Patent ID: 7419585

Claim:
A process for upgrading a residua feedstock having a Conradson Carbon content of from about 5 to 55 wt % to produce an increase in total liquid products in a process unit comprising (i) a heating zone wherein solids containing carbonaceous deposits are received from a stripping zone and heated in the presence of an oxidizing gas; (ii) a short vapor contact time reaction zone containing a horizontal moving bed of fluidized hot solids recycled from the heating zone, which reaction zone is operated at a temperature from about 450° C. to about 700° C. and operated under conditions such that substantially all of the solids that are passed from the heating zone pass through the reaction zone and wherein the solids residence time is from about 5 to about 60 seconds, and the vapor residence time is less than about 4 seconds; and wherein said reaction zone is fluidized by a mechanical means comprised of one or more horizontally disposed screws within the reactor; and (iii) a stripping zone through which solids having carbonaceous deposits thereon are passed from the reaction zone and wherein lower boiling hydrocarbons and volatiles are recovered with a stripping gas; said process comprising the steps: (a) atomizing the residua feedstock so that the residua feedstock has a liquid droplet size between about 300 μm to about 1400 μm Sauter mean diameter; (b) fluidizing hot solids particle size between about 150 μm to 2800 μm Sauter mean diameter, wherein the ratio of fluidized hot solids particle size to feed liquid droplet size is between 0.5 to 2.0; (c) passing the atomized liquid residua feedstock to the short vapor contact time reaction zone where it contacts the fluidized hot solids, thereby resulting in high Conradson Carbon components and metal-containing components being deposited onto said hot solids, and a vaporized fraction; (d) separating the vaporized fraction from the solids; (e) passing the solids to said stripping zone where they are contacted with a stripping gas, thereby removing volatile components therefrom; (f) passing the stripped solids to a heating zone where they are heated to an effective temperature that will maintain the operating temperature of the reaction zone; and (g) recycling hot solids from the heating zone to the reaction zone such that substantially all of the solids that are passed from the heating zone pass through the reaction zone and where they are contacted with fresh feedstock.