If desired,` to provide cooling or additionalcocling to the upper portion of.fractionating tower 2,

the light -inaphtha vaporsl may be partially or I.

completely condensed in exchanger 9, passed to separator l0 from which aportion of the liquid is moved by pump H kthrough line I3 and valve cracking-are combinedand mixed with a pori3 to fractionating tower 2.` Remaining light the crude are elimi- .t

naphtha may be removed through valvey I6 'and line I1 to Abe disposed of as will hereinafterfbe described.

Reduced crude/leavingfractionator 2 through line is moved by pump I8 to coil I9 in furnace setting 20'. Pump I9 lraises the pressure of the reduced crudes stream to some convenient mod. eratepressure, for example, 50' to 300 pounds per square inch gage, more or less, while the temperatureof this stream is brought up tothe neighborhood of 850' to"900 F., mdre or less,

during" passage through coil I9, in furnace setting 20. Under the conditions'imposed, a considerable portion of the reduced 'crude is viscosity broken, that is, 'isconverted'into gas oil'with the simultaneous formation of relativelyminor proportions of gasoline Jandgas.

Instead of beingth'ermally viscositybroken, the reduced crude may be coke'd by.r known means, the liquid' products from"this 'operation being processed as will be described in connectifon'with the products from viscosity breaking vfurnace 20. If coked, the reduced crude may, for example, be heated to.a temperature in the rang 875 to 925 .F., more or less, during passage through coil I9 in furnace setting 20. 'I'he heated material is then discharged intoj one or more of a plurality of coke drums (not shown)v where the material cokes due to its contained heat., Overhead fromthe coke drums may be passed to a suitableevap orating tower, for example a towerv capableA of separating heavy gas oil as bottoms, the overhe passing to fractionator 11. .While on stream the f coke drums operate'at a rather low pressure, for example, 25 to 60 poundsy per square Ainch gage ,or even less. For continuous operation, a plurality of coke drums is employed, one or .mor e drums being on stream whileone or moreother drums is .being cleaned. Or, if desired,'the.re

duced crude may be catalytically hydrogenated to render the material more amenable to subsequent treating, the resulting liquid products from this operation being processed as will be described in connection With'the products from viscosity breaking vfurnace 2,0. If .hydrogenated the re\ duced crude may forexarnple be mixed with a suitable catalyst, for example, tin'oxalateor the sulildes or oxides of molybdenum or tungsten and a large excess of hydrogen added, the resulting slurry being heated to a temperature of- 850". to A,

950 F., more `or less, in coil I9 in furnace setting 20, the pressure being rather high, for example, 1000 to 3000 pounds per square inch',- gage, more or less. I (not shown), vapors, therefrom being suitably fractionated While bottoms .therefrom are re. cycled.

Material from visocisity breaking coil. I9 passes through valve 2| and enters fractionator 22 which preferably operates at somewhat lower.

pressure vthan coil I9, 'for example, at 25.to 75.

pounds per square inch gage.. -Fractionaton 22 is provided with bubble trays 23 or other suitable means to promote liquid-vapor Contact. Fractionatingtower 22 maybe provided with lupper disposed cooling means and may be provided with lower disposed Vheating means (not shown), f Bottoms from tower- 22 leave through line 2Qv through valve 25 to vacuum flasher 26. Vacuum vflasher 26 is providedwithdisc and doughnut trays 2 1 or other suitable means for promoting` The chargeis sent to a reactor means and lower disposedheating-- means 29 Qto` aidtin vaporizing the flighterj components, of I'the liquid `bottoms in vacuum flasher 2.6. Vac;-

. uum lflasher 29 preferably` operatsfat subatinospheric pressure, for example, "0.1 atmosphere,

more or less.: "Bottoms from -vacuumilasher 29 leave through line 29 and are moved by'pump '39 to. storage. vOverhead from lvacuum flasher '29 leaves through line 3l, is cooled inexchanger 22 yand condenser 39 and then passes`to separator 24.. Liquid from "separator 24 leaves through line j Il .and is. movedby pump 36Yto line 31.' Afportion of the-liquid Apasses througlivalve 38 to i the upper portion of vacuum flasher-26 to provide cooling therein, .the remainder is heated in \example, the lighter.l and accordingly more val uable ltar eliminated through'line 24may, if l desired, be coked by a methodv similar to that '30 previously described,.or, if desired, itvmay. be

hydrogenated byl a method similar It'othat previ- 'ously described. Or, if desired, this-lighter and accordingly more valuable tar may be propane deasphalted.- To accomplish .this,the cooled tar is mixed withliquid propane and the resulting mixture is heated to precipitate "asphalt, the -heavy liquid hydrocarbon-propane mixturey being passed .to a suitable fractionating tower. Obviously, if desired, `vacuun'lf'flashed tar from 1U-line 29 may be ceked. hydrogenated orpropane deasphalted. However the gasoline value of 'this 9 material is so low that such treatmentisr rarely justified. v .il 1- Heavy viscositylbreaker gasoil is drawnfrom A an intermediate point of fractionating tower 2 2 through line l2and is moved by pump 43 tocoil 44 in furnacev setting. l'The liquid incoil 44 is heated to an elevated temperiatture. v -If desired, to Aaid in the vaporization'of this material, a iluid having a lowercritical temperature substantially unreactive therewith, for, .examp1,e, Y steam or'a 'gas stream madeinlthe process being shown. Also, vif desired, `the 'heated material to remove any unvaporized components prior to processing. An ordinary ,separator similar to those well known in the art maybe employed whereinthe substantially completely vaporized charge is passed to a well insulated drum preferably provided with baiiies' or other suitable de- A entraining means, vapors beingtaken overhead .while unvaporized material is removed as bottoms. Or, if desired, a centrifugal separator may be used. similar, fcrwexample'jto that de scribed in United States Patent 2,192,214. vIn

any event, to aid in vaporization; the pressure in `coil M and lin subsequent elements lshould preferably be as little above atmospheric as is consistent with satisfactory operation. The in aterial leaving coil 44 is passed to a catalytic cracking section. atalytioreactors maytake several diierent vliquid-vapor contact andillperfdisposed cooling Y ods. may be used to secure the. eliminationl of.

than said heavy viscosity' breaker4 'gas oil and described, may be addedv thereto by means not,

may be'passed through a separator (not shown) forms. Among state.

, cai alytic' z ne;

these may be mentioned the following:

l. Single reactors containing a lstationary bed of catalyst.

2.-Plural reactors of'cata'lyst. 3. Reactors designed alysts.

4. Reactors catalysts.

Whilefor an; given set of conditions, one of the fori'iuse Vwith moving cat vdesignedior use with powdered above typesv ofreactors 'is usually preferable to the others, these types are more o r less interchangeable. Simply for purposes of variety and with no intentto limit the description. toy lthe particular typeselected forany given application, an example of each 'type of reactor niencontaining a stationary bed tioned will be included in the instant descrip tio'n. `For the catalyticcracking of heavy. viscosity breaker gas oil, a reactor designed for pow--gv dex-ed catalystV operation willl be described.-

The heated material from coil 44 is passed through valve 46 and is then mixedwith powdered catalyst introduced through. vline l1,- valve .4t being closed This catalyst preferably com prises a silica-alumina complex,`either natural or synthetic, and for reasons that will hereinafter become apparent is in a highly heated .On mixing with the heated i'naterial entering through valve 46, said material is immediately brought up -to reaction temperature and vaporized. If desired, the powdered catalyst may be slurried into the Iliquid feed prior to` entering coil Il .but generally, it is. preferable to catalyst and feed at the point shown. Forl the catalytic cracking' of this' stock, a somewhatV inactive (comparatively) catalystais desirable. 'This stock is ,high boiling and as it' is desirable to operate in 'the ,vapor phase or substantially vapor phase a high temperature is required.V If the mostl active crackingvcatalysts are employedjat the high temperatures required for -vaporizatiom it is d ifllcult to control the reaction so as to avoids considerabley secondary deleave reactor 49 through line il, following which the gaseous reaction products .are separated from Y j the solid, suspended catalyst. This maybeacg-` complished by any suitable -known'means or any 'combination thereof. a cyclone separator Il being shown in` the figure. Separated catalyst leaves cyclone'separator Il. through line l2 and to the regeneration element. Prior to regeneration, the separated catalyst is`preferably steamed or otherwise treated to remove anyx adsorbed or absorbed reaction products therefrom by suitable means not shown. 'Theused catalyst in line 2 issuspended in' a stream of air or dilute air introduced ythrou'ghline 53 and the suspension is passed through regenerator 54 which preferably takes the form of an elongated .conduit wherein regenera- -tion of the catalyst by 'combustion of carbonaceous residues on the surface thereof occurs. If desired,A

regenerator 54 may take the form of a plurality of regenerators in series witlian intercooler-between each pair in order to better control the heat evolved duringregeneration. 49V and regenerator 54 may each take the form tors, an interheater` being interposed between each pair'of reactors. As the catalytic cracking l.

reaction isendothermic' while the regeneration reaction isexothermic, partial reaction 'products may' -berehead in' thelmrheaters by indirect heat exchange withpartial regeneration `products which aresim'ultaneously cooled. Thus the interheaters on the one hand and the intercoolers onl the other may both be combined in the form of indirect heat exchangers.

The regenerated catalyst suspension leaves regenerator 54 through line 5B following which the gaseous products are separated from the regenerated suspended catalyst by any suitable k'nown means or any combination thereof, a cyclone sepcomposition. Accordingly, rather inactive crack# ing catalysts are preferable in this particular When such. comparativelyin- Y active cata ysts 'are employed, operating tem-r peratures in thel neighborhood of 950 F. may

safely be used, charging about 1 to. 3 pounds ofcatalyst per pound of oil charged to the unit. Suitable catalysts for. the purpose include 4activated montmorillnitic clays, the commercial materials known as,v Super Filtrol' and Tonsil being particularly useful. Other suitable catalysts, comprising synthetic silica-alumina complexes have been described in my copending rapplica*- arator 58 being shownin the ligure. Separated catalyst leaves cyclone separator il through line l1 for recycling to the cracking zone. Obviously fthe catalyst is highly heated and a portionvof the heat content may be employed to heat and vaporize'the charge as previously described. Prior to recycling, the vcatalyst may be steamed if desiredv or otherwise treated to remove any adsorbed air from the surface thereof by means not shown.

from the system through valve 58 and is in 'part recycled by turbine 59 to'line 53, necessary makeup air being added through valve 60. Eliminated tions,.Serial No. 305,473 tiled November 21, 1939, f

Serial No. 313,898 led JanuaryA 15,'v 1940 andv serian No. 317,770 med February '1, 1940.

Itmay be mentioned in passing that powdered catalyst operation oiers the most convenient method to -accuratelycontrol reaction temperatureand contact time and accordingly is the most suitable method to employif a highly active catalystvis used in the cracking 'of heavy gas oils. Forf the same reason, 4with' an inactive catalyst, a higher temperature may be employed when using the powdered catalyst technique than with any other means for contacting catalyst and charge without running any risk of secondary decomposition. i y

The catalyst, suspended in the v aporized charge,

combustion gas may, if desired, be employed to supply the endothermicheat of reaction to reactor ,49 by indirect heat exchange.

Hydrocarbon-reaction products leave cyclone .separator 5| through line BI and pass to fractionator 62. This tower is provided with means vto facilitate liquid-vapor contact, for example, bubble trays 63 and is also provided with bottom heating -means 64 andl uppel disposedr cooling means. fractionated intowei 62, products heavier than gasoline leaving? through lineV E5 to' be further processed as will hereinafter bedescribed, gasoline and lighter products leaving through line 66.

Gasoline and lighter products in line 66 are partiallyfcondensed in heat-exchanger S1 'and pass to separator 68. Liquid products arefmoved by passes through reactor which preferably takes J pump 69 and are-in part passed through valve il If desired, reactor Y The hydrocarbon reaction products are.

- and line '1| to provide open'reilux therein, thermainder from said tower passing to fractionator 1.1.

insure continuous operation a plurality of cata'- 'the upper portion @mower sz to Pass' ing through valve 'I2-and line 'I3 to be utilized as" aswillhereinafter be described.

If desired, the heavy viscosity breaker gas oil V.catalytic cracking step .may be eliminated entirely. This is accomplished by closing valve 46 and opening valve ,48, theheated heavygas oil passing then to tower 22. By this means all heavy viscosity 4breaker gas oil is ultimately converted into viscosity breaker gasoline, light viscosity breaker gas oil and tar. When this procedure is I followed it is advisable to operate coil 44 at some convenient elevated pressure, for example, 400

pounds perv square inch gage and at a temperature at the coil'outlet of 950 F. or'in the neighborhood of this ilgure. In the event that this scheme is used it may be advisable to discharge the products passing through valve 48 to a tower similar to but, separate from .towerV 22. In this way a cracked tar is eliminated free from or substantially free A'amants l o and valve 81 tn be disposedofiasfwillhereir'i-4 after-be explained. (laseous products leave: sepa U will hereinafter bev described. vGas from separator o I8 leaves through line 14 and line 15 to be utilized rator 82 through valve 88 and line 8'9.. The disposition oi these lwill be explained subsequently Part or all ofy the liquid inline 86 maybe sent through valve I99if desired for reasonsthat will hereinafter beexplained. q

Bottomsirom tower 11, lcomprising'light 'visl cosity breaker gas oil, are rmoved 4by pump 90 into line 9|` where they vare joined withl virgin erably used in reactor 95; -A catalyst such as is from virgin fractions and is thus eminently suitable for use in the manufacture of road oils.

As will b'e apparent to those skilled inthe art it is also possible to pass' the heavy viscosity. breaker gas oil in line 42 directly vto line 8 for recycling to the furnace coil I9.

If desired, the reduced crude leaving tower 2 `30 through line 3 may be catalytically viscosity broken. f To accomplishI this, Ithe reduced crude is heated to a temperature in the range 850 to 925 F., more or less, in coil I9, the pressure being comparatively low, for example, 50 pounds or less per square inch/gage, The heated and substantially vaporized charge may or may not then be subjectecllto a separating step, using any suitablel means, for example, ya drum separator or a centrifugal separator similar to devices already de'- scribed. Also, if desired, a fluid oflower critical temperature than the reduced crude charge 'and 'substantially unreactive therewith, for example,

steam or gas made in the process, may be added to the reduced crude charge to facilitate the vaporization thereon '.Ihe 'heated substantially completely vaporized-reduced crude charge is then passed to one or more of a plurality of catalytic reactors (not shown) containing cOIJlparativel'y inactive catalytic material, for example, montmade by impregnating silica gel With'aluminum nitrate or other thermally decomposable aluminum salt, and then igniting may be employed. 0r, if desired, catalysts such 'as are described in my copending applications, Serial-No. 305,472, filed November 21,1939, now U. S. Patent 2.278,-

59ol and serial No. 300,390, filed october 21,1939,

may be employed in reactor 95." Of course, catalysts such as are described in connection with reactor -i9 may be employed in'reactor 95 if de o sired.

Reactor 95 may Atake any convenient form. In the figure it is 'shown as being of similar conf struction to a tubularboiler or heat exchanger. Catalytic material is introduced into vthe top of reactor gthrough conduit Q6, passes downward through the tubes in reactor 95 and is removed from the reactor via conduit 9F. If desired, the

tubes in reactor 9,5 may be heated by surrounding morillonitic argillaceous material, puinice, porous earthenware or the like.v Reaction products are f passed to a tower (not shown) eliminating heavy f viscosity breaker gas oil as bottoms, the overhead To lytic reactors is employed, one or more -being on stream while the catalytic material in one or more others is being regeneratedl by procedures known to those skilled in the art and which will be described in somewhat more detail hereinafter.-

Returning now to the illustrated embodiment, overhead products from tower 22 leave through line 'I6 and pass to fractionating tower 11. Fraccilitate liquid-'vapor"contact, for example, bubble trays I8, with bottom heating means 19 and upper disposed cooling means. Gasoline and lighter' products leave tower Hf through line 80, are partially condensed in heat exchanger v8| and the i products are passed to separator 82. -Liquid prod-.

ucts are moved fromseparator 8 2 by pump 83 and them with hot iiuid, for example, hot combustion gas from a source later to be revealed, entering through line 98 and leavingthrugh line 9901' vice-versa. Vaporous reaction products leave'reactor- 95'through line |09.

The descent of the catalystthough theftubesy in reactor 95 may. be facilitated by means of .shakers or other similar devices (notshown). The rate of catalyst additionto and removal from 'reactor A95 is so regulated that the catalyst removed is exhausted or nearly so. This material is moved through conduit 91 to regeneratoriill. The catalyst is moved in conduit 91, as well as in conduit 96, either mechanically or pneumatically,

',theV term pneumatically being employed in its takes theA form of a multiple hearth furnace, for

o tionating tower TI is provided with means tofa-- e5 example, the' furnace known in the art as the Herreschoi furnace. In its descent through they multiple hearths of the furnace the catalyst is contacted with a risingv stream of airi or prefer--v ably inert gas vcontaining air introduced through line |02; Carbonaceous deposits are burned from. the catalyst in regenerator |0| and hot combustion gases leave through line |03 and are recirculated by turbine |04. vPart yof these combustion lgases are discharged through valve |05 and part are in part, passed through valve 84 and line 85 to the upper part o f tower 11 to provide open re iux therein, the ren'nainder passing through line 75.V

or all of 'these may be introduced'into line 98 to` supply heat to the tubes in reactor 95. Necessary 'makeup air is introduced through valve |06.

Regenerated catalyst fallsr to the bottom of re generator |0|, is picked up by conduit 96 and is returned t reactor 95.

.pena fuller description and more .detailed illustration of reactorfmultiple hearth regenerator of tower |01 to p'rovide cooling therein While the' tower |01 are removed through line |20 to be the scheme already described.

inch or higher. 'I'he heated and vaporized naphsystem reference' .maybe ha'dto my copendlng, application, Serial No, 277,885, filed June 7., 19.39.

Vaporous'reaction products from,reaetor 05 l are conducted by line| to fractionating tower 5 |01. Thistower is'provided withbotto'm heating means |08, means` to promote liquid-.vapor con .ta'ct5such asv bubble trays |00, and with top cooling means.4 Overhead from tower '-I01. leaves through line i I0, is cooled in exchanger and passes to separator ||2. Liquids are 'removed from separator. 2by p'unp 'I |3, part are passed through valve ||4iand line ||5j backjojthetop' remainder pass through lin'e '|I1 and va1ve||64 rto be disposed of as will hereinafter bel-described. j Gaseousfproducts are removed from separator I I 2- by valve H6 andline IIS. The treatment of these will be described shortly. Bottoms from.

further processed as will hereafterbe described.

1 Heavy naphtha is removed-from the upperfportion of fractlonating tower -2 through line 6 and is moved by pump |2|to heating coil |22 infurnace setting |22A. If desired, part or all of the viscosity breaker gasoline from tower 11 may be added to `the naphtha charged to the heating coil |22. This may be accomplished by partially or 'completely closing valve 51 and partially or comy pletely'opening valve |08 in line 200. If it is desired to treat only the heavier portions of the viscosity breaker gasoline, vline 1.6 may pass over to tower 2 rather than to tower 11 as shown. In this way, light viscosity breaker gas oil leaves, mixedwith light virgin gas oil, through line 1', heavy viscosity breaker gasoline leaves, mixedwith kheavy virgin naphtha, through line 6 and lightlvisco'sity breaker gasoline and light Virgin naphtha leave through line 5. By this mode of procedure, obviously .tower 11 with all of its auxliliary equipment is unnecessary. Also, if desired,

all virgin gasoline may be passed to coil |22. To accomplish this,.1 ine 6 is omitted and all components in the crude of gasolineboiling range,v pass overhead from tower. 2, the liquid portions thereof being ytransferred via line I5 to coil .|22

. by a line not "shown, In this modification, the

total viscosity breaker gasoline maybe processed in conjunction with the total virgin gasoline by The naphtha-charge isheated to a tempera- `ture of from 875 to 1050 F. more or less, preferably to a temperature within the range 925 to 1000" F. The naphtha may be yunder a pressure of from atmospheric or somewhat above up to a pressure of 200 to 300 pounds per square tha passes through line |23 and valve |24 to catalytic reactor |25. Preferably, before enter ing the catalytic reactor, the naphtha is mixed with hydrogen at a rate of for example 1 to 5 moles per mole of naphtha, said hydrogen being introduced, for examp1e, through line |26, this hydrogen being obtained from compressor I8 I Reactor |25 may take any desired form, for 65 example, the tubular formshown and described with respect `to reactor 95. The catalyst in re actor |25 may comprise chromium oxide gel but preferably comprisesA alumina, especially `the variety of aluminum oxide known commercially 1oas "activated alumina, bearing thereon a relatively minor portion, saylto preferably 5 to 10%,of a sixth group metal oxide, particularly chromium oxide or molybdenum oxide.- Vaporous reaction` lproducts leave reactor |25 75 through valve |21 lline |42 and are quentiy.

-valve |66 and line |64.

and travel by line |28 to iractionator |26. i -Fractionating tower |20 is provided with bottom heating means |60, means for. promoting liquid-vapor contact,:for example, bubble trays ISI, and top cooling means.

line |4|, the'further treatment, of these being described immediately hereafter.- Bottoms are removed from fractionating .tower .|29 through utilized' as described subsey j i y The gas elim essentially of hydrogen but is diluted with more or less gaseous hydrocarbons. If desired, this gas may be subjected toany suitable separation process `to giveV more nearly pure hydrogen. This maybe accomplished, for'fexample, by absorbing the greater part of the gaseous hydrocarbons in a suitab1e liquid. -To accomplishjthis, the gas lstream in line 4| may be moved to the lower portion of absorberi4j3. Absorber- 43 is preferi ably provided v with liquid-Vaporu contact means,

for example, bubble` trays |44. The ascending gas stream meetsa descending stream of absorber i oil introduced through line and concentrated hydrogen leaves through line |46. Rich absorberr oil is taken from the bottom of absorberill by,

pump |41, is heatedy in indirect heat exchanger |48 andA passes through line- |40 to stripper |50. Stripper. |50 is provided with bottom heating means I5| and means for promoting liquid-vapor contact, for example, bubble trays |52. 'v Gas comprising predominantly gaseous. hydrocarbons is eliminated through line |53 and valve' |54 to be further processed as will be described. Stripped absorber oil is removed from the bottom` of stripper |50 by line |55,- is moved by pump |56A r |48, cooler |51 through indirect heat exchange and line I 45 back to absorber |43.

Returning now to reactor |25: When the catalyst in reactor |25 becomes exhausted,I the reactor is removed from stream by closing valvesr |24 and |21, twin reactor |58 being simultaneously put, on stream by opening valves |59/and |60. The catalyst in reactor |25 isfthen regenerated 4b'y burning carbonaceous residues therefrom by introducing air or dilute air through line I 6| andvalve |62, combustion products being removed from reactor |25 via valve |63 and line |64. When the catalyst in reactor |58 isexhausted that in reactor |25 is restored and the functions of the two reactors are then reversed by closing valves |59, |60, I 62 and |63, simultaneously opening valves |24 and |21.' Exhausted catalyst in reactor |58 is thenr regenerated by introducing air or dilute air through line |6I and valve |65, removing combustion products through or any combination thereof are hydrogenated to render them amenable to further processing. If des1red, only bottoms from` tower 62, or only Overhead from`4 tower |29 leaves through line |32, is cooled in exchanger |33- andpasses'to separator |34. 4Liq "uid products are removed from separator |54 by .pump |35, part passing through ,valve |36and line |31 to the top of-tower |28 to provide cool-y ing therein, the remainder passing through line l las and vaive las to befurther processed as will hereinafterbe. described. Gaseous products arel removed from separator,` 34 by valve |40 and inated through line I,4I consists bott .maths .dem {owen-Int drmy 52,315,445 oms from `gasoline through destructive hydrogenation; al'

tower` |29, orponly bottoms!'nomi-towers 62 and though normally a small amount otpmater'ialqin *the gasoline boiling range is produced. l To aci'l, or only bottoms from towers l2 and' |28 org.

only bottoms from ltowers |01 and Harney be so treated. The'exabtarran'gement'of theovervg'reactor |84 are relatively/.mild The operating l lheadsvstexn maybe changed it desired depending pressure is/low, for example, in thev range 500 Ito upon the exact method of treating the bottoms# 1500 pounds per` quare( inch and the operatingv complisb this desired end, operating conditions in The overheadsystem shown in, the ligure. is the I' .f temperature is in/therange 850 to 900'? F., more most flexible system. `Iifbottoms from towers, |01 and lis are combinedrand hydrogenated ,it is obviously possible-to combine these .three towers` into a single-tower. instead of using the three separate towers shown.l Likewise, if only bottoms from tower B2v are hydrogenatedr then, if desired,

towers |01 and -lzmay be combined; this same scheme mayzzbe followed, if desired, if only bot/ -genated Similarly, if vonly bottoms 'from tower |071 are to behydrogenated', then, ifdesir'ed, towers 62 y'and t28'maybecombined into a single mwen-'this same design may be 'rolf' lcwedgif desired, if only bottoms, from towers" t3 and |39- areto` be hydrogenated. Likewise, if bottoms from 'only tower' b2b are to:

pointed out that in' general, one or the other' of' but two 'systems of vworking up'bottoms is usually followed.` In general, bottomsfrom towers t2 and lill are combined and hydrogenated while bottoms from tower |29 may or may not' be added .to this combined stream as desired. Bottoms from tower '29 are smallin quantity and have many uses after little or no fu'rthen processing.

While various tower combinations and various employed if desired.

or less. About one to tenmoles of mole i'- charge areemployed. ,.1 'Y Obviously, destructive hydrogenation may `be Many factors however -militate against its use.l In the rst place, op

erating conditions must be lquitesevere result-v AAlso, large amounts of 4hydrogen are consumed 'and' this usually necessitates the .construction .of- .a hydrogen.' producing element, whichy is "charged, lfor example, with' gaseous hydrocarbonsrnade in the process. l I il l` igReaction products from tower .lfl pass vvia line 5 through cooler |85; through reducing valve i8? Yto separator its. Hydrogen and other'g'ase- .ous products are passedfbypump 89 and line |83 to absorber lit for. purification as previously described'. Liquid products from, separator E38 are moved `byfpurnp ,ist `through line j'592. toline l.

to the heating means (not shown) used to preheat the crude charge 'inline l.

These enter line i preferably prior As the 'catalystemployediin reacto |85 has ,extremelyvlong active -life onlyone reactor 'ls y shown. When, after many months, the catalyst r,becomes inactive the unit `may be shut down, the

^ by freshmaterial'.

If. desired, ,part or all of the buttoms from towerl t2 may" be removed to /stbrage orotherpossible vways of working up bottoms have been, f

described, in the-description to follow it shall be assumed that three separate towers, 62, ifland 420, are available and that bottoms from all are combined andhydrogenated." Y l Bttomsfromftower- 62f are removed through line $5 and aren/loved by pump |61 through valve '|68 and line'i69 to line 13. Bottoms from tower i'l are removed through line |20 and are moved' by pump |14 through valve |15 vto line HS. Bottoms from tower |29 `are Iremoved through line |42 and are moved by pump |79 through valve yill and line |12 to line l'lt?.A Material in' lines H3 and H6 -are -joined vand epass through line ITI and are moved by pump |18 to furnace 19, the mixed charge passing through elongated conduit 4Hill-disposed in furnace E19. Prior to entering the furnace coil, the charge in line lll' is mixed with hydrogen -fed by compressor .l8l to line |82.

Heated material from furnace coil lpasses temptismadetoconvertthesetowerbottomsinto'75-b11tneftheref0m, the Separated materials becatalyst removed from wise through line me and 'valve itil; part or all removed through'line 1&95 and valve E96 while part or all of the bottoms troml tower l29may be removed via line. ist and valve i98.v

bottoms' from tower-|07 may be movedl through line 695, valve igt and by a .line (not shown)l to heating coil "dil furnace @5 where itis heated and further processed with heavy visbeen mentioned previously, heavy viscosity breaker gas oil is'catalyticaily converted at temperatures higher than`is,y employed in the catalytic conversion 'oflight gas oil. Cycle stock from the catalytic conversion oflight gas oil', while too refractory to be converted at a satis- A factory rate if 4recycled to the .light gasoil catalytic cracking zone,A can be further lprocessed catalytically in a satisfactory manner if sent instead to the heavy viscosity breaker gas oilcatalytic conversion tures prevail. f A,

The various predominantly hydrocarbon g'as `zone where higher tempera!- v (streams, for example, the gas discharged through valve i6 and line il, the gasdischarged through valve .14 and line l5, the gas discharged through valve @Band line 8s, the gas discharged through valve ||8 and line H9 and the gas dischargedthrough valve |53 and line |54 or any suitable. combination of. these streams may be combined andltreated by any known mea`ns, for example,

absorption to separate any normally liquid hydrocarbons and if desired, higher molecular-A weight. gaseous hydrocarbons such Vas normal hydrogen per ving in large equipment and processing costs..

reactor i8@ and replaced ofthe bottoms from tower l0? may be similarly `Cin another modification of possible processes for working up tower bottoms, part or allI of the cosity breaker gasoil from tower 1 2. As has ing blended with the gasoline produced or otherwise disposed of as desired.

Similarly, the various naphtha and gasoline streams, or any combination thereof may be combined and stabilized by known means to remove part or all of the four carbon atom hydrocarbons therefrom together with lower boiling hydrocarbons. For example, virgin light naphtha discharged through valve M and line II, viscosity breaker gasoline discharged through line 86 and valve 81, cataiytically cracked gasoline discharged through valve IIS and line lil, cataiytically cracked gasoline discharged through valve 12 and line I3 and cataiytically reformed naphtha discharged through line 138 and valve |39 or any combination of these streams, may be combined and stabilized.

To further elucidate my invention a single specic example thereof is given. It is to be understood that this example is illustrative only and in no way is to be considered as limiting the scope of my invention.

Example naphtha having a1o% point of 285 F., a 50% point of 325 F. and a 90% point of 390 F.; a gas oil having a point of 450 F., a 50% point of 540 F. and a 90% point of 635 F. and finally bottoms having. a 10% DOint of 660 F. (In a separate experiment in which the crude oil alone was fractionated into cuts having the boiling ranges specified it was found that of 71 A. P. I, light naphtha having a motor octane rating of 71 was produced, 17% of 49 A. P. I. heavy naphtha having a motor octane number of 45, 29% gas oil and 30% reduced crude bottoms were produced, these fractions representing fresh feed to the system the percentages being by volume).

The bottoms were subjected to a thermal once through viscosity breaking operation using a coil outlet temperature of 870 F. and a coil outlet pressure of 150 pounds per square inch. The viscosity broken products were fractionated with the elimination ofa 4 A. P. I, viscosity breaker tar, taking overhead 10% viscosity breaker gasoline having an A. P. I. gravity of 59, a 10% point of 160 F., a 50% point of 270 F., a 90% point of 355 F. anda motor octane number of 65; 19% of light viscosity breaker gas oil having a 10% point of 470 F., a point of 560 F., and a 90% point of 640 F., the remaining product being heavy viscosity breaker gas oil.

The-heavy viscosity breaker gas oil was subjected to catalytic cracking conditions using the powdered catalyst technique. Commercial Super Filtrol was .employed as'catalyst. The catalyst to oil weight ratio was 1.9 and the average reaction Itemperature was 950 F. While these cataiytically cracked products were combined with those from the light gas oil catalytic cracking zone and the two were fractionated together, a grab sample from the operation now being described indicated the production of 40% by-volume of gasoline of 79 octane number (motor) and 10 pounds Reid vapor pressure, 55% cycle stock by volume, 11% gas by weight and 3% by weight of coke and loss.

The light viscosity breaker gas oil, in admixture with the previously mentioned gas oil consisting of light virgin gas oil, was subjected to catalytic cracking conditions using the moving catalyst'technique. A synthetic catalyst similar to that described in Vmy copending application Serial No. 305,472, filed November 21, 1939, was

employed. This composite feed was heated to' 800 F, and charged to the catalyst-chamber at a rate of about one volume liquid composite feed per hour per volume of catalyst space. Catalyst was added to and abstracted from the reactor at a rate half as great as the rate of oil feed, i. e., the catalyst holding time was two hours. While the cataiytically cracked products were combined with those from the heavy gas oil catalytic cracking zone and the two were fractionated t0- gether, a grab sample from'the operation now being described indicated the production of 30% by volume of 78 octane number (motor) 10 pound Reid vapor pressure gasoline, 7% by weight of gas, 64% by volume of cycle stock and 1.5% by weight of coke and loss. Y

' The heavy naphtha was cataiytically reformed in the presence of a catalyst consisting of 10% chromium oxide on alumina. The liquid charge was mixed with hydrogen at a rate of three moles hydrogen per mole of naphtha charge, the whole was passed at a pressure of 300 pounds per square inch and a rate of one volume of liquid feed per hour per volume of catalyst space through the catalytic reactor, the average temperature being 1000 F. An 80% yield of 80 octane numberv (motor) liquid boiling within the usual motor fuel boiling range was obtained. The net hydrogen production amounted to slightly ,more than 500 cubic feet per barrel of naphtha charged. The total gas was subjected to absorption so as to pro duce a hydrogen rich fraction, a portion of which was recycled as already described, the remainder being employed as will be evident immediately hereafter.

The products formed in the light gas oil catalytic` cracking zone and the heavy gas oil catalytic cracking zone were/combined and fractionated eliminating gas, gasoline and bottoms. Net hydrogen made in the catalytic reforming zone was added to the bottoms at a rate of ilve moles per mole and the resulting mixture was passed over tungsten sulfide and oxide on pumice at a temperature of 900 F. and a pressure of 1000'pounds per square inch. The flow rate was so regulated that but little material in the gasoline boiling range was formed. Hydrogen absorption was appreciable however. The reaction products were cooled and separated, gases passing to the previously 'mentioned absorber while the liquids were mixed with the crude and fractionated to give light naphtha, heavy naphtha, gas oil and bottoms .of the boiling ranges already given.

On blending the-light naphtha formed in the primary fractionation, cataiytically reformed heavy naphtha, viscosity breaker gasoline and the gasoline producedin thetwo catalytic crackling zones the major ultimate product of the process was obtained. f

I claim:

1. in theconversionof a hydrocarbon mixture of wide boilingrange into hydrocarbons boiling within the usual lmotor -fuel range, the process comprising iractionating said hydrocarbon mixture in a ilrst fractionation zone to torm a plu- *asia-14s rality of condensates including a condensate at least the major vportieri .of which boils within the usuai'motorfuel range anda condensate at least the major portion'of whichboils above the usual motor fuel range; subjecting said higher boiling condensate, in the presence of `a cracking catalyst, to, a vconversion temperature under catalytic i cracking-conditions to effect the formation of a n high yield of gasoline components, subjecting catalytically cracked/products to fractionation in a second fractionating zone to form a residue and a condensate comprising gasoline; blending thev lower boiling condensate from said first fractionating zone with hydrogen from a source hereinafter described, subjecting the blend, in the presencecf a reforming catalyst, to a conversiontemperature under catalytic reforming conditions to veffec:I the formation of a high yield of aromatics within the usual ,motor fuel boiling range and hydrogen, subjectingbatalytically reformed prod ucts to fractionation in a third fractionating zone y to form a condensate comprising aromatics'within the usual motor fuel boiling `range and hydrogen ;A

recycling a portion of'said hydrogen tothe catalytic reforming zone; subjecting thev residue from said second fractionating zone in the presence'ofy condensate at least the major portion of which boils above the usual motor fuel range and a oondensate at least the major portion of which boils within theusual motor fuel range; subjecting said residue to a decomposition temperature to eect the formation of a high yield-of light gas oil components and as low yield of' gasoline com'- ponents, fractionatlng the resulting products in a secc-nd fractionating zone to form a residue and a plurality of condensates comprising light gas oil and gasoline; blending the higher boiling con# densate from the first fractionating zone and the iight gas oil, subjectingthe blend, in the presence of a cracking catalyst, 'to a conversion temperature under catalytic crackingconditions toeifect the formation of a high yield of gasoline components; fractionating catalytically cracked products in a third fractionating zone to form a residue and a condensate comprising gasoline;`

blending the lower boiling condensate from the rst fractionating zone and hydrogen from a source hereinafter described, subjecting the blend, in the presence of a reforming catalyst, to

a conversion temperature under catalyticre-f' forming conditions to effect the formation Aof a high yield of aromatics within ythe usual motor lthird fractionating zone in the presence of a hydrogenation catalyst and a portion of the aforementioned gas comprising hydrogen, to a con`- l I version temperature under hydrogenatlng condi- Y tions to eect the upgrading of said residue and passing saidupgraded residue 'to' theilrst fractionating zone. u 3. The process in accordancewith claim'Z, further characterized by fthejfact' that said gasoline' from thesecond fractionating v zone is catalyt-V ically reformed in admixture vwiththe lower boilingcondensate from the flrstfractionating zone.`

i 4. In the conversion of` a hydrocarbon mixture of wide boiling rangeintofhydrocarbons boiling within the usual motor fuel` range, the process comprising fractionating said hydrocarboximixture in a first fractionating zone to form a re`s`i.-

duefand a plurality of condensates including a condensate at least ,the majorl portion ofwhich f boils above the usualx'notor fuel range and a con- `densate at least the majorportion of which boils within the usual motor fuel `range; subjectingy said residue to a decomposition temperature to effect th formation of a high yield of gasoil' components and a low yield of gasoline compo-l nents, fractionating the resulting products ii a second fractionating zone'to form ay residue. and l a plurality of condensatescornprising'heavy gas` 'oil, light gas oil an'd gas`oline; ,subjecting heavy gas oil in a rst catalytic cracking zone and in the presence of a-cracking catalyst, .to a conversion temperature under catalytic cracking conditions to effect theformation of a high yield of gasoline components, blending the higher boilingy con densate from 'the rstfracticnation zone and the light gas oil, subjecting the resulting blend in a tol fuelv boiling range and hydrogen, fractionating second catalytic cracking zone and in the presence of a cracking catalyst,` to aconversion temperature under catalytic cracking conditions to effect 'the formation of a high yield of gasoline components; fractionating catalytically cracked products from yboth catalytic cracking zones in a third fractionating zoneto form a residue and a condensate comprising gasoline; blending the lower boiling condensate from the first fraction-A 'ating zone and hydrogen from a source vherein-- after described, subjecting the resulting blend;v

in the presence of a reforming catalyst to agcon# version' temperature under catalytic reforming of aromatics within the usual motor fuel boiling range and hydrogen, fractionating catalytically conditions to eiectthe'formation ofa high yield 'v reformed products in a fourth fractionating zone to form a condensate comprising aromatics Within the usual motor fuel boiling range and aV gas' comprisinghydrogen; recycling a portion of said hydrogen tothe catalytic reforming zone, subjecting the residue from the third fractionating zone* in the presence or' a hydrogenating'catalyst anda portion ofthe aforementioned'gas coin-V prising hydrogen, to a conversion temperature under hydrogenating conditions to effect the upresidue to the first fractionating zone.

5. The process in accordance withclaim 4, fur- Vgrading of said residue and passing upgraded",

of wide boiling range into hydrocarbons boiling within the usuaLmotor fuel range, the process comprising fractionating said hydrocarbonmixture in Aa rst fractionating zone to form a residue and a\ plurality of condensates including a condensate atl least the major portion of which boils within the usual motor fuel range and a boils above the usual motor fuel range; subjectcondensate at least the major portion of which 1o to effect the formation of ahigh'yield of gas oil components and a low yield of gasoline components, fractionating the resulting products in a second fractionating zone to form a residue and a plurality of condensates comprising heavy gas oil, light gas oil and gasoline; subjecting heavy gas oil in a first catalytic cracking zone andin 'the presence of a crackingcatalyst, toa conver- 1 oondiuons to. effect the formation of o high yield I of aromatics within the usual motor fuel boiling range and hydrogen, i'ractionating catalytically sion temperatire undercatalytic ,cracking conditions to eifectthe formation of a high yield of gasoline components, fractionating ycatalytically cracked products ,in a third fractionation zone to fgrm a residue and a condensate comprising 'gasoline; blending the higher boiling condensate from the first fractionating zonev and the light gas oil,

l subjecting the resulting blend in a, 'second cataing hydrogen, to a conversion temperature under y hydrogenating conditions-t0 effect the upgrading lytic cracking zone and, lin the presence of a cracking catalyst, to a conversion temperature under catalytic cracking conditions to eilect'the l f formation of a' high yield ofgasoline components,

fractionating catalytically cracked products from the second catalytic cracking zone inf/a fourth Afractionating zone to forma residue and a condensate comprising'gasoline; blending the loweri. boiling condensate from the ,first fractionating zone and hydrogen from a source hereix'iafterdescribed, subjecting vthe blend in the presence of a reforming catalyst, to a .conversion temperature under catalytic reforming conditions toeifect the formation of' a high yield ofaromatics within the usual motor fuel boiling range and hydrogen,

fractions-ting catalytically reformed products in a fifth fractionatlng zone to form a condensate comprising aromatics within the usual motor fuel conditions to effect the upgrading offsaid blend, and passing the upgraded blend to the rst'fractionating zonc.` Y Y ther characterized by the fact that said gasoline from the `said fractionating.'zone.is catalytically reformed in admxture with the'- lower boiling condensate from the first fractionating zone. 8. 1n the conversion of ahydrocarbon mixture of wide boiling range into hydrocarbons boiling t Within Ythe usualmotor fuel -range, the process reformed products in a fourth fractionating lzoneto form a condensate comprising aromatics boiling within the usual motor fuel range and a gas comprising-hydrogen; recycling la portion of said hydrogen to the catalytic reforming zone; subjecting the residue from thethird fractionating zone, in the presence of a hydrgenation catalyst and o portion of the `aforementioned gas'comprisof said iesidueand passing said upgraded residue to the first fractionati'ng zone, 9. The process in accordance with claim 8, further characterized bythe fact that said gasoline from the vsecond fractionating zone is catalytically reformed in admixture with the heavy naphtha from the first fractionating zone.

10. In the conversion of a hydrocarbon mixture 'of' wide boiling range intofhydrocarbons boiling within the'usual motor fuel range the process comprising fractionating said hydrocarbon mixture in' a first fractionating zone to form a residue land a plurality lof condensatescomprising gas oil,y heavynaphtha and light naphtha; subjecting said residue toa decomposition temperature to eiect formation of a high yield of gas oil components and a low yield of gasoline components,

fractionating the .resulting products in a second fractionating zone to forma residue and a plu` rality of condensates comprising heavy gas' oil,.

light fgas oil and gasoline; subjecting heavy gas oil in a first catalytic cracking zone and in the presence of a cracking catalyst toa conversion temperature under catalytic `cracking conditions to effect the formation of a high yield of gasoline components; blending the gas oil and the light 40: fgas oil, subjecting the resulting blend in a second 7. The process in accordance with claim 6 fur-v 45 a reforming catalyst, to a conversion temperature comprising fractionating said hydrocarbon mix-' ture in a first fractionating zone to form a resl.

due'and a plurality of condensates comprising lgas oil, heavy naphtha and light `naphtlia; sub- -jecting said residue toa decomposition temperature to effect formation of a high yield of light gas oil componentsand a low yield of gasoline` components, fractionating the resulting products in, a second fractionating zone to form a residue gas oilandgasoline; blending",y the gas oil and the light gas oil,;subjecting the blend, in the ,presence of a' cracking `cata1yst,to a conversion temperature under catalytic cracking'conditions to effect the formation of a high yield-of gasoline compo.

nents, fractionat-lng' catalytically cracked products in a third fractionating zoneto form a residue and a condensate comprising gasoline; blending the heavy naphtba andhydrogen from a source hereinafter described subjecting-the blend.,

inthe presence of a reforming catalyst, to a conversiontemperature under catalytic reforming '7 -and a plurality of condensates comprising light catalytic cracking zone and in the presence of a' cracking Icatalyst, to a conversion temperature under catalytic cracking conditions to effect the x formation of a highlyieid of gasoline components, fractionating catalytically cracked products from both catalytic cracking zones in a third fractionating zone to form a residue and a condensate -comprising gasoline; blending the heavy naphtha and hydrogen from a source hereinafter .described, vsubjecting the blend in thel presence of under catalytic reforming conditions to effect the formation of a high yield of aromatics within the usual motor fuel boiling range and hydrogen; fractionating 'catalytically reformed products'in a fourth fractionating zone to form acondensate comprising aromatics boiling within the usual motor fuel, range and a gas comprising hydrogen; recycling a portion of said hydrogen to the cata.-

lytic reforming zone; subjecting the residue from `said third fractionating zone lin the presence of a hydrogenation catalyst and a portion of the aforementionedgas comprising hydrogento a conversion temperature under lhydrogenating conditions to effect the upgrading of said residue, n

and vpassing'upgraded residue to the first fractionation zone. o

11'. The process in accordance with claim- 10, further characterized by the fact that said gasoline from theisecond fractionating zone is catalytically reformed in admixture with the heavy naphtha from the first fractionation zone.'v

l12. In the conversion of a hydrocarbon mixture of wide boilingrage into hydrocarbons boiling within theusual motor-fuel 'range,'the yprocess comprising fractionating said hydrocarbon mixture in -a first fractionating zone to form a residue and a plurality of condensates comprising gas oil, heavy naphtha and light naphtha; subjecting said residue to a decomposition temperature to effect formation of a high yield of gas oil compo-V nents and a small yield of gasoline components, fractonating the resulting products in a second fractionating zone to form a residue and a plurality of condensates comprising heavy gasoil, light gas oil and gasoline; subjecting heavy gas oil in a iirst catalytic cracking zone and in the presence of a cracking catalyst, to a conversion temperature under catalytic cracking conditions to effect the formation-of a high yield of gasoline components, fractionating the catalytically cracked products in a. third fractionating zone to form a residue and a condensate comprising gasoline; blending the gas oil and the light gas oil, subjecting the resulting blend in a second catalytic cracking zone and in thepresence of a cracking catalyst, to a conversion temperature described, subjecting the blend in the presence of a reforming catalyst, to a conversion temperature under catalytic reforming conditions to eifect the formation of a high yield of aromatics within the usual motor fuel boilingl range and hydrogen, fractionating catalytically reformed products in a fifth fractionation zone toform a condensate comprising aromatics within the usual motor fuel Iboilingrange and a gas comprising hydrogen;

. recycling a portion of said hydrogen to the cataunder catalytic cracking conditions to effect the formation of a high yield of gasoline components, fractionating catalytically cracked products from the second catalytic cracking zone in a fourth fractionating zone to form a residue and a conlytic reforming zone; blending the residues from said third and fourth fractionating zones, subjecting the blend in the presence of a hydrogenation catalyst and a portion of the aforementioned gas comprising hydrogen to a conversion tem/perature under hydrogenating conditions to effect the upgrading of said residues and passing the upgraded residues to the rst fractionating zone. 13. The process in accordance with claim l2, further characterized by the fact that said gasoline from the second fractionation zone is catalytically reformed in admixture with the heavy naphtha from the first fractionating zone.

ROBERT RUTHRUFF.

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