AU2010235874B2 - Hydrotreating processes for fabricating petroleum distillates from light fischer-tropsch liquids - Google Patents

Hydrotreating processes for fabricating petroleum distillates from light fischer-tropsch liquids Download PDF

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AU2010235874B2
AU2010235874B2 AU2010235874A AU2010235874A AU2010235874B2 AU 2010235874 B2 AU2010235874 B2 AU 2010235874B2 AU 2010235874 A AU2010235874 A AU 2010235874A AU 2010235874 A AU2010235874 A AU 2010235874A AU 2010235874 B2 AU2010235874 B2 AU 2010235874B2
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hydrogenation
lftl
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Peter Kokayeff
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Honeywell UOP LLC
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    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10GCRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G45/00Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds
    • C10G45/02Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to eliminate hetero atoms without changing the skeleton of the hydrocarbon involved and without cracking into lower boiling hydrocarbons; Hydrofinishing
    • C10G45/04Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to eliminate hetero atoms without changing the skeleton of the hydrocarbon involved and without cracking into lower boiling hydrocarbons; Hydrofinishing characterised by the catalyst used
    • C10G45/10Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to eliminate hetero atoms without changing the skeleton of the hydrocarbon involved and without cracking into lower boiling hydrocarbons; Hydrofinishing characterised by the catalyst used containing platinum group metals or compounds thereof
    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10GCRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G2/00Production of liquid hydrocarbon mixtures of undefined composition from oxides of carbon
    • C10G2/30Production of liquid hydrocarbon mixtures of undefined composition from oxides of carbon from carbon monoxide with hydrogen
    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10GCRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G3/00Production of liquid hydrocarbon mixtures from oxygen-containing organic materials, e.g. fatty oils, fatty acids
    • C10G3/42Catalytic treatment
    • C10G3/44Catalytic treatment characterised by the catalyst used
    • C10G3/45Catalytic treatment characterised by the catalyst used containing iron group metals or compounds thereof
    • C10G3/46Catalytic treatment characterised by the catalyst used containing iron group metals or compounds thereof in combination with chromium, molybdenum, tungsten metals or compounds thereof
    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10GCRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G3/00Production of liquid hydrocarbon mixtures from oxygen-containing organic materials, e.g. fatty oils, fatty acids
    • C10G3/42Catalytic treatment
    • C10G3/44Catalytic treatment characterised by the catalyst used
    • C10G3/47Catalytic treatment characterised by the catalyst used containing platinum group metals or compounds thereof
    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10GCRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G3/00Production of liquid hydrocarbon mixtures from oxygen-containing organic materials, e.g. fatty oils, fatty acids
    • C10G3/42Catalytic treatment
    • C10G3/44Catalytic treatment characterised by the catalyst used
    • C10G3/48Catalytic treatment characterised by the catalyst used further characterised by the catalyst support
    • C10G3/49Catalytic treatment characterised by the catalyst used further characterised by the catalyst support containing crystalline aluminosilicates, e.g. molecular sieves
    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10GCRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G3/00Production of liquid hydrocarbon mixtures from oxygen-containing organic materials, e.g. fatty oils, fatty acids
    • C10G3/50Production of liquid hydrocarbon mixtures from oxygen-containing organic materials, e.g. fatty oils, fatty acids in the presence of hydrogen, hydrogen donors or hydrogen generating compounds
    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10GCRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G45/00Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds
    • C10G45/02Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to eliminate hetero atoms without changing the skeleton of the hydrocarbon involved and without cracking into lower boiling hydrocarbons; Hydrofinishing
    • C10G45/04Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to eliminate hetero atoms without changing the skeleton of the hydrocarbon involved and without cracking into lower boiling hydrocarbons; Hydrofinishing characterised by the catalyst used
    • C10G45/06Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to eliminate hetero atoms without changing the skeleton of the hydrocarbon involved and without cracking into lower boiling hydrocarbons; Hydrofinishing characterised by the catalyst used containing nickel or cobalt metal, or compounds thereof
    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10GCRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G45/00Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds
    • C10G45/02Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to eliminate hetero atoms without changing the skeleton of the hydrocarbon involved and without cracking into lower boiling hydrocarbons; Hydrofinishing
    • C10G45/04Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to eliminate hetero atoms without changing the skeleton of the hydrocarbon involved and without cracking into lower boiling hydrocarbons; Hydrofinishing characterised by the catalyst used
    • C10G45/12Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to eliminate hetero atoms without changing the skeleton of the hydrocarbon involved and without cracking into lower boiling hydrocarbons; Hydrofinishing characterised by the catalyst used containing crystalline alumino-silicates, e.g. molecular sieves
    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10GCRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G65/00Treatment of hydrocarbon oils by two or more hydrotreatment processes only
    • C10G65/02Treatment of hydrocarbon oils by two or more hydrotreatment processes only plural serial stages only
    • C10G65/04Treatment of hydrocarbon oils by two or more hydrotreatment processes only plural serial stages only including only refining steps
    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10GCRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G2300/00Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
    • C10G2300/10Feedstock materials
    • C10G2300/1022Fischer-Tropsch products
    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10GCRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G2300/00Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
    • C10G2300/20Characteristics of the feedstock or the products
    • C10G2300/30Physical properties of feedstocks or products
    • C10G2300/304Pour point, cloud point, cold flow properties
    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10GCRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G2300/00Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
    • C10G2300/20Characteristics of the feedstock or the products
    • C10G2300/30Physical properties of feedstocks or products
    • C10G2300/307Cetane number, cetane index
    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10GCRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G2400/00Products obtained by processes covered by groups C10G9/00 - C10G69/14
    • C10G2400/04Diesel oil
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P30/00Technologies relating to oil refining and petrochemical industry
    • Y02P30/20Technologies relating to oil refining and petrochemical industry using bio-feedstock

Abstract

A system for obtaining a petroleum distillate product comprising: a first hydrogenating unit that subjects an untreated light Fischer-Tropsch liquid to a first hydrogenation and yields a hydrotreated light Fischer-Tropsch liquid composite; and a second 5 hydrogenating unit that subjects the hydrotreated light Fischer-Tropsch liquid composite to a second hydrogenation and yields the petroleum distillate product

Description

P/on/01i1 Regulation 3.2 AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION FOR A DIVISIONAL PATENT ORIGINAL Name of Applicant: UOP LLC Actual Inventor: Peter KOKAYEFF Address for Service: Houlihan 2 , Level 1, 70 Doncaster Road, Balwyn North, Victoria 3104, Australia invention Title: HYDROTREATING PROCESSES FOR FABRICATING PETROLEUM DISTILLATES FROM LIGHT FISCHER TROPSCH LIQUIDS The following statement is a full description of this invention, including the best method of performing it known to HYDROTREATING PROCESSES FOR FABRICATING PETROLEUM DISTILLATES FROM LIGHT FISCHER-TROPSCH LIQUIDS The present application is a divisional application from Australian patent 5 application number 2008207432. The entire disclosure of" Australian patent application number 2008207432 is incorporated herein by reference. TECHNICAL FIELD [0001] This disclosure relates generally to the processes of fabricating various petroleum based fuels, and more specifically, to hydrogenation processes for obtaining petroleum 10 distillate from light Fischer-Tropsch liquids. BACKGROUND INFORMATION [0002] Fischer-Tropsch synthesis is known to yield a broad mixture of products including primarily paraffins, and some olefins. The individual compounds of such mixture can contain up to 200 carbons, the number of carbons between 20 and 150, with average 15 number 60 being typical. Certain quantities of oxygenated products and trace amounts of sulfur- or nitrogen containing products or aromatic compounds can be also present. [0003] Some Fischer-Tropsch processes yield mixtures enriched with ( 5
-C
30 alkanes and also containing a significant quantity of olefins and oxygenated compounds such as alcohols or acids. Such mixtures are known as "light Fischer-Tropsch liquids" or 20 "LFTL." Light Fischer-Tropsch liquids are frequently used as a raw material for obtaining various petrochemical products, such as, e.g., petroleum distillates, or diesel fuels, among others. [0004] To make LFTL useful and suitable as blending stock for diesel fuel, olefins and oxygenated compounds contained therein are removed, typically by the saturation of 25 olefins and by conversion of oxygenated compounds into water via hydrogenation also known as hydrotreating, which involves the processes of hydrogenation of LFTL in the presence of hydrogen and a catalyst. -2- [0005] Despite its many advantages, hydrotreating of LFTL is characterized by a number of drawbacks and deficiencies. For example, the process usually requires using very high pressures and temperatures. In addition, while traditional hydrotreating does allow for removal of olefins and oxygenated compounds, the final product often has a cloud point 5 that is too high, limiting the amount of the product that can be blended into diesel fuels. [0006] To avoid or lessen the effects of the above-mentioned deficiencies, as well as for the purposes of improvement of the overall process efficiency, better processes are needed to be used with light Fischer-Tropsch liquids. SUMMARY 10 [0007] We provide a system for obtaining a petroleum distillate that subjects an untreated light Fischer-Tropsch liquid to a first hydrogenation and yields a hydrotreated light Fischer-Tropsch liquid composite, and a second hydrogenating unit that subjects the hydrotreated light Fischer-Tropsch liquid composite to a second hydrogenation and yields the petroleum distillate product. 15 [0008] In one embodiment, the system further comprises a device that maintains pressure in each of the first and the second hydrogenating units between 1 and 15 MPa. [0009] In another embodiment, the first hydrogenation unit comprises a catalyst having an amorphous substrate and a first metallic composition embedded therein. [0010 In another embodiment, the first metallic composition comprises a base metal 20 composition selected from the group consisting of a nickel-molybdenum composition, a cobalt-molybdenum composition, a nickel-tungsten composition, and mixtures thereof [0011] In another embodiment, the first metallic composition comprises a noble metal composition comprising at least one noble metal selected from the group consisting of platinum, palladium, and mixtures thereof. 25 [0012] In another embodiment, the second hydrogenation unit comprises a catalyst having an amorphous substrate and a second metallic composition embedded therein. -3- [0013] In another embodiment, the second metallic composition comprises a base metal composition selected from the group consisting of a nickel-molybdenum composition, a cobalt-molybdenum composition, a nickel-tungsten composition, and mixtures thereof. [0014] In another embodiment, the second metallic composition comprises a noble metal 5 composition comprising at least one noble metal selected from the group consisting of platinum, palladium, and mixtures thereof. BRIEF DESCRIPTION OF THE DRAWINGS [0010] FTG. 1 illustrates schematically a system for hydrogenating of light Fischer Tropsch liquids according to one embodiment of the present invention. 10 [00111 FIG. 2 illustrates schematically a system for hydrogenating of light Fischer Tropsch liquids according to another embodiment of the present invention. DETAILED DESCRIPTION [0012j The following definitions and abbreviations are used below, unless otherwise described: 15 [0013] The term "a light Fischer-Tropsch liquid" or the abbreviation "LFTL" is defined as a mixture comprised of n-paraffins having the number of carbons between 5 and 50, the mixture containing a substantial portion of C 5
-C
3 o alkanes and also containing olefins and oxygenated compounds. [00141 The term "a hydrocarbon" is defined as an organic compound, the molecule of 20 which consists only of carbon and hydrogen. [0015] The terms "a paraffin" and alkanee" are used interchangeably and refer to a hydrocarbon identified by saturated carbon chains, which can be normal (straight), branched, or cyclic ("cycloparaffin"), and described by a general formula CnH 2 1 1
±
2 , where n is an integer. Paraffins or alkanes are substantially free of carbon-carbon double bonds (C=C). -4- [0016] The term "an olefin," also known as "alkene" is defined as a hydrocarbon containing at least one carbon-carbon double bond, and described by a general formula CnH 2 a, where n is an integer. [0017] The terms "hydrogenation" and "hydrotreating" are used interchangeably and refer 5 to a process of addition of hydrogen to unsaturated organic compounds, such as olefins (alkenes), typically, in a presence of a suitable catalyst, to obtain saturated organic compounds, such as alkanes, as a result. [0018] The term "a catalyst" is defined as substance that changes the speed or yield of a chemical reaction without being itself substantially consumed or otherwise chemically 10 changed in the process. [0019] The term "a noble metal" refers to a metal that is highly resistant to corrosion or oxidation, and does not easily dissolve, as opposed to most base metals. Examples include, but are not limited to, platinum, palladium, gold, silver, tantalum, or the like. [00201 The team "a base metal" refers to any non-precious metal that is capable of being 15 readily oxidized. Examples include, but are not limited to, nickel, molybdenum, tungsten, cobalt, or the like. [0021J The term "a bromine index" or "bromine number" indicates the degree of aliphatic unsaturation and is defined as the amount of bromine in grams absorbed by 100 grams of a sample containing an unsaturated compound, such as an olefin. 20 [00221 The term "a cloud point" refers to a temperature at which fuel starts congealing and starts becoming cloudy due to the appearance of wax crystals, when the fuel is tested in accordance with the American Society for Testing and Materials (ASTM) Specification D2500. The cloudiness increases as the temperature is lowered further. 100231 The term "diesel fuel" is defined in accordance with the specifications described in 25 the ASTM Specification D975 and refers to a petroleum fraction having containing primarily
CIO-C
24 hydrocarbons and having distillation temperatures of 16 0 *C at the 10 % recovery point and 340 0 C at the 90 % recovery point. -5- [0024] The term "API gravity" refers to American Petroleum Institute's measure of the density of a petroleum product relative to the density of water. [0025] The abbreviation "WABT" means "weighted bed average temperature" and refers to an average temperature on the bed of catalyst. 5 [0026] The abbreviation "LHSV" means "liquid hourly space velocity" and refers to a ratio between the hourly volume of feedstock used in the process of hydrogenation and the volume of catalyst used. [0027] The abbreviations "IBP" and "EBP" refer to the temperatures that are the initial boiling point of a product and the ending boiling point, respectively. 10 [0028] A petroleum distillate product may be obtained by using a two-stage process of hydrogenation. At the first stage, where most of the hydrotreating occurs, an untreated light Fischer-Tropsch liquid may be subjected to hydrogenation, which includes reacting the untreated LFTL with gaseous hydrogen, at an elevated temperature and elevated pressure, in the presence of a catalyst. During hydrogenation, the olefins that are present in the untreated 15 LFTL react with hydrogen and become saturated by forming alkanes. If the original LFTL contained some quantity of cycloolefins, in addition cycloalkanes may be also formed. As a result, a hydrotreated light Fischcr-Tropsch liquid composite is formed and water is released as a by-product. 10029] The hydrotreated light Fischer-Tropsch liquid composite obtained as described 20 above is then further hydrogenated to complete the process. Again, the second stage of hydrogenation includes reacting the hydrotreated LFTL, at an elevated temperature and elevated pressure, in the presence of a catalyst. Upon the completion of the process of hydrogenation, the final petroleum distillate product may be recovered. The final product is a diesel range material that may be substantially devoid of olefins and oxygenated products 25 and may be suitable for blending with diesel fLels. [00301 Both stages of hydrogenation may be carried out in a hydrotreating unit, or in two separate hydrogenating units, as desired. The temperature at which hydrogenation is carried out may be between 200"C and 370"C, such as 315 0 C. The pressure at which hydrogenation is carried out may be between 1 MPa and 15 MPa, for example, 4 MPa. A desired rate of -6supply of hydrogen gas can be selected. For example, hydrogen gas can be supplied at a rate between 170 and 840 m 3 per 1 m3 of the untreated LFTL at the first stage of hydrogenation or per 1 m 3 of the hydrotreated LFTL at the second stage. [00311 Each stage of hydrogenation can be carried out under the same conditions, such as 5 temperature, pressure, and the rate of hydrogen supply, or under the different conditions so long as the temperature and pressure are within the respective ranges disclosed above. 100321 The process of hydrogenation can be described by the exemplary reaction schemes (1) (for straight-chained olefins such as methylbutene) and (2) (for cycloolefins such as cyclopentene):
CH
3 H3 Catalyst (1) Catalyst + H2 (2) [00331 As can be seen from the reaction schemes (1) and (2), the process of hydrogenation 15 is carried out in the presence of a catalyst. An appropriate catalyst can be selected from a variety of available options known in the art. For example, the catalyst that can be used is a base metal composition, such as a nickel-molybdenum composition, a cobalt-molybdenum composition, or the like. Alternatively, or a noble metal composition comprising, for example, platinum, palladium, or the like can be employed. The same catalyst or different 20 catalysts can be utilized at the first and second stages of hydrogenation as discussed above. [0034J Any LFTL can be used as feedstock as the starting product in the hydrogenation processes described above, including a variety of commercially available light Fischer -7- Tropsch liquids. The starting untreated LFTL may have distillation temperatures of 90"C at the 10 % recovery point and 370*C at the 90 % recovery point. [0035] An acceptable LFTL that can be used may include a substantial quantity of paraffins, which may include one or more straight-chained paraffin(s) and may in addition 5 include at least one branched paraffin. Such straight-chained and branched paraffin(s) are the principal components of the untreated starting LFTL. In addition to straight-chained paraffin and branched paraffin(s) the paraffin composition can farther comprise at least some quantity of cycloparaffin(s). [0036] Furthermore, the starting LFTL may have the contents of olefins that is 10 characterized by the bromine number greater than 10. In addition, the starting LFTL may include a quantity of oxygenated products that is characterized by the total oxygen contents between I mass % and 20 mass %. Not more than just trace amounts of any aromatic compounds, including alkyl aromatic compounds and polyalkyl aromatic compounds, may be present in the original LFTL. 15 10037] The final product of the entire process of hydrogenation can be for blended with diesel fuels and with jet oil, may have the cetane number of at least 50, and may have a cloud point of 5"C or less. 10038] Various systems and apparatuses can be used for conducting our processes. One embodiment of such a system that can be used is shown by FIG. I and can be described as 20 follows. FIG. 1 illustrates the system 100 comprising three hydrotreatment reactors 4, 11, and 19. All three reactors may be the same or different. In the exemplary system 100 shown by FIG. 1, the reactors 4 and 11 may use a nickel/molybdenum catalysts such as KF-647 or KF-846, and the reactor 19 may utilize a platinum/palladium catalyst. The catalysts are described in more detail in the "Examples" portion of the application, below. 25 [00391 The LFTL feed 1 can be mixed with the hydrogen gas 2 that can be supplied at a rate between 170 and 840 m 3 per 1 m 3 of the LFTL. The LFTL/H2 mixture can be then pre heated to the desired temperature (e.g., 200"C and 370"C, such as 315"C) and can be then directed to the first hydrotreatment reactor 4. The process of hydrogenation then occurs inside the reactor 4 and includes the reaction of the LFTL with hydrogen gas on a bed, such -8as a fixed bed, of a catalyst (not shown). As hydrogen is consumed during this process, hydrogen may be replenished from a make-up source of hydrogen 3, and hydrogen provided from this source may contain some amount of H2S. The process may be carried out at a pressure between 1 MPa and 15 MPa, for example, 4 MPa. The required pressure can be 5 generated and maintained using the compressor 7. [0040] The exothermic reactions occurring in reactor 4 may lead to a temperature increase. In order to control the temperature in the reactor the reacting fluid may be cooled (quenched). Such quenching can be achieved by supplying cool hydrogen via the by-pass line 5. Upon completion of this stage of hydrogenation, the partially hydrogenated product 10 then may exit the reactor 4 and be directed into the separator 6, where water is separated as the stream 13. The prodLLct may exit the separator 6 via the line 8, and may then be directed to the second hydrotreatment reactor 11, using the pump 9. [0041] In the second reactor 11, the process of hydrogenation may be continued using additional hydrogen that may be supplied via the line 10. The conditions for the second stage 15 hydrogenation may be the same as those used for the hydrogenation in the reactor 4, as described above. [0042] The hydrogenated product then may exit the reactor 11 and be directed into the separator 12, where water is separated as the stream 13, and the product may exit the separator 12 via the line 14, and may then be directed to the stripper 15, where the H2S gas is 20 removed as the stream 16, and the product may exit the stripper 15 via the line 17, and may then be directed to the third hydrotreatment reactor 19, using the pump 18. [0043] The final stage of the process of hydrogenation then occurs inside the reactor 19 and includes the reaction of the partially treated LFTL with hydrogen gas on a bed, such as a fixed bed, of a catalyst (not shown). As hydrogen is consumed during this process, hydrogen 25 may be replenished from a make up source of hydrogen 20, where hydrogen may be typically free of H2S. The process may be carried out at a pressure between 1 MPa and 15 MPa, for example, 4 MPa. The required pressure can be generated and maintained using the compressor 23. -9- 100441 The exothermic reactions occurring in reactor 19 may lead to a temperature increase. In order to control the temperature in the reactor the reacting fluid may be cooled (quenched). Such quenching can be achieved by supplying cool hydrogen via line 21. Upon completion of this stage of hydrogenation, the partially hydrogenated product then may exit 5 the reactor 19 via the line 22, then may be directed to the separator 24. After the process of separation, the final product can exit the system 100 as the stream 25 and then may be directed to fractionation. [0045] Another embodiment of a system that can be used is shown by FIG. 2 illustrating the system 200 comprising two hydrotreatment reactors 29 and 40. These reactors may be 10 the same or different. In the exemplary system 200 shown by FIG. 2, the reactor 29 may use a nickel/molybdenum catalysts such as KF-647 or KF-846, and the reactor 40 may utilize a platinum/palladium catalyst. 10046] The LFTL feed 26 can be mixed with the hydrogen gas 27 that can be supplied at a rate between 170 and 840 ma per 1 m 3 of the LFTL. The LFTL/H 2 mixture can be then pre 15 heated to the desired temperature (e.g., 200'C and 370*C, such as 315*C) and can be then directed to the first hydrotreatment reactor 29. [0047J The process of hydrogenation then occurs inside the reactor 29 and includes the reaction of the LFTL with hydrogen gas on a bed of a catalyst (not shown). Hydrogen may be replenished from a make-up source of hydrogen 28, and hydrogen supplied from this 20 source may contain some amount of H2S. The process may be carried out at a pressure between 1 MPa and 15 MPa, for example, 4 MPa. The required pressure can be generated and maintained using the compressor 33. [0048j The exothermic reactions occurring in reactor 29 may lead to a temperature increase. In order to control the temperature in the reactor the reacting fluid may be cooled 25 (quenched), which can be achieved by supplying cool hydrogen via line 30. The partially hydrogenated product then may exit the reactor 29 and be directed via the line 31 into the separator 32, where water is separated as the stream 37. The product may exit the separator 32 via the line 34, and may then be directed to stripper 35, where the H2S gas is removed as the stream 36. The product may then exit the stripper 35 via the line 38, and may then be 30 directed to the second hydrotreatment reactor 40, using the pump 39. -10-- [00491 A later stage of the process of hydrogenation then occurs inside the reactor 40 and includes the reaction of the partially treated LFTL with hydrogen gas on a bed of a catalyst (not shown). As hydrogen is consumed during this process, hydrogen may be replenished from a make up source of hydrogen 41, where hydrogen may be typically free of H 2 S. The 5 process may be carried out at a pressure between I MPa and 15 MIPa, for example, 4 MPa. The required pressure can be generated and maintained using the compressor 42. [0050] The exothermic reactions occurring in reactor 40 may lead to a temperature increase. In order to control the temperature in the reactor the reacting fluid may be cooled (quenched) by supplying cool hydrogen via the by-pass line 44. Upon completion of this 10 stage of hydrogenation, the partially hydrogenated product then may exit the reactor 40 via the line 43, then may be directed to the separator 45. After the process of separation, the final product can exit the system 200 as the stream 46 and then may be directed to fractionation. EXAMPLES [0051] The following examples are provided to further illustrate the advantages and 15 features of our processes and systems, but are not intended to limit the scope of this disclosure. EXAMPLE 1. Starting Material [0052] The starting material that was used as a feed in hydrogenation was a commercially available light Fischer-Tropsch liquid and had the properties and characteristics shown in 20 Table 1. In Table 1, the data for distillation temperatures show the boiling temperature at the beginning and the end of the recovery (by mass %) range. For example, the entry "10/20" in the property column and "100/142" in the value column signifies the boiling temperature of 100 C at the 10 % mass recovery point and 142 0 C at the 20 % mass recovery point -11- TABLE 1. Properties of Starting Untreated LFTL Property Value Specific gravity, g/cm3 0.7884 API Gravity 47.98 Sulfur Contents, ppm*), mass Less than 1 Nitrogen Contents, ppm', mass 10 Oxygen Contents, mass % 5.9 Bromine Index 56 Acid Number 25.9 Distillation Temperature"), 0 C IBP/5 21/86 10/20 100/142 30/40 167/190 50/60 418/454 70/80 266/296 90/95 336/373 EBP 469 Contents of Aromatic Compounds, mass % One Ring 0.8 Two Rings 0.2 Three or More Rings 1.5 parts per million determined in accordance with ASTM Specification D2887 5 * determined in accordance with Institute of Petroleum Test IP-391 EXAMPLE 2. Hydrogenation of the Starting LFTL [0053] The starting untreated LFTL described in Example 1 was subjected to hydrogenation. The process was carried out in a two reactor (R-l and R-2) configuration, with the removal of water between reactors. Nickel/molybdenum catalysts KF-647 and KF 10 846 were used in reactors R-1 and R-2, respectively. The catalysts were obtained from Albemarle Corp. of Baton Rouge, LA. -12- 100541 The process yielded hydrotreated LFTL composite. The conditions of the process of hydrogenation are shown in Table 2, and the properties of the product are shown in Table 3. TABLE 2 5 Operating Conditions Used for Hydrogenating LFTL Operating Condition Reactor I (R-1) Reactor 2 (R-2) Pressure, MPa 4.14 4.14 WABT*), *C 316 316 LI-ISV'', hr- 2.5 1.67 Overall LHSV, hr-' 1.00 Recycle Gas to Reactor 1, m' 337 per 1 m9 of LFTL weighted bed average temperature liquid hourly space velocity -13- TABLE 3 Properties of Hydrotreated LFTL Composite Property Value Speci fic Gravity, g/cm- 0.7387 API Gravity 60.04 Hydrogen Contents, mass % 15.39 Bromine Index Less than 10 Oxygen Contents, mass % Less than 0.02 Acid Number 0.005 Distillation Temperature, 0 C TBP/5 -9/66 10/20 88/126 30/40 152/175 50/60 197/218 70/80 255/287 90/95 331/369 EBP 510 Distillation Temperature~, "C IBP/5 48/85 10/20 103/128 30/40 148/167 50/60 189/214 70/80 239/Solidified 90/95 N/A (Solidified) EBP N/A (Solidified) ' determined in accordance with ASTM Specification D2887 **) determined in accordance with ASTM Specification D86, fractions are in volume % 5 [0055] The product obtained as described above and having properties shown in table 3 was then fractionated into two fractions to separate naphtha from diesel fuel. The first fraction (i.e., the naphtha fraction) had the IBP of 149 C, and the second fraction (i.e., the diesel fraction) had the IBP above 149 "C. The properties of the diesel fraction are provided in Table 4. -14- TABLE 4 Properties of the Diesel Fraction (IBP > 149 'C) Property Value API Gravity 53.9 Cloud Point, "C 12.2 Flash Point, "C 57.2 Distillation Temperature% "C IBP/5 168/181 10/20 184/192 30/40 203/216 50/60 232/249 70/80 268/293 90/95 N/A//N/A (Solidified) EBP N/A (Solidified) 9 determined in accordance with ASTM Specification D86, fractions are in volume % [00561 As can be seen from Tables 3 and 4, in the process described above, it was not 5 possible to complete the distillation according to ASTM Specification D86, and the diesel fraction had the cloud point which was quite high (12*C), thus limiting the amount of the hydrotreated LFTL that can be used for blending into a diesel fuel. The following example demonstrates improvement of the process illustrated in Example 2. 10 EXAMPLE 3. Further Processing of the Hydrotreated LFTL Composite [0057] The product described in Table 3, obtained as discussed in Example 2 above (prior to fractionating the hydrotreated LFTL composite into the naphtha and diesel fractions), was further processed by additional hydrogenation, as follows. [00581 The hydrotreated LFTL composite described in Table 3 was hydrogenated over a 15 catalyst comprising 0.45 mass % of platinum and 0.45 mass % of palladium embedded on a support comprising a zeolite. The processing conditions for the process of hydrogenation are described in Table 5. -15- TABLE 5 Conditions for Processing the Hydrotreated LFTL Composite by Hydrogenation over a Platinum/Palladium Catalyst Operating Condition Value Pressure, MPa 6.9 LHSV, hr 4 1.0 Hydrogen Flow, m 3 per 1 m 3 of LFTL 1,011 Temperature, "C" 265.6 291.7 two separate experiments 5 [0059] As can be seen from Table 5, the process of hydrotreating was carried out at two different temperatures. Using the lower temperature, i.e., 265.6*C, may be suitable for improving the quality of the diesel fraction, while using the higher temperature, i.e., 291.7 0 C, may be beneficial if the product is to be used in the manufacturing of jet fuel with enhanced properties. 10 [0060] The product obtained under conditions shown in Table 5 was then fractionated and the light and the heavy naphtha fractions were removed by distillation. The properties of the remaining fraction are provided in Tables 6 and 7. Table 6 shows the properties of the diesel fraction that remained, as obtained after the hydrogenation carried out at the lower hydrogenation temperature of 265.6 0 C. 15 TABLE 6 Properties of the Diesel Fraction After Processing the Hydrotreated LFTL Composite by Hydrogenation over a Platinum/Palladium Catalyst at 265.6 0 C Stream Liquid IBP/85"C 85 0 C/143 0 C 143 0 C/EBP Product Yield, g 9,357 779 1,865 6,642 Yield, mass % N/A 8.4 20.1 71.5 API Gravity 59.8 84.5 69.6 54.6 -16- Specific Gravity, g/cm 3 0.7397 0.6550 0.7036 0.7602 Hydrogen Contents, mass % N/A N/A 15.78 15.33 Flash Point, *C N/A N/A 2. 8 53.9 Cloud Point, "C N/A N/A N/A 3.9 Pour Point, *C N/A N/A N/A -6.1 Viscosity at -20 *C, cSt N/A N/A 1.185 N/A Iron Contents, mass % N/A N/A <0.00002 < 0.00002 Reid Vapor Pressure, Pa N/A N/A 9,928.5 896.3 Micro Research Octane N/A N/A <40 N/A Number Micro Motor Octane N/A N/A < 40 N/A Number Cetane Number N/A N/A N/A 73.7 Distillation Ternperatures', "C IBP -1.1 -9.4 63.9 139.4 5 66.7 17.8 87.2 149.4 10 96.7 30.0 96.7 150.0 20 126.1 33.3 98.3 173.9 30 151.1 35,6 99.4 195.0 40 173.9 56.7 105.6 207.2 50 196.1 67.2 118.9 223.3 60 216.7 69.4 126.7 243.9 70 246.7 70.0 127.8 270.0 80 273.9 70.6 128.9 288.3 90 316.1 70.6 129.4 329.4 95 356.1 87.2 141.1 366.7 EBP 500.6 97.2 149.4 475.6 Distillation Temperatures) "C IBP N/A N/A 103.9 166.7 5 N/A N/A 107.2 178.3 10 N/A N/A 108.3 178.3 20 N/A N/A 109.4 186.7 -17- 30 N/A N/A 111.1 196.1 40 N/A N/A 112.8 208.3 50 N/A N/A 115.0 222.2 60 N/A N/A 117.2 238.3 70 N/A N/A 120.0 257.2 80 N/A N/A 123.3 279.4 90 N/A N/A 127.2 315.6 95 N/A N/A 130.6 N/A EBP N/A N/A 143.9 354.4 Recovery, mass % N/A N/A 98.7 93.9 simulated, determined in accordance with ASTM Specification D2887 **) Engler distillation, determined in accordance with ASTM Specification D86 [0061J As can be seen from the data presented in Table 6, the cloud point has been substantially improved compared with that of the diesel fraction recovered from the 5 hydrotreated LFTL composite (see Table 4 for comparison of the respective cloud points), and the cetane number is quite high. Thus, the diesel fraction characterized in Table 6 may be used for blending with various diesel fuels. It may be also noticed that the difficulties previously experienced with the ASTM D86 distillation were eliminated. 100621 Table 7 shows the properties of the kerosene/jet fuel fraction that remained, as 10 obtained after the hydrogenation carried out at the higher hydrogenation temperature of 291.7 0 C, and demonstrates that the product can be used as a high quality jet fuel blending component. TABLE 7 Properties of the Kerosene/Jet Fuel Fraction After Processing the Hydrotreated LFTL 15 Composite by Hydrogenation over a Platinun/Palladiiun Catalyst at 291.7 0 C Stream Liquid IBP/85 0 C 85*C/135 0 C 135"C/EBP Product Yield, g 4,995 649 1,307 2,965 Yield, mass % N/A 13.2 26.6 60.3 API Gravity 65.1 85.2 70.0 58.3 -18- Specific Gravity, g/cm 3 0.7197 0.6530 0.7022 0.7456 Hydrogen Contents, mass % N/A N/A 15.78 15.44 Total Sulfur Contents, mass ppm N/A N/A <0.05 0.07 Flash Point, *C N/A N/A 1.0 43.0 Cloud Point, C N/A N/A N/A -35.0 Pour Point, *C N/A N/A N/A -57.0 Smoke Point, mm N/A N/A N/A 39 Freeze Point, C N/A N/A N/A -56.6 Viscosity at -20 C, cSt N/A N/A 1.137 3.250 Iron Contents, mass % N/A N/A < 0.00002 < 0.00002 Reid Vapor Pressure, Pa N/A N/A 10,824.8 1,930.5 Micro RON N/A N/A < 40 N/A Micro MON N/A N/A <40 N/A Distillation Temperatures?( OC IBP -22.2 -12.2 63.3 123.3 5 33.9 16.7 85.0 140.6 10 72.8 18.3 87.2 142.3 20 97.8 32.2 97.2 151.1 30 117,8 34.4 98.9 165.0 40 131.7 52.8 100.0 174.4 50 151.7 57.2 115.0 186.7 60 167.8 66.1 117.8 196.7 70 187.2 68.3 125.6 208.3 80 205.0 69.4 127.2 221.1 90 227.8 70.0 128.3 238.9 95 245.0 83.9 131.1 253.9 EBP 286.7 95.6 148.9 286.1 Distillation Temperatures, *C IBP N/A N/A 101.1 156.1 5 N/A N/A 103.9 164.4 10 N/A N/A 105.0 163.9 -19- 20 N/A N/A 106.7 168.3 30 N/A N/A 107.8 172.2 40 N/A N/A 109.4 177.2 50 N/A N/A 111.1 184.4 60 N/A N/A 113.3 191.7 70 N/A N/A 116.1 201.1 80 N/A N/A 119.4 2122 90 N/A N/A 123.9 229.4 95 N/A N/A 128.3 247.2 EBP N/A N/A 141.1 248.3 Recovery, mass % N/A N/A 97.0 95.8 simulated, determined in accordance with ASTM Specification D2887 **) Engler distillation, determined in accordance with ASTM Specification D86 [00631 Although our methods and systems have been described with reference to the above-discussed reactions and structures, it will be understood that modifications and 5 variations are encompassed within the spirit and scope of the disclosure as defined in the appended claims. -20-

Claims (6)

  1. 2. The system of claim 1, further comprising a device that maintains pressure in each of 10 the first and the second hydrogenating units between 1 and 15 MPa.
  2. 3. The system of claim 1 or claim 2, wherein the first hydrogenation unit comprises a catalyst having an amorphous substrate and a first metallic composition embedded therein.
  3. 4. The system of claim 3, wherein the first metallic composition comprises a base metal 15 composition selected from the group consisting of a nickel-molybdenum composition, a cobalt-molybdenum composition, a nickel-tungsten composition, and mixtures thereof
  4. 5. The system of claim 3 or claim 4, wherein the first metallic composition comprises a noble metal composition comprising at least one noble metal selected from the group consisting of platinum, palladium, and mixtures thereof 20 6. The system of any one of claims I to 5, wherein the second hydrogenation unit comprises a catalyst having an amorphous substrate and a second metallic composition embedded therein.
  5. 7. The system of claim 6, wherein the second metallic composition comprises a base metal composition selected from the group consisting of a nickel-molybdenum 25 composition, a cobalt-molybdenum composition, a nickel-tungsten composition, and mixtures thereof. -21- 8& The system of claim 6 or claim 7, wherein the second metallic composition comprises a noble metal composition comprising at least one noble metal selected from the group consisting of platinum, palladium, and mixtures thereo
  6. 9. The system of any one of claims 1 to 8, substantially as hereinbefore described with 5 reference to either of the drawings. -22-
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US6602402B1 (en) * 1999-04-29 2003-08-05 Institut Francais Du Petrole Flexible process for producing base stock and distillates by conversion-hydroisomerisation using a catalyst with low dispersion followed by catalytic dewaxing

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