The focus of this invention is the economic integration of two well-known technologies to provide an economical, integrated process unit for the complete conversion of residue feedstock. The technologies employed are heavy oil hydrocracking, which can be via an ebullated-bed, fixed-bed or slurry bed process, and coking, which can be via a delayed coking or fluid coking (with or without integrated gasification). The invention is most applicable to residue hydrocracking of high CCR and metals atmospheric and vacuum residues where coking of the unconverted hydrocracker residue is the most practical and economical method of hydrocracking bottoms disposal.

Reactor for recovery or recycling of hydrocarbon products from hydrocarbon-containing material by decomposing and gasifying the material in a reactor housing, comprising a gas/particle separator device arranged to separate solid particles accompanying the gas and to return these particles directly to the reactor housing in the opposite direction to axially flowing gasified hydrocarbon products, and/or comprising a rotor shaft with axially running channels which are in flow communication with a coolant, and/or comprising a radial play formed between the periphery of a rotor and the inside of the reactor housing and amounting to at least 3 cm and at most 6 cm.

Reactor for recovery or recycling of hydrocarbon products from hydrocarbon-containing material by decomposing and gasifying the material in a reactor housing, comprising a gas/particle separator device arranged to separate solid particles accompanying the gas and to return these particles directly to the reactor housing in the opposite direction to axially flowing gasified hydrocarbon products, and/or comprising a rotor shaft with axially running channels which are in flow communication with a coolant, and/or comprising a radial play formed between the periphery of a rotor and the inside of the reactor housing and amounting to at least 3 cm and at most 6 cm.

A fluidized bed coking reactor apparatus comprises a reaction vessel; a temperature sensor inside the reaction vessel for measuring a reactor temperature, a solids feed mechanism for feeding solid particles into the reactor vessel at a mass flow rate, a feed material feed mechanism for feeding feed material into the reactor at an operating feed rate; and a supervisory controller programmed to determine an upper feed material feed rate of the reactor when operating at the reactor temperature and receiving solid particles at the mass flow rate. The upper feed material feed rate is defined as a feed rate of feed material deposited onto a selected fraction of a fluidized bed of solid particles that causes defluidization in the reactor when the reactor is operating under conditions having a selected degree of backmixing in the fluidized bed, wherein the degree of backmixing is modeled as a selected number of reactors arranged in series and each operating under continuous well-mixed conditions, with the selected number of reactors being an integer between one and infinity.

A fluidized bed coking reactor apparatus comprises a reaction vessel; a temperature sensor inside the reaction vessel for measuring a reactor temperature, a solids feed mechanism for feeding solid particles into the reactor vessel at a mass flow rate, a feed material feed mechanism for feeding feed material into the reactor at an operating feed rate; and a supervisory controller programmed to determine an upper feed material feed rate of the reactor when operating at the reactor temperature and receiving solid particles at the mass flow rate. The upper feed material feed rate is defined as a feed rate of feed material deposited onto a selected fraction of a fluidized bed of solid particles that causes defluidization in the reactor when the reactor is operating under conditions having a selected degree of backmixing in the fluidized bed, wherein the degree of backmixing is modeled as a selected number of reactors arranged in series and each operating under continuous well-mixed conditions, with the selected number of reactors being an integer between one and infinity.

A variety of systems and methods are disclosed, including, in one embodiment, a method of performing coking on a combined feed, comprising: combining a resin feedstock with a coker feedstock comprising a T10 distillation point of about 343 C. or higher to form a combined feedstock, wherein the resin feedstock comprises a thermoset resin having a median particle size of about 5 mm or less; and exposing at least a portion of the combined feedstock to coking conditions in a coking reactor to form at least coke and a coker effluent.

A variety of systems and methods are disclosed, including, in one embodiment, a method of performing coking on a combined feed, comprising: combining a resin feedstock with a coker feedstock comprising a T10 distillation point of about 343 C. or higher to form a combined feedstock, wherein the resin feedstock comprises a thermoset resin having a median particle size of about 5 mm or less; and exposing at least a portion of the combined feedstock to coking conditions in a coking reactor to form at least coke and a coker effluent.

Systems and methods are provided for integrated coking and gasification of a biomass feed in a three-vessel fluidized coking system under co-processing conditions so that biomass is co-fed with a conventional and/or mineral coker feed, such as a feed containing resid or heavy crude oil. It has been discovered that co-processing of a biomass feed can unexpectedly increase the reaction rate for coking of the conventional/mineral coker feed. This unexpected increase in reaction rate can allow for modification of how the three-vessel fluidized coking reaction system is operated. The resulting modification in operating conditions can allow for production of a modified and/or improved product slate from the fluidized coker. The modifications in the product slate can include an increase in total liquid products as well as a decrease in micro carbon residue and/or n-heptane insolubles in the total liquid products.

Systems and methods are provided for integrated coking and gasification of a biomass feed in a three-vessel fluidized coking system under co-processing conditions so that biomass is co-fed with a conventional and/or mineral coker feed, such as a feed containing resid or heavy crude oil. It has been discovered that co-processing of a biomass feed can unexpectedly increase the reaction rate for coking of the conventional/mineral coker feed. This unexpected increase in reaction rate can allow for modification of how the three-vessel fluidized coking reaction system is operated. The resulting modification in operating conditions can allow for production of a modified and/or improved product slate from the fluidized coker. The modifications in the product slate can include an increase in total liquid products as well as a decrease in micro carbon residue and/or n-heptane insolubles in the total liquid products.

Systems and methods are provided for co-processing plastic waste in a coker as part of an integrated refinery environment that produces kerosene, jet fuel, and/or jet fuel blending components as a product. The co-processing can be performed in a fluidized coker, a delayed coker, or a combination of fluidized cokers and delayed cokers. After coking, hydroprocessing can be performed on one or more portions of the coker effluent that contribute to formation of the kerosene, jet fuel, and/or jet fuel blending component product(s). The hydroprocessing can be used to reduce or minimize the presence of unexpected nitrogen contaminants in the resulting kerosene, jet fuel, and/or jet fuel blending component product(s).