Coking, fluidized bed

Anthony EJ, Jia L, Burwell SM, Najman J, Bulewicz EM (2006) Understanding the Behavior of Calsium Compounds in Petroleum Coke Fluidized Bed Combustion (FBC) Ash. journal of Energy Resources Technology 128 290-299... 

Fluid Coking", developed in 1953. The reaction proceeds at atmospheric pressure, at about SOO-SSOT, in a reactor whose feed is mixed in a fluidized bed of hot coke which maintains the desired temperature. 

Carbochlorination. Milled zircon and coke are reacted with hot chlorine gas in a fluidized bed using chlorine as the fluidizing medium ... 

Fluid coking (Fig. 4) is a continuous process that uses the fluidized soflds technique to convert atmospheric and vacuum residua to more valuable products (12,13). The residuum is converted to coke and overhead products by being sprayed into a fluidized bed of hot, fine coke particles, which permits the coking reactions to be conducted at higher temperatures and shorter contact times than they can be in delayed coking. Moreover, these conditions result in decreased yields of coke greater quantities of more valuable Hquid product are recovered in the fluid coking process. 

The chlorination is mostly carried out in fluidized-bed reactors. Whereas the reaction is slightly exothermic, the heat generated during the reaction is not sufficient to maintain it. Thus, a small amount of oxygen is added to the mixture to react with the coke and to create the necessary amount of heat. To prevent any formation of HCl, all reactants entering the reactor must be completely dry. At the bottom of the chlorination furnace, chlorides of metal impurities present in the titanium source, such as magnesium, calcium, and zircon, accumulate. 

Fig. 27. A Flexicoking unit combining fluid coking and gasification using three-bed fluidized beds.

Chloride Process. In the chloride process (Fig. 3), a high grade titanium oxide ore is chlorinated in a fluidized-bed reactor in the presence of coke at 925-1010°C ... 

Na2B0402 10H2O, and cmde oil residue (41) in a rotary kiln heated to 1038°C. Borax is fed at the rate of 1360 kg/h and sprayed with 635 kg/h of 17% residue cmde oil. The heated mixture then reacts with CI2 at 760°C in a separate reactor to yield BCl. On a smaller scale, BCl can be prepared by the reaction of CI2 and a mixture of boron oxide [1303-86-2] 2 3 coke, and lampblack in a fluidized bed (42). Other methods for the preparation... 

Hydrogen sulfide and carbon react at 900°C to give a 70% yield of carbon disulfide (102,103). A process for reaction of coke and hydrogen sulfide or sulfur in an electric-resistance-heated fluidized bed has been demonstrated on a laboratory scale (104). Hydrogen sulfide also forms carbon disulfide in reactions with carbon monoxide at 600—1125°C (105) or carbon dioxide at 350—450°C in the presence of catalysts (106). 

Exxon was the first to investigate the suitabiUty of a wide range of different U.S. coals for conversion. Operation of the EDS process was demonstrated in a 230 t/d unit in Baytown, Texas that had a start-up in May of 1980. Data on the response of a variety of coals to once-through and bottoms recycle operations are shown in Eigure 4. Eigure 5 presents typical Hquefaction product distributions for the system operated both with and without the Elexicoking (fluidized-bed coking) option. 

The fluohmic process is a third process for manufacturing hydrogen cyanide, which is being appHed in Spain and AustraUa. This process involves the reaction of ammonia with a hydrocarbon, usually propane or butane, in a fluidized bed of coke particles. The endothermic heat of reaction is suppHed electrically through electrodes immersed in the fluid bed. Yields from propane and ammonia are reportedly above 85% and the waste gas is essentially hydrogen, but the costs for electricity are high. Thus this process is appHcable only when there is an inexpensive source of power. 

The Fischer-Tropsch reaction is highly exothermic. Therefore, adequate heat removal is critical. High temperatures residt in high yields of methane, as well as coking and sintering of the catalyst. Three types of reac tors (tubular fixed bed, fluidized bed, and slurry) provide good temperature control, and all three types are being used for synthesis gas conversion. The first plants used tubular or plate-type fixed-bed reactors. Later, SASOL, in South Africa, used fluidized-bed reactors, and most recently, slurry reactors have come into use. 

Ammonium sulfate is produced as a caprolactam by-product from the petrochemical industry, as a coke by-product, and synthetically through reaction of ammonia with sulfuric acid. Only the third process is covered in our discussion. The reaction between anunonia and sulfuric acid produces an ammonium sulfate solution that is continuously circulated through an evaporator to thicken the solution and to produce ammonium sulfate crystals. The crystals are separated from the liquor in a centrifuge, and the liquor is returned to the evaporator. The crystals are fed either to a fluidized bed or to a rotary drum dryer and are screened before bagging or bulk loading. 

In the fluid coking process, part of the coke produced is used to provide the process heat. Cracking reactions occur inside the heater and the fluidized-bed reactor. The fluid coke is partially formed in the heater. Hot coke slurry from the heater is recycled to the fluid reactor to provide the heat required for the cracking reactions. Fluid coke is formed by spraying the hot feed on the already-formed coke particles. Reactor temperature is about 520°C, and the conversion into coke is immediate, with... 

FIGURE 6.9 Flexicoking is a commercial process for refining petroleum that has been applied to heavy oil and tar sand fractions. The process employs circulating fluidized beds and operates at moderate temperatures and pressures. The reactor produces liquid fuels and excess coke. The latter is allowed to react with a gas-air mixture in the gasifier fluidized bed to provide a low-value heating gas that can be desulfurized and used as a plant fuel. Courtesy, Exxon Research and Engineering Company. 

Three different types of furnaces are generally in use for calcination. The shaft furnace is considered to be the most suited for calcining coarse limestone. Furnaces of the rotary kiln type are used for handling materials of mixed particle sizes and lumps which disintegrate during the process. Calcination can be carried out in a fluidized bed-reactor for materials of small and uniform particle size. These furnaces are usually fired with gas, oil or coke in some cases electric heating is resorted to. 

This process involves the reaction of dried rutile ore and coke with chlorine in the chlorinator to produce titanium tetrachloride. The liquefied titanium tetrachloride is sent to the distillation unit to remove impurities and then to a fluidized bed reactor to react with oxygen to form titanium dioxide and chlorine. Solid titanium dioxide formed at this stage is vacuum degassed before being treated... 

Combifining A petroleum refining process which removes asphaltenes, sulfur, and metals from residues, before further treatment. The catalyst is an activated petroleum coke in a fluidized bed, operated under hydrogen pressure at 380 to 420°C. 

KK [Kunugi and Kunii] A process for cracking crude petroleum or heavy oil in a fluidized bed, using coke as the heat carrier. Developed originally by Kunigi and Kunii, subsequently improved by the Japanese Agency of Industrial Science with five Japanese companies. Piloted between 1979 and 1982. 

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