The present disclosure is directed to the upgrading of heavy hydrocarbon feedstock. The systems of the present disclosure provides for improved reactor geometries to create more efficient processing and upgrading of the feedstocks. The reactor geometry may be varied by the addition of periodic bumps on the reactor walls and/or by the tapering of the diameter of the upflow reactor.

A process for thermally cracking a fuel, said process comprising the steps ofon a solid carrier in a first reaction cracking fuel thereby producing Hydrogen and Carbon speciesin a second reaction combusting said Carbon on the solid carrier wherein the first and second reaction is carried out in at least one fluidized bed.

A fluid coking unit for converting a heavy oil feed to lower boiling products by thermal has a centrally-apertured annular baffle at the top of the stripping zone below the coking zone to inhibit recirculation of solid particles from the stripping zone to the coking zone. By inhibiting recirculation of the particles from the stripping zone to the coking zone, the temperatures of the two zones are effectively decoupled, enabling the coking zone to be run at a lower temperature than the stripping zone to increase the yield of liquid products.

A fluid coking unit for converting a heavy oil feed to lower boiling products by thermal has a centrally-apertured annular baffle at the top of the stripping zone below the coking zone to inhibit recirculation of solid particles from the stripping zone to the coking zone. By inhibiting recirculation of the particles from the stripping zone to the coking zone, the temperatures of the two zones are effectively decoupled, enabling the coking zone to be run at a lower temperature than the stripping zone to increase the yield of liquid products.

Present invention relates to a novel process for upgrading a residual hydrocarbon oil feedstock having a significant amount of Conradson Carbon Residue (concarbon), metals, especially vanadium and nickel, asphaltenes, sulfur impurities and nitrogen to a lighter more valuable hydrocarbon products by reducing or minimizing coke formation and by injecting fine droplets of oil soluble organo-metallic compounds at multiple elevations of the riser with varying dosing rates.

Implementations of the disclosed subject matter provide a process for upgrading refinery residue feedstock. Step a) may include introducing the refinery residue feedstock into a fluidized bed reactor as a solid. In step b), the refinery residue feedstock may be heated to a devolatilizing and thermal cracking temperature in the fluidized bed reactor to produce a product stream comprising gaseous hydrocarbons and solid coke. The gaseous hydrocarbons may be subjected to catalytic hydroprocessing, in step c), in the presence of molecular hydrogen to increase the hydrogen to carbon ratio and lower the average molecular weight of the gaseous hydrocarbons. In step d), the gaseous hydrocarbons may be separated from the solid coke. In step e), the gaseous hydrocarbons from step d) may be subjected to further processing to produce at least one of: C1-C3 hydrocarbons, liquefied petroleum gas, naphtha range hydrocarbons, and middle distillate range hydrocarbons.

Implementations of the disclosed subject matter provide a process for upgrading refinery residue feedstock. Step a) may include introducing the refinery residue feedstock into a fluidized bed reactor as a solid. In step b), the refinery residue feedstock may be heated to a devolatilizing and thermal cracking temperature in the fluidized bed reactor to produce a product stream comprising gaseous hydrocarbons and solid coke. The gaseous hydrocarbons may be subjected to catalytic hydroprocessing, in step c), in the presence of molecular hydrogen to increase the hydrogen to carbon ratio and lower the average molecular weight of the gaseous hydrocarbons. In step d), the gaseous hydrocarbons may be separated from the solid coke. In step e), the gaseous hydrocarbons from step d) may be subjected to further processing to produce at least one of: C1-C3 hydrocarbons, liquefied petroleum gas, naphtha range hydrocarbons, and middle distillate range hydrocarbons.

A fluid coking operation for converting bitumen to lighter hydrocarbons can be controlled or monitored using a stripper fouling indicator to mitigate foulant accumulation on the sheds of the stripper within the lower section of the coker and avoid flooding. The stripper fouling indicator can be linked to the liquid carry-under to the stripper which can be correlated to certain measurable variables such as which feed nozzles are used for bitumen injection, solids circulation rate of the coke particles, and reactor temperature. The coking can be kept below the stripper fouling indicator to avoid flooding while operating with high yield and performance.

A fluid coking operation for converting bitumen to lighter hydrocarbons can be controlled or monitored using a stripper fouling indicator to mitigate foulant accumulation on the sheds of the stripper within the lower section of the coker and avoid flooding. The stripper fouling indicator can be linked to the liquid carry-under to the stripper which can be correlated to certain measurable variables such as which feed nozzles are used for bitumen injection, solids circulation rate of the coke particles, and reactor temperature. The coking can be kept below the stripper fouling indicator to avoid flooding while operating with high yield and performance.

Processes for upgrading a hydrocarbon-containing feed. The feed and a first particle stream can be contacted under pyrolysis conditions to effect pyrolysis of the feed to produce a pyrolysis effluent that can include olefins and the particles, where coke can be formed on the particles. A first gaseous stream and a second particle stream can be obtained from the pyrolysis effluent. At least a portion of the first gaseous stream can be contacted with oligomerization catalyst particles under oligomerization conditions to effect oligomerization of at least a portion of olefins in the first gaseous stream.