CA2977388A1 - Process to make diesel using oil sands derived distillate product - Google Patents
Process to make diesel using oil sands derived distillate product Download PDFInfo
- Publication number
- CA2977388A1 CA2977388A1 CA2977388A CA2977388A CA2977388A1 CA 2977388 A1 CA2977388 A1 CA 2977388A1 CA 2977388 A CA2977388 A CA 2977388A CA 2977388 A CA2977388 A CA 2977388A CA 2977388 A1 CA2977388 A1 CA 2977388A1
- Authority
- CA
- Canada
- Prior art keywords
- distillate
- coker
- stream
- diesel
- gas oil
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 238000000034 method Methods 0.000 title claims abstract description 69
- 230000008569 process Effects 0.000 title description 30
- 238000004517 catalytic hydrocracking Methods 0.000 claims abstract description 49
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 claims abstract description 26
- 239000010426 asphalt Substances 0.000 claims abstract description 23
- 239000005864 Sulphur Substances 0.000 claims abstract description 17
- 238000012544 monitoring process Methods 0.000 claims abstract description 15
- 239000011593 sulfur Substances 0.000 claims abstract description 9
- 229910052717 sulfur Inorganic materials 0.000 claims abstract description 9
- 239000003054 catalyst Substances 0.000 claims description 34
- 238000002156 mixing Methods 0.000 claims description 17
- 239000000203 mixture Substances 0.000 claims description 16
- 239000000446 fuel Substances 0.000 claims description 14
- CIWBSHSKHKDKBQ-JLAZNSOCSA-N Ascorbic acid Chemical compound OC[C@H](O)[C@H]1OC(=O)C(O)=C1O CIWBSHSKHKDKBQ-JLAZNSOCSA-N 0.000 claims description 13
- 239000000654 additive Substances 0.000 claims description 10
- 230000000996 additive effect Effects 0.000 claims description 6
- 238000001914 filtration Methods 0.000 claims description 6
- 239000000047 product Substances 0.000 description 46
- 239000003921 oil Substances 0.000 description 30
- 239000007789 gas Substances 0.000 description 25
- 239000007788 liquid Substances 0.000 description 19
- 239000004215 Carbon black (E152) Substances 0.000 description 13
- 229930195733 hydrocarbon Natural products 0.000 description 13
- 150000002430 hydrocarbons Chemical class 0.000 description 13
- 238000011068 loading method Methods 0.000 description 13
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 12
- 239000003225 biodiesel Substances 0.000 description 12
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 12
- 229910052739 hydrogen Inorganic materials 0.000 description 11
- 239000001257 hydrogen Substances 0.000 description 11
- 238000006243 chemical reaction Methods 0.000 description 10
- 238000004821 distillation Methods 0.000 description 9
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 8
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 7
- 238000000926 separation method Methods 0.000 description 7
- 239000010779 crude oil Substances 0.000 description 5
- 238000004519 manufacturing process Methods 0.000 description 5
- 229910052751 metal Inorganic materials 0.000 description 5
- 239000002184 metal Substances 0.000 description 5
- 238000010791 quenching Methods 0.000 description 5
- 239000000126 substance Substances 0.000 description 5
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 4
- 229910021536 Zeolite Inorganic materials 0.000 description 4
- 238000001816 cooling Methods 0.000 description 4
- 239000002283 diesel fuel Substances 0.000 description 4
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 description 4
- 230000000694 effects Effects 0.000 description 4
- 238000011049 filling Methods 0.000 description 4
- 239000007791 liquid phase Substances 0.000 description 4
- 229910052757 nitrogen Inorganic materials 0.000 description 4
- 239000012071 phase Substances 0.000 description 4
- 239000010457 zeolite Substances 0.000 description 4
- 229910021529 ammonia Inorganic materials 0.000 description 3
- 238000004891 communication Methods 0.000 description 3
- 238000013461 design Methods 0.000 description 3
- 230000006872 improvement Effects 0.000 description 3
- 238000002347 injection Methods 0.000 description 3
- 239000007924 injection Substances 0.000 description 3
- 238000012986 modification Methods 0.000 description 3
- 230000004048 modification Effects 0.000 description 3
- 239000002245 particle Substances 0.000 description 3
- 239000011148 porous material Substances 0.000 description 3
- 125000003118 aryl group Chemical group 0.000 description 2
- 238000009835 boiling Methods 0.000 description 2
- 235000009508 confectionery Nutrition 0.000 description 2
- 239000003502 gasoline Substances 0.000 description 2
- 239000012535 impurity Substances 0.000 description 2
- 239000000314 lubricant Substances 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 150000002739 metals Chemical class 0.000 description 2
- 238000011045 prefiltration Methods 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 238000009938 salting Methods 0.000 description 2
- 150000003839 salts Chemical class 0.000 description 2
- 238000005070 sampling Methods 0.000 description 2
- 239000000377 silicon dioxide Substances 0.000 description 2
- 238000003860 storage Methods 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- 238000012546 transfer Methods 0.000 description 2
- 238000011144 upstream manufacturing Methods 0.000 description 2
- 239000012808 vapor phase Substances 0.000 description 2
- 101100325856 Caenorhabditis elegans bed-3 gene Proteins 0.000 description 1
- 208000033830 Hot Flashes Diseases 0.000 description 1
- 206010060800 Hot flush Diseases 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 150000001491 aromatic compounds Chemical class 0.000 description 1
- 239000002199 base oil Substances 0.000 description 1
- 239000006227 byproduct Substances 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 238000004523 catalytic cracking Methods 0.000 description 1
- 230000003197 catalytic effect Effects 0.000 description 1
- 238000004939 coking Methods 0.000 description 1
- 239000000356 contaminant Substances 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 230000009849 deactivation Effects 0.000 description 1
- 230000003111 delayed effect Effects 0.000 description 1
- 230000008021 deposition Effects 0.000 description 1
- -1 diesel Substances 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000005194 fractionation Methods 0.000 description 1
- 239000002828 fuel tank Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000005984 hydrogenation reaction Methods 0.000 description 1
- 239000003350 kerosene Substances 0.000 description 1
- 239000002808 molecular sieve Substances 0.000 description 1
- 239000003498 natural gas condensate Substances 0.000 description 1
- 229910000510 noble metal Inorganic materials 0.000 description 1
- 150000002902 organometallic compounds Chemical class 0.000 description 1
- 230000000737 periodic effect Effects 0.000 description 1
- 239000003209 petroleum derivative Substances 0.000 description 1
- 230000036619 pore blockages Effects 0.000 description 1
- 238000011084 recovery Methods 0.000 description 1
- 238000007670 refining Methods 0.000 description 1
- 238000012552 review Methods 0.000 description 1
- 238000009738 saturating Methods 0.000 description 1
- 230000001932 seasonal effect Effects 0.000 description 1
- 238000012163 sequencing technique Methods 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 239000000779 smoke Substances 0.000 description 1
- URGAHOPLAPQHLN-UHFFFAOYSA-N sodium aluminosilicate Chemical compound [Na+].[Al+3].[O-][Si]([O-])=O.[O-][Si]([O-])=O URGAHOPLAPQHLN-UHFFFAOYSA-N 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- 230000008685 targeting Effects 0.000 description 1
- 238000004227 thermal cracking Methods 0.000 description 1
- 238000004018 waxing Methods 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING 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
- C10G1/00—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal
- C10G1/02—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal by distillation
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING 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
- C10G47/00—Cracking of hydrocarbon oils, in the presence of hydrogen or hydrogen- generating compounds, to obtain lower boiling fractions
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING 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
- C10G47/00—Cracking of hydrocarbon oils, in the presence of hydrogen or hydrogen- generating compounds, to obtain lower boiling fractions
- C10G47/36—Controlling or regulating
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING 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
- C10G7/00—Distillation of hydrocarbon oils
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING 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
- C10G7/00—Distillation of hydrocarbon oils
- C10G7/12—Controlling or regulating
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING 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
- C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
- C10G2300/10—Feedstock materials
- C10G2300/107—Atmospheric residues having a boiling point of at least about 538 °C
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING 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
- C10G2400/00—Products obtained by processes covered by groups C10G9/00 - C10G69/14
- C10G2400/02—Gasoline
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING 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
- C10G2400/00—Products obtained by processes covered by groups C10G9/00 - C10G69/14
- C10G2400/04—Diesel oil
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
- C10L2200/00—Components of fuel compositions
- C10L2200/04—Organic compounds
- C10L2200/0407—Specifically defined hydrocarbon fractions as obtained from, e.g. a distillation column
- C10L2200/0438—Middle or heavy distillates, heating oil, gasoil, marine fuels, residua
- C10L2200/0446—Diesel
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
- C10L2270/00—Specifically adapted fuels
- C10L2270/02—Specifically adapted fuels for internal combustion engines
- C10L2270/026—Specifically adapted fuels for internal combustion engines for diesel engines, e.g. automobiles, stationary, marine
Abstract
Method of preparing ultra low sulfur diesel, said method comprising the steps of:- feeding bitumen into a bitumen column;- obtaining at least two output streams from the bitumen column;- feeding the atmospheric bottoms stream to a coker fractionator;- monitoring the distillate from the coker fractionator to obtain a coker distillate 95% cut pointat no more than 335°C to meet a -38°C cloud point;- monitoring and controlling the addition of cracked components to meet diesel cloud pointspecification of Coker Distillate 95% point;- combining the light atmospheric gas oil distillate and coker distillate to form a combineddistillate stream; and- performing a step of mild hydrocracking on the combined distillate stream, which yields aneffluent comprising no more than 15 ppm sulphur.
Description
PROCESS TO MAKE DIESEL USING
OIL SANDS DERIVED DISTILLATE PRODUCT
FIELD OF THE INVENTION
This invention is directed to a novel process for producing diesel from mined bitumen, more specifically it is directed to a combined various treated distillate streams to produce diesel.
BACKGROUND OF THE INVENTION
Oil sands upgrading typically involves the thermal cracking of bitumen (PUG) into more valuable short hydrocarbon streams followed by hydroprocessing (SUG). These streams and the naturally occurring light gas oil from the bitumen can be combined to produce a synthetic crude oil (SCO). Hydroprocessing combines hydrogen with the untreated product streams to stabilize and treat the products to remove sulphur, nitrogen and other impurities. Typically a dedicated Naphtha Hydrotreater (NHT), a Distillate Hydrotreater (DHT) and a Gasoil Hydrotreater (GOHT) are used for the purpose. These hydrotreated products are combined to produce oil sands derived light sweet synthetic crude oil.
Generally, light sweet crude oils give a higher refinery yield of products such as diesel, gasoline and kerosene.
Providing ultra low sulphur diesel (USLD) during the winter period is especially difficult due to the low cloud point specifications required during cold winter months. There are some prior art patent which address the production of diesel but it is clear upon review thereof that improvements can be made to provide a new and more efficient process given the large capital expenditure that such plants require. The following is a brief discussion of the more relevant patents found.
US patent No. 8,936,714 discloses a process for hydrocracking a primary hydrocarbon feed and a diesel co-feed in a hydrocracking unit and hydrotreating a diesel product from the hydrocracking unit in a hydrotreating unit. The diesel stream fed through the hydrocracking unit is pretreated to reduce sulfur and ammonia and can be upgraded with noble metal catalyst.
US patent No. 8,721,871 teaches a process for the hydroprocessing of a low value light cycle oil (LCO) hydrocarbon feed to provide a high-value diesel-range product. The process comprises a hydrotreatment stage followed by a hydrocracking stage, each of which is conducted under liquid-full reaction conditions wherein substantially all the hydrogen supplied to the hydrotreating and hydrocracking reactions is dissolved in the liquid-phase hydrocarbon feed. Ammonia and other gases formed during
OIL SANDS DERIVED DISTILLATE PRODUCT
FIELD OF THE INVENTION
This invention is directed to a novel process for producing diesel from mined bitumen, more specifically it is directed to a combined various treated distillate streams to produce diesel.
BACKGROUND OF THE INVENTION
Oil sands upgrading typically involves the thermal cracking of bitumen (PUG) into more valuable short hydrocarbon streams followed by hydroprocessing (SUG). These streams and the naturally occurring light gas oil from the bitumen can be combined to produce a synthetic crude oil (SCO). Hydroprocessing combines hydrogen with the untreated product streams to stabilize and treat the products to remove sulphur, nitrogen and other impurities. Typically a dedicated Naphtha Hydrotreater (NHT), a Distillate Hydrotreater (DHT) and a Gasoil Hydrotreater (GOHT) are used for the purpose. These hydrotreated products are combined to produce oil sands derived light sweet synthetic crude oil.
Generally, light sweet crude oils give a higher refinery yield of products such as diesel, gasoline and kerosene.
Providing ultra low sulphur diesel (USLD) during the winter period is especially difficult due to the low cloud point specifications required during cold winter months. There are some prior art patent which address the production of diesel but it is clear upon review thereof that improvements can be made to provide a new and more efficient process given the large capital expenditure that such plants require. The following is a brief discussion of the more relevant patents found.
US patent No. 8,936,714 discloses a process for hydrocracking a primary hydrocarbon feed and a diesel co-feed in a hydrocracking unit and hydrotreating a diesel product from the hydrocracking unit in a hydrotreating unit. The diesel stream fed through the hydrocracking unit is pretreated to reduce sulfur and ammonia and can be upgraded with noble metal catalyst.
US patent No. 8,721,871 teaches a process for the hydroprocessing of a low value light cycle oil (LCO) hydrocarbon feed to provide a high-value diesel-range product. The process comprises a hydrotreatment stage followed by a hydrocracking stage, each of which is conducted under liquid-full reaction conditions wherein substantially all the hydrogen supplied to the hydrotreating and hydrocracking reactions is dissolved in the liquid-phase hydrocarbon feed. Ammonia and other gases formed during
2 hydrotreatment are removed in a separation step prior to hydrocracking. The LCO feed is advantageously converted to diesel in high yield with little loss of hydrocarbon to naphtha.
US Patent No. 8,002,967 teaches a partial conversion hydrocracking process comprising the steps of (a) hydrotreating a hydrocarbon feedstock with a hydrogen rich gas to produce a hydrotreated effluent stream comprising a liquid/vapor mixture and separating the liquid/vapor mixture into a liquid phase and a vapor phase, and (b) separating the liquid phase into a controlled liquid portion and an excess liquid portion, and (c) combining the vapor phase with the excess liquid portion to form a vapor plus liquid portion, and (d) separating an FCC feed-containing fraction from the controlled liquid portion and simultaneously hydrocracking the vapor plus liquid portion to produce a diesel containing fraction, or hydrocracking the controlled liquid portion to produce a diesel-containing fraction and simultaneously separating a FCC feed-containing fraction from the vapor plus liquid portion. It is also stated that the process can include an apparatus for carrying out the partial conversion hydrocracking process.
US 6,153,087 teaches a process for converting a hydrocarbon fraction comprises a step a) for treating a hydrocarbon feed in the presence of hydrogen in at least one three-phase reactor, containing at least one hydrotreatment catalyst in an ebullating bed, operating in riser mode of liquid and of gas, the reactor comprising at least one means located close to the bottom of the reactor for extracting catalyst from the reactor and at least one means located close to the top of the reactor for adding fresh catalyst to the reactor, a step b) for treating at least a portion of the effluent from step a) in the presence of hydrogen in at least one reactor containing at least one hydrocracking catalyst in a fixed bed under conditions for producing an effluent with a reduced sulphur content, and a step c) in which at least a portion of the product from step b) is sent to a distillation zone from which a gaseous fraction, a gasoline type engine fuel fraction, a diesel type engine fuel fraction and a liquid fraction which is heavier than the diesel type fraction are recovered. The process can also comprise a step d) for catalytic cracking of the heavy fraction obtained from step c).
US 8,999,256 teaches an apparatus for producing diesel from a hydrocarbon stream comprising:
hydrotreating reactor; a hot separator for separating a hydrotreating effluent stream into a vaporous hot hydrotreating effluent stream in a hot separator overhead line and a liquid hot hydrotreating effluent stream in a hot separator bottoms line; a cold separator in direct communication with the hot separator overhead line for separating said vaporous hot hydrotreating effluent stream into a vaporous cold hydrotreating effluent stream and a liquid cold hydrotreating effluent stream in a cold separator bottoms line; a fractionation column in communication with said cold separator bottoms line; and a hydrocracking reactor in
US Patent No. 8,002,967 teaches a partial conversion hydrocracking process comprising the steps of (a) hydrotreating a hydrocarbon feedstock with a hydrogen rich gas to produce a hydrotreated effluent stream comprising a liquid/vapor mixture and separating the liquid/vapor mixture into a liquid phase and a vapor phase, and (b) separating the liquid phase into a controlled liquid portion and an excess liquid portion, and (c) combining the vapor phase with the excess liquid portion to form a vapor plus liquid portion, and (d) separating an FCC feed-containing fraction from the controlled liquid portion and simultaneously hydrocracking the vapor plus liquid portion to produce a diesel containing fraction, or hydrocracking the controlled liquid portion to produce a diesel-containing fraction and simultaneously separating a FCC feed-containing fraction from the vapor plus liquid portion. It is also stated that the process can include an apparatus for carrying out the partial conversion hydrocracking process.
US 6,153,087 teaches a process for converting a hydrocarbon fraction comprises a step a) for treating a hydrocarbon feed in the presence of hydrogen in at least one three-phase reactor, containing at least one hydrotreatment catalyst in an ebullating bed, operating in riser mode of liquid and of gas, the reactor comprising at least one means located close to the bottom of the reactor for extracting catalyst from the reactor and at least one means located close to the top of the reactor for adding fresh catalyst to the reactor, a step b) for treating at least a portion of the effluent from step a) in the presence of hydrogen in at least one reactor containing at least one hydrocracking catalyst in a fixed bed under conditions for producing an effluent with a reduced sulphur content, and a step c) in which at least a portion of the product from step b) is sent to a distillation zone from which a gaseous fraction, a gasoline type engine fuel fraction, a diesel type engine fuel fraction and a liquid fraction which is heavier than the diesel type fraction are recovered. The process can also comprise a step d) for catalytic cracking of the heavy fraction obtained from step c).
US 8,999,256 teaches an apparatus for producing diesel from a hydrocarbon stream comprising:
hydrotreating reactor; a hot separator for separating a hydrotreating effluent stream into a vaporous hot hydrotreating effluent stream in a hot separator overhead line and a liquid hot hydrotreating effluent stream in a hot separator bottoms line; a cold separator in direct communication with the hot separator overhead line for separating said vaporous hot hydrotreating effluent stream into a vaporous cold hydrotreating effluent stream and a liquid cold hydrotreating effluent stream in a cold separator bottoms line; a fractionation column in communication with said cold separator bottoms line; and a hydrocracking reactor in
3 communication with said hot separator bottoms line for hydrocracking said liquid hot hydrotreating effluent stream.
US Patent Application 2015/0083643 discloses a process for the hydroprocessing of a gas oil (GO) hydrocarbon feed to provide a high yield of a diesel fraction. The process comprises a liquid-full hydrotreating reaction zone followed by a liquid-full hydrocracking reaction zone. A refining zone may be integrated with the hydrocracking reaction zone. Ammonia and other gases formed during the hydrotreatment are said to be removed in a separation step prior to hydrocracking.
US 8,969,233 teaches a hydrocracking and/or hydrotreatment process using a catalyst comprising an active phase containing at least one hydrogenating/dehydrogenating component selected from the group V1B
elements and the non-precious elements of group VIII of the periodic table, used alone or in a mixture, and a support comprising at least one dealuminated zeolite.
US 5,935,414 teaches a process for reducing the wax content of wax-containing hydrocarbon feedstocks to produce middle distillate products including low freeze point jet fuel and/or low pour point and low cloud point diesel fuel and heating oil. The process involves contacting the feedstock with a hydrocracking catalyst containing a carrier, at least one hydrogenation metal component of Group V1B and Group VIII metals, and a large pore zeolite such as a Y type zeolite, in a hydrocracking zone in the presence of hydrogen at elevated temperature and pressure, and contacting the entire effluent from the hydrocracking zone with a dewaxing catalyst containing a crystalline, intermediate pore size molecular sieve selected from metallosilicates and silicoaluminophosphates in a hydrodewaxing zone in the presence of hydrogen at elevated temperature and pressure.
US 8,992,764 B2 teaches a method for producing a diesel fuel and a lubricant basestock, comprising:
contacting a feedstock with a hydrotreating catalyst under effective hydrotreating conditions to produce a hydrotreated effluent; fractionating the hydrotreated effluent to produce at least a first diesel product fraction and a bottoms fraction; hydrocracking the bottoms fraction under effective hydrocracking conditions;
dewaxing the bottoms fraction under effective catalytic dewaxing conditions, the dewaxing catalyst including at least one non-dealuminated, unidimensional, 10-member ring pore zeolite, and at least one Group VI
metal, Group VIII metal, or combination thereof; and fractionating the hydrocracked, dewaxed bottoms fraction to form at least a second diesel product fraction and a lubricant base oil product fraction.
US Patent Application 2015/0083643 discloses a process for the hydroprocessing of a gas oil (GO) hydrocarbon feed to provide a high yield of a diesel fraction. The process comprises a liquid-full hydrotreating reaction zone followed by a liquid-full hydrocracking reaction zone. A refining zone may be integrated with the hydrocracking reaction zone. Ammonia and other gases formed during the hydrotreatment are said to be removed in a separation step prior to hydrocracking.
US 8,969,233 teaches a hydrocracking and/or hydrotreatment process using a catalyst comprising an active phase containing at least one hydrogenating/dehydrogenating component selected from the group V1B
elements and the non-precious elements of group VIII of the periodic table, used alone or in a mixture, and a support comprising at least one dealuminated zeolite.
US 5,935,414 teaches a process for reducing the wax content of wax-containing hydrocarbon feedstocks to produce middle distillate products including low freeze point jet fuel and/or low pour point and low cloud point diesel fuel and heating oil. The process involves contacting the feedstock with a hydrocracking catalyst containing a carrier, at least one hydrogenation metal component of Group V1B and Group VIII metals, and a large pore zeolite such as a Y type zeolite, in a hydrocracking zone in the presence of hydrogen at elevated temperature and pressure, and contacting the entire effluent from the hydrocracking zone with a dewaxing catalyst containing a crystalline, intermediate pore size molecular sieve selected from metallosilicates and silicoaluminophosphates in a hydrodewaxing zone in the presence of hydrogen at elevated temperature and pressure.
US 8,992,764 B2 teaches a method for producing a diesel fuel and a lubricant basestock, comprising:
contacting a feedstock with a hydrotreating catalyst under effective hydrotreating conditions to produce a hydrotreated effluent; fractionating the hydrotreated effluent to produce at least a first diesel product fraction and a bottoms fraction; hydrocracking the bottoms fraction under effective hydrocracking conditions;
dewaxing the bottoms fraction under effective catalytic dewaxing conditions, the dewaxing catalyst including at least one non-dealuminated, unidimensional, 10-member ring pore zeolite, and at least one Group VI
metal, Group VIII metal, or combination thereof; and fractionating the hydrocracked, dewaxed bottoms fraction to form at least a second diesel product fraction and a lubricant base oil product fraction.
4 Diesel fuel is prone to waxing in cold climates. This involves the solidification of particles present in the diesel oil into a partially crystalline state. Below the cloud point the fuel begins to develop solid wax particles giving it a cloudy appearance. The presence of solidified wax particles thickens the oil and results in the clogging of fuel filters and injectors in engines. The crystals build up in the fuel line (especially in fuel filters) until the engine is starved of fuel, causing it to stop running.
Winter diesel specification requirements are thus much more challenging to meet and require test run process regulations in the delayed coker unit (DCU) and the DHT, as well as consideration for additional catalyst changes in the DHT reactor, in order to determine if the winter cold flow properties and cetane requirements can be met.
In light of the prior art there still exists a need for a process which can produce diesel, preferably ultra low sulfur diesel. The process according to the present invention uses using stringent distillation endpoint control of LAGO (Light Atmospheric Gas Oil) and Coker Distillate, along with mild hydrocracking catalyst in a distillate hydrotreating (DHT) reactor, with no additional process units or distillation columns to produce an ultralow sulphur diesel (ULSD) with low cloud point properties directly from a typical oil sands upgrading facility.
It is expected that by specifically targeting the components that are generally routed to a DHT and by adjusting the operation of the DHT reactor, a high volume (up to 55,000 bbl/d) of diesel could be produced in an already established processing plant with minimal additional equipment.
SUMMARY OF THE INVENTION
Accordingly, one aspect of the present invention provides for a process using stringent distillation endpoint control of LAGO (Light Atmospheric Gas Oil) and Coker Distillate, along with mild hydrocracking catalyst in a distillate hydrotreating (DHT) reactor, with no additional process units or distillation columns to produce an ultralow sulphur diesel (ULSD) with low cloud point properties directly from a typical oil sands upgrading facility.
According to a preferred embodiment, a distillate hydrotreater (DHT) catalyst was replaced with a mild hydrocracking catalyst. The DHT product meets summer diesel specifications with proper chemical additives including lubricity improver, cetane improver and conductivity improver. According to a preferred embodiment, the addition of biodiesel can also be performed. Preferably, a diesel blending facility provides equipment for cooling, settling, blending, injecting additives, sampling and loading of specification summer diesel for trucking.
Winter diesel specification requirements are thus much more challenging to meet and require test run process regulations in the delayed coker unit (DCU) and the DHT, as well as consideration for additional catalyst changes in the DHT reactor, in order to determine if the winter cold flow properties and cetane requirements can be met.
In light of the prior art there still exists a need for a process which can produce diesel, preferably ultra low sulfur diesel. The process according to the present invention uses using stringent distillation endpoint control of LAGO (Light Atmospheric Gas Oil) and Coker Distillate, along with mild hydrocracking catalyst in a distillate hydrotreating (DHT) reactor, with no additional process units or distillation columns to produce an ultralow sulphur diesel (ULSD) with low cloud point properties directly from a typical oil sands upgrading facility.
It is expected that by specifically targeting the components that are generally routed to a DHT and by adjusting the operation of the DHT reactor, a high volume (up to 55,000 bbl/d) of diesel could be produced in an already established processing plant with minimal additional equipment.
SUMMARY OF THE INVENTION
Accordingly, one aspect of the present invention provides for a process using stringent distillation endpoint control of LAGO (Light Atmospheric Gas Oil) and Coker Distillate, along with mild hydrocracking catalyst in a distillate hydrotreating (DHT) reactor, with no additional process units or distillation columns to produce an ultralow sulphur diesel (ULSD) with low cloud point properties directly from a typical oil sands upgrading facility.
According to a preferred embodiment, a distillate hydrotreater (DHT) catalyst was replaced with a mild hydrocracking catalyst. The DHT product meets summer diesel specifications with proper chemical additives including lubricity improver, cetane improver and conductivity improver. According to a preferred embodiment, the addition of biodiesel can also be performed. Preferably, a diesel blending facility provides equipment for cooling, settling, blending, injecting additives, sampling and loading of specification summer diesel for trucking.
5 Typical oil sands DHT reactors have only hydrotreating capabilities, the inventors have surprisingly found that by substituting hydrocracking catalyst in the last bed of the reactor, ULSD base stock can be produced directly from treated distillate product.
To produce ULSD the preferable parameter that is targeted is the sulphur content. Ultra-Low Sulfur Diesel (ULSD) must not exceed 15 ppm sulphur or it cannot be used as ULSD
diesel (government regulations). Preferably, one targets 10 ppm to meet or exceed specification, in order to avoid retreating/blending which is often very difficult.
Preferably also, the method further comprises a step of maximizing naphtha in the distillate product.
According to one embodiment, the step of maximizing the naphta in distillate product is perfomed at the coker fractionator by minimizing the overhead temperature of the fractionator, and forcing the lighter components of the stream above the distillate (naphtha) into the coker distillate product. The temperature is limited by fractionator overhead salting constraints temperatures. In the event the temperature is too low, the fractionator will foul with salts.
According to another embodiment, the step of maximizing the naphta in distillate product is perfomed at the distillate stripper column in the DHT by minimizing the overhead temperature to force the lighter components from the wild naphtha stream into the distillate product.
Here also, the temperature is also limited by salting constraint temperatures. In the event, the temperature is too low, the stripper will foul with salts.
According to yet another embodiment, the step of maximizing the naphta in distillate product is perfomed at the coker fractionator by minimizing the overhead temperature of the fractionator, and forcing the lighter components of the stream above the distillate (naphtha) into the coker distillate product and at the distillate stripper column in the DHT by minimizing the overhead temperature to force the lighter components from the wild naphtha stream into the distillate product.
Preferably, the method further comprises a step of filtration and coalescing of the treated distillate after the step of mild hydrocracking. Filtration and coalescing are post DHT, although there is a feed filter in the DHT (to protect the DHT catalyst bed). Filtration and coalescing are in the diesel blending facility.
Preferably, the method further comprises a step of blending the produced diesel blend with an external source of jet fuel to improve the cloud point of the diesel blend.
To produce ULSD the preferable parameter that is targeted is the sulphur content. Ultra-Low Sulfur Diesel (ULSD) must not exceed 15 ppm sulphur or it cannot be used as ULSD
diesel (government regulations). Preferably, one targets 10 ppm to meet or exceed specification, in order to avoid retreating/blending which is often very difficult.
Preferably also, the method further comprises a step of maximizing naphtha in the distillate product.
According to one embodiment, the step of maximizing the naphta in distillate product is perfomed at the coker fractionator by minimizing the overhead temperature of the fractionator, and forcing the lighter components of the stream above the distillate (naphtha) into the coker distillate product. The temperature is limited by fractionator overhead salting constraints temperatures. In the event the temperature is too low, the fractionator will foul with salts.
According to another embodiment, the step of maximizing the naphta in distillate product is perfomed at the distillate stripper column in the DHT by minimizing the overhead temperature to force the lighter components from the wild naphtha stream into the distillate product.
Here also, the temperature is also limited by salting constraint temperatures. In the event, the temperature is too low, the stripper will foul with salts.
According to yet another embodiment, the step of maximizing the naphta in distillate product is perfomed at the coker fractionator by minimizing the overhead temperature of the fractionator, and forcing the lighter components of the stream above the distillate (naphtha) into the coker distillate product and at the distillate stripper column in the DHT by minimizing the overhead temperature to force the lighter components from the wild naphtha stream into the distillate product.
Preferably, the method further comprises a step of filtration and coalescing of the treated distillate after the step of mild hydrocracking. Filtration and coalescing are post DHT, although there is a feed filter in the DHT (to protect the DHT catalyst bed). Filtration and coalescing are in the diesel blending facility.
Preferably, the method further comprises a step of blending the produced diesel blend with an external source of jet fuel to improve the cloud point of the diesel blend.
6 Preferably also, the method further comprises the blending of the produced diesel blend with the addition of at least one of the components selected from the group consisting of: off-road diesel dye, cetane additive, lubricity additive and combinations thereof.
According to a preferred embodiment, the method comprises performing the hydrotreatment at temperatures ranging from 287 C to 370 C.
According to a preferred embodiment, the method comprises performing the mild hydrocracking bed at temperatures ranging from 310 C to 370 C.
According to one aspect of the present invention, there is provided a method of preparing ultra low sulfur diesel, said method comprising the steps of:
- feeding bitumen into a bitumen column;
- obtaining at least two output streams from the bitumen column; said at least two streams comprising:
- a light atmospheric gas oil stream; and - an atmospheric bottoms stream;
- feeding the light atmospheric gas oil stream to a light atmospheric gas oil side stripper;
- monitoring the distillate from the light atmospheric gas oil side stripper to obtain a light atmospheric gas oil distillate 95% cut point at no more than 370 C;
- feeding the atmospheric bottoms stream to a coker fractionator; and - monitoring the distillate from the coker fractionator to obtain a coker distillate 95% cut point at no more than 335 C to meet a -38 C cloud point;
- monitoring and controlling the addition of cracked components to meet diesel cloud point specification (Coker Distillate 95% point);
- combining the light atmospheric gas oil distillate and coker distillate to form a combined distillate stream;
- performing a step of mild hydrocracking on the combined distillate stream, to the hydrotreattnent yields an effluent comprising no more than 15 ppm sulphur.
It is thought that monitoring the distillate from the coker fractionator to obtain a coker distillate 95%
cut point at no more than 335 C is a key parameter for making low cloud point ULSD. To meet -38 Deg C
According to a preferred embodiment, the method comprises performing the hydrotreatment at temperatures ranging from 287 C to 370 C.
According to a preferred embodiment, the method comprises performing the mild hydrocracking bed at temperatures ranging from 310 C to 370 C.
According to one aspect of the present invention, there is provided a method of preparing ultra low sulfur diesel, said method comprising the steps of:
- feeding bitumen into a bitumen column;
- obtaining at least two output streams from the bitumen column; said at least two streams comprising:
- a light atmospheric gas oil stream; and - an atmospheric bottoms stream;
- feeding the light atmospheric gas oil stream to a light atmospheric gas oil side stripper;
- monitoring the distillate from the light atmospheric gas oil side stripper to obtain a light atmospheric gas oil distillate 95% cut point at no more than 370 C;
- feeding the atmospheric bottoms stream to a coker fractionator; and - monitoring the distillate from the coker fractionator to obtain a coker distillate 95% cut point at no more than 335 C to meet a -38 C cloud point;
- monitoring and controlling the addition of cracked components to meet diesel cloud point specification (Coker Distillate 95% point);
- combining the light atmospheric gas oil distillate and coker distillate to form a combined distillate stream;
- performing a step of mild hydrocracking on the combined distillate stream, to the hydrotreattnent yields an effluent comprising no more than 15 ppm sulphur.
It is thought that monitoring the distillate from the coker fractionator to obtain a coker distillate 95%
cut point at no more than 335 C is a key parameter for making low cloud point ULSD. To meet -38 Deg C
7 cloud point spec 335 C is target, to meet -40 C specification (Dec 16th to January 31st period), 325 C 95% is required. Cloud point specification is a seasonal specification with -40 C the lowest value.
Preferably, the step of mild hydrocracking is carried out in the presence of a mild hydrocracking catalyst in a last bed of a distillate hydrotreater (DHT) reactor alongwith hydrotreating step in all the catalyst beds.
According to a preferred embodiment of the present invention, the step of mild hydrocracking is carried out in the presence of a mild hydrocracking catalyst in a last bed of a distillate hydrotreater (DHT) I 0 reactor alongwith hydrotreating step in all the catalyst beds.
Preferably, the method further comprises a step of maximizing naphtha in the distillate product. Preferably also, the step of maximizing the naphta distillate product is perfomed at the coker fractionator by minimizing the overhead temperature of the fractionator, and forcing the lighter components of the stream above the distillate (naphtha) into the coker distillate product.
Also preferably, the step of maximizing the naphta distillate product is perfomed at the distillate stripper column in the DHT by minimizing the overhead temperature to force the lighter components from the wild naphtha stream into the distillate product.
According to a preferred embodiment of the present invention, the step of maximizing the naphta distillate product is perfomed at the coker fractionator by minimizing the overhead temperature of the fractionator, and forcing the lighter components of the stream above the distillate (naphtha) into the coker distillate product and at the distillate stripper column in the DHT by minimizing the overhead temperature to force the lighter components from the wild naphtha stream into the distillate product. Preferably, the method further comprises a step of filtration and coalescing of the treated distillate after the step of mild hydrotreatment.
According to a preferred embodiment of the present invention, the method further comprises a step of blending the produced diesel blend with an external source of jet fuel to improve the cloud point of the diesel blend. Preferably also, the method further comprises the blending of the produced diesel blend with the addition of at least one of the components selected from the group consisting of: off-road diesel dye, cetane additive, lubricity additive and combinations thereof.
According to prefererred embodiment of the present invention, the method comprises running the hydrotreatment at temperatures ranging from 287 C to 370 C. Preferably, the method further comprises running the hydrocracking bed at temperatures ranging from 310 C to 370 C.
Preferably, the step of mild hydrocracking is carried out in the presence of a mild hydrocracking catalyst in a last bed of a distillate hydrotreater (DHT) reactor alongwith hydrotreating step in all the catalyst beds.
According to a preferred embodiment of the present invention, the step of mild hydrocracking is carried out in the presence of a mild hydrocracking catalyst in a last bed of a distillate hydrotreater (DHT) I 0 reactor alongwith hydrotreating step in all the catalyst beds.
Preferably, the method further comprises a step of maximizing naphtha in the distillate product. Preferably also, the step of maximizing the naphta distillate product is perfomed at the coker fractionator by minimizing the overhead temperature of the fractionator, and forcing the lighter components of the stream above the distillate (naphtha) into the coker distillate product.
Also preferably, the step of maximizing the naphta distillate product is perfomed at the distillate stripper column in the DHT by minimizing the overhead temperature to force the lighter components from the wild naphtha stream into the distillate product.
According to a preferred embodiment of the present invention, the step of maximizing the naphta distillate product is perfomed at the coker fractionator by minimizing the overhead temperature of the fractionator, and forcing the lighter components of the stream above the distillate (naphtha) into the coker distillate product and at the distillate stripper column in the DHT by minimizing the overhead temperature to force the lighter components from the wild naphtha stream into the distillate product. Preferably, the method further comprises a step of filtration and coalescing of the treated distillate after the step of mild hydrotreatment.
According to a preferred embodiment of the present invention, the method further comprises a step of blending the produced diesel blend with an external source of jet fuel to improve the cloud point of the diesel blend. Preferably also, the method further comprises the blending of the produced diesel blend with the addition of at least one of the components selected from the group consisting of: off-road diesel dye, cetane additive, lubricity additive and combinations thereof.
According to prefererred embodiment of the present invention, the method comprises running the hydrotreatment at temperatures ranging from 287 C to 370 C. Preferably, the method further comprises running the hydrocracking bed at temperatures ranging from 310 C to 370 C.
8 According to one aspect of the present invention, there is provided a method of preparing ultra low sulfur diesel, said method comprising the steps of:
- feeding bitumen into a bitumen column;
- obtaining at least two output streams from the bitumen column; said at least two streams comprising:
- a light atmospheric gas oil stream; and - an atmospheric bottoms stream;
- feeding the light atmospheric gas oil stream to a light atmospheric gas oil side stripper;
- monitoring the distillate from the light atmospheric gas oil side stripper to obtain a light atmospheric gas oil distillate 95% cut point at no more than 370 C;
- feeding the atmospheric bottoms stream to a coker fractionator; and - monitoring the distillate from the coker fractionator to obtain a coker distillate 95% cut point at no more than 335 C;
- monitoring and controlling the addition of cracked components to meet diesel cloud point specification (Coker Distillate 95% point);
- performing a step of mild hydrocracking, to yield an effluent comprising no more than 15 ppm of sulphur.
Preferably, the effluent comprises no more than 10 ppm of sulphur.
One of the advantages over the prior known processes is that mild hydrocracking results in improvement in sulfur and nitrogen content. According to a preferred embodiment, sulphur content is reduced from 400 to < 15 wpprn; and nitrogen content is reduced from 65 to < 1 wppm compared to hydrotreating.
For minimal cost and minimal modification to a typical oil sands upgrading facility, untreated distillate product can be used to make low cloud point ULSD diesel having sulphur content < 15 ppm.
Control of product qualities is linked directly back to the upstream component identified as major contributing variable. The inventors have observed that to make low cloud point winter diesel, control of the coker distillate 95% distillation was identified as an important variable.
Total upgrader product blend balance through the hydrotreaters is managed by maximizing the light atmospheric gas oil (LAGO) component of distillate hydrotreater feed. In this way, total upgrader capacity is not negatively affected.
=
- feeding bitumen into a bitumen column;
- obtaining at least two output streams from the bitumen column; said at least two streams comprising:
- a light atmospheric gas oil stream; and - an atmospheric bottoms stream;
- feeding the light atmospheric gas oil stream to a light atmospheric gas oil side stripper;
- monitoring the distillate from the light atmospheric gas oil side stripper to obtain a light atmospheric gas oil distillate 95% cut point at no more than 370 C;
- feeding the atmospheric bottoms stream to a coker fractionator; and - monitoring the distillate from the coker fractionator to obtain a coker distillate 95% cut point at no more than 335 C;
- monitoring and controlling the addition of cracked components to meet diesel cloud point specification (Coker Distillate 95% point);
- performing a step of mild hydrocracking, to yield an effluent comprising no more than 15 ppm of sulphur.
Preferably, the effluent comprises no more than 10 ppm of sulphur.
One of the advantages over the prior known processes is that mild hydrocracking results in improvement in sulfur and nitrogen content. According to a preferred embodiment, sulphur content is reduced from 400 to < 15 wpprn; and nitrogen content is reduced from 65 to < 1 wppm compared to hydrotreating.
For minimal cost and minimal modification to a typical oil sands upgrading facility, untreated distillate product can be used to make low cloud point ULSD diesel having sulphur content < 15 ppm.
Control of product qualities is linked directly back to the upstream component identified as major contributing variable. The inventors have observed that to make low cloud point winter diesel, control of the coker distillate 95% distillation was identified as an important variable.
Total upgrader product blend balance through the hydrotreaters is managed by maximizing the light atmospheric gas oil (LAGO) component of distillate hydrotreater feed. In this way, total upgrader capacity is not negatively affected.
=
9 BRIEF DESCRIPTION OF THE FIGURES
The present invention may be better understood in consideration of the following description of various embodiments of the invention in connection with the accompanying drawings, in which:
Figure 1 is a schematic view of the hydrotreater unit used in the processing step of the bitumen derived coker distillate and LAGO streams for the hydrotreatment and hydrocracking steps according to a preferred embodiment of the present invention;
Figure 2 is a schematic view of the process according to a preferred embodiment of the present invention.
Figure 3 is a close up schematic view of a portion of the process according to a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The particular values and compositions discussed in these non-limiting examples can be varied and are cited merely to illustrate at least one embodiment and are not intended to limit the scope thereof.
According to a preferred embodiment of the present invention, there is provided a method to use a typical oil sands upgrading facility after minimal cost and minimal modification, untreated distillate product can be used to make low cloud point ULSD diesel.
According to a preferred embodiment of the present invention, the feed for the production of mine diesel is a combination of streams, LAGO and coker distillate, this stream may contain up to 2000 to 3000 ppm of total water with up to 150 ppm of chemically bonded water. Cloud point specification is a very important for parameter for the production of low cloud point winter mine diesel. Low cloud point winter diesel can be made if the coker distillate 95% ASTM-D2887 cut point does not exceed 335 C. Coker distillate and LAGO has a direct effect on density, flashpoint, distillation 90% recovered, cetane carbon residue and viscosity but are not a constraint to diesel production if coker distillate and LAGO 95% ASTM-D2887 are kept below 335 C and 370 C respectively.
Separation of the feed from the rest of the distillation According to a preferred embodiment of the present invention, the coker fractionator and bitumen distillation column are used to separate the distillate fraction from the Dilbit (bitumen diluted with one or =
more lighter petroleum products, typically natural-gas condensates such as naphtha) and cracked coker fractionator feed respectively. Preferably, untreated distillates streams and LAGO streams from these columns are collected in an intermediate tank before being processed in the mild hydrocracking reactor.
Process steps Referring now to Figures 2 and 3, bitumen (1) is fed to a bitumen column (2).
This column produces three streams, LAGO (Light Atmospheric Gas Oil), HAGO (Heavy Atmospheric Gas Oil) and ATM
(Atmospheric Bottoms). Small off-gas and sour water streams are produced as by-products. ATM is fed to the coking unit (4) whereas the LAGO stream (3) once having gone through a LAGO side stripper (6) is then recombined with the coker distillate (5). This combined distillate (7) (untreated distillate) is sent to storage (35) before treating it.
The broad steps of a preferred embodiment of the process according to the present invention comprise untreated distillate being fed to a hydrotreater; product from the hydrotreater is stored in a tank; and a stream from this treated distillate tank being used to prepare diesel.
According to a preferred embodiment of the present invention, in order to minimize hydrotreating and to maximize hydrocracking of combined distillate stream in the DHT
reactor, inventors have established that this is accomplished by running low temperature on hydrotreating beds, and higher inlet temperatures on the hydrocracking bed.
=
Hydrotreating primarily involves the removal of sulphur and nitrogen in addition to the saturation of olefinic and aromatic compounds by breaking their double carbon bonds, and removing other contaminants such as oxygenates and organometallic compounds. Preferably, the distillate hydrotreating process Units (DHTU) Plant is designed to achieve a cetane number of 40 in the 177 C - 343 C
boiling range of the overall synthetic crude oil blend. The extent of the saturation of the various aromatics is performed to achieve the desired SCO cetane number requirement. This is however limited by reaction kinetic equilibria. By saturating the aromatics to less than 25 % volume in the final 177 C - 343 C
boiling range, an increase in the cetane number to approximately 43 in the DHTU stripper bottoms is achieved.
According to a preferred embodiment, make up hydrogen gas is supplied.
The DHTU produces a final Distillate product from the bottom of stripper column (48) and sends it to the blend station in the blending unit (52). Wild Naphtha (651) produced from the top of the stripper column is recirculated back to a naphtha hydrotreating unit (51).
According to the illustrated preferred embodiment, the first section of the reaction section is the fresh feed section which allows the coker distillate (53) and light atmospheric gas oil (LAGO) (71) to be delivered to the DHTU reactor (42) from the untreated distillate tank (35). Feed filtration can be carried out first to reduce catalyst deactivation by pore blockage. The combined stream (37) is then fed into the horizontal feed surge drum where the water phase is separated from the liquid hydrocarbon phase. The remaining distillate feed which has been separated of water then pumped through a cascade of heat exchangers before entering the DHTU reactor (40). The feed is mixed with hot recycle hydrogen stream containing greater than 92%
hydrogen (heated up to 347 C) and this mixed feed (39) enters from the top of the DHTU reactor (42).
Cold quench hydrogen is introduced at various sections to keep the reactor temperature at desirable temperatures.
In the preferred embodiment illustrated in Figure 1, the DHTU is a single reactor design reactor (42) has five catalyst beds (I42a, 142b, 142c, 142d, 242, 342, 442, 542a and 542b) each separated a quench zone (144, 244, 344, 444). The quench zones comprise: a catalyst support grid; a liquid collect tray; a splash tray and support beams; vapour/liquid distribution tray; a quench distributor and a mixing chamber.
The top bed (142) of the reactor is filled with graded layer of cayalysts (142a, I42b, 142c, I42d).
The primary function of this bed to capture impurities such as metals corrosion products, silica and other foulants, with little hydrotreating activity. Bed-2 and Bed-3 of the reator are filled with catalysts that have hydrotreating and silicon absorbing capability. High silica tolerant material was used to manage the high solica content present in coker distillate feed. The fourth catalyst bed (442) and the upper portion of the fifth catalyst bed (542a) are loaded with high activity catalyst used primarily for denitrification, desulphunzation and aromatic saturation. The cracking catalyst is loaded on the lower half of the fifth bed (542b).
One of the primary objective of the distillate reactor is to achieve sufficient aromatics saturation to meet the synthetic crude oil (SCO) cetane specification of 40 and jet cut smoke point of 18 mm. limitations for aromatic saturation favour low temperature and high pressure to achieve low concentrations and closer approaches to equilibrium point. Consequently, the distillate hydrotreater is run at a similar reactor outlet pressure (9393 kPa) to the gas oil hydrotreater, but at a lower temperature through the catalyst bed.
Inter-bed hydrogen quench is preferably used to control the catalyst bed temperatures that would otherwise increase due to the heat release from the exothermic saturation, denitrification and desulphurization reactions The reactor effluent leaves the reactor from the bottom and is sent to the reactor effluent cooling through a cascade of heat exchangers, then into the hot and cold separation sections.
According to the preferred embodiment illustrated, the reactor effluent exits the bottom of the reactor (642) and is cooled to 316 C through a cascade of heat exchangers; the condensed portion of the reactor effluent is separated from vapour in a vertical hot separator (44).
The condensed portion of reactor effluent from hot separator is let-down into the hot flash drum (46) under level control, and is subsequently sent to the stripper (48). This configuration maintains heat in the liquid phase, reducing the utility load at the stripper (48).
The vapors from hot separator goes through series of heath exchanges (600) for heat recovery. Wash water is injected upstream the hot separator vapour condenser to present deposition of ammonia salts. Final cooled stream (645) is collected in cold separator for vapor-liquid-aqueous separation. The hydrocarbon liquid from cold separator (45) is send to cold flash drum (671) and then to stripper (48), after preheating.
According to a preferred embodiment of the present invention, only the last half of the last reactor bed (542b) contains a mild hydrocracking catalyst.
Diesel blending facility The final diesel blending facility (55) can provide the necessary equipment to accomplish water separation (if necessary) (58), chemical treatment (if necessary) (60) and loading (62).
According to a preferred embodiment of the present invention, the diesel blending facility consists of 4 tanks each with 2500 bbl capacity. One tank is designated for receiving the raw treated distillate in batches. The remaining three tanks cycle through four stages: a circulation and settling stage, a testing stage, a hold stage and a loading stage. The system also contains transfer pumps, recirculation pumps, loading pumps and pump dedicated to the addition of biodiesel. In addition, a cooling system is provided to cool the disele product during circulation and chemical addition. A separate tank of biodiesel is provided to facilitate blending of biodiesel at appropriate quantities in summer, in order to meet the annual biodiesel specifications. The same tank is used as jet fuel tank during winter months.
During winter months, when biodiesel injection is stopped, the biodiesel storage tank is used to store and inject jet fuel as required to meet the cloud point specification. To that effect, there is also preferably a pump to inject biodiesel/jet fuel. Also preferably, there is an additives injection system for lubricity, cetane, and conductivity improvers as a single concoction via totes and pumps. There can also be a sump to collect water from tank dewatering & sampling, complete with vacuum out connections.
Properties of the blended product According to a preferred embodiment, the temperature of the supplied diesel product to trucks from facility is a maximum of 35 C. The water content limit in mine diesel is a maximum of 250 ppmw. In some process embodiments, the diesel product obtained meets industry CGSB
specifications and even exceeds the CGSB specifications for certain parameters (eg. CGSB specification is minimum of 40 cetane number and the diesel produced according to the present invention has typical of 42 cetane number).
Preferably, the biodiesel content is of 5% during the summer fuel period.
Design Features of blending facility Preferably, a 5 micron filter is provided in the loading line. Moreover, a prefilter (3 micron) and a coalescer (2 micron) are provided for improved water separation capability to ensure that water content in diesel product is less than 250 ppmw.
Process Description The raw treated distillate is transferred via the filling pump and passes via a fin fan cooler and then via the prefilter and coalescer and it then goes to a designated filling tank.
Recirculation & Settling Stag_e Upon completion of filling, the filling tank will transfer the fluid-to one of the three 2500 bbl tanks via the circulation pump. During recirculation through a fin-fan heat exchanger, 5 % biodiesel will be added to the recirculation product using a bio diesel pump. Other chemical additives such lubricity improver, cetane improver and conductivity improver will also be added during this stage to achieve desired product specifications.
In an embodiment of the present invention, the distillate temperature in the tank (52) is elevated at 45-50 C cooling is required to meet temperature design criteria of less than 35 C. A fin-fan air cooler can be used to cool distillate product to below 35 C. Subsequently, the tank which has received the materials after injection of biodiesel and chemicals via the circulation pump will be in a settling stage until it is required to go in loading stage. During the settling stage, dewatering of the tank is done.
After dewatering is done in the settling stage, a tank sample is collected and sent to the lab. The 2500 bbl tanks allow for the collection of samples from top middle and bottom sample points to analyze for water content. If the tank is off spec for any parameter it must be corrected at this stage or pumped back to (52) as uncorrectable. Upon lab clearance, the tank content is certified and awaits sequencing into the Loading Stage. This is the holding stage.
Once the previous 2500 bbl tank which is in the loading stage reaches a low level, the tank which is in the holding stage moves on the loading stage. It provides diesel product for loading trucks via a loading pump (preferably, one on line and one spare) loading filter (5 micron) and bottom loading arm (one on line and one spare) which is equipped with a flow meter.
It will be appreciated that variations of the above disclosed and other features and functions, or alternatives thereof, maybe desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein maybe subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.
The present invention may be better understood in consideration of the following description of various embodiments of the invention in connection with the accompanying drawings, in which:
Figure 1 is a schematic view of the hydrotreater unit used in the processing step of the bitumen derived coker distillate and LAGO streams for the hydrotreatment and hydrocracking steps according to a preferred embodiment of the present invention;
Figure 2 is a schematic view of the process according to a preferred embodiment of the present invention.
Figure 3 is a close up schematic view of a portion of the process according to a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The particular values and compositions discussed in these non-limiting examples can be varied and are cited merely to illustrate at least one embodiment and are not intended to limit the scope thereof.
According to a preferred embodiment of the present invention, there is provided a method to use a typical oil sands upgrading facility after minimal cost and minimal modification, untreated distillate product can be used to make low cloud point ULSD diesel.
According to a preferred embodiment of the present invention, the feed for the production of mine diesel is a combination of streams, LAGO and coker distillate, this stream may contain up to 2000 to 3000 ppm of total water with up to 150 ppm of chemically bonded water. Cloud point specification is a very important for parameter for the production of low cloud point winter mine diesel. Low cloud point winter diesel can be made if the coker distillate 95% ASTM-D2887 cut point does not exceed 335 C. Coker distillate and LAGO has a direct effect on density, flashpoint, distillation 90% recovered, cetane carbon residue and viscosity but are not a constraint to diesel production if coker distillate and LAGO 95% ASTM-D2887 are kept below 335 C and 370 C respectively.
Separation of the feed from the rest of the distillation According to a preferred embodiment of the present invention, the coker fractionator and bitumen distillation column are used to separate the distillate fraction from the Dilbit (bitumen diluted with one or =
more lighter petroleum products, typically natural-gas condensates such as naphtha) and cracked coker fractionator feed respectively. Preferably, untreated distillates streams and LAGO streams from these columns are collected in an intermediate tank before being processed in the mild hydrocracking reactor.
Process steps Referring now to Figures 2 and 3, bitumen (1) is fed to a bitumen column (2).
This column produces three streams, LAGO (Light Atmospheric Gas Oil), HAGO (Heavy Atmospheric Gas Oil) and ATM
(Atmospheric Bottoms). Small off-gas and sour water streams are produced as by-products. ATM is fed to the coking unit (4) whereas the LAGO stream (3) once having gone through a LAGO side stripper (6) is then recombined with the coker distillate (5). This combined distillate (7) (untreated distillate) is sent to storage (35) before treating it.
The broad steps of a preferred embodiment of the process according to the present invention comprise untreated distillate being fed to a hydrotreater; product from the hydrotreater is stored in a tank; and a stream from this treated distillate tank being used to prepare diesel.
According to a preferred embodiment of the present invention, in order to minimize hydrotreating and to maximize hydrocracking of combined distillate stream in the DHT
reactor, inventors have established that this is accomplished by running low temperature on hydrotreating beds, and higher inlet temperatures on the hydrocracking bed.
=
Hydrotreating primarily involves the removal of sulphur and nitrogen in addition to the saturation of olefinic and aromatic compounds by breaking their double carbon bonds, and removing other contaminants such as oxygenates and organometallic compounds. Preferably, the distillate hydrotreating process Units (DHTU) Plant is designed to achieve a cetane number of 40 in the 177 C - 343 C
boiling range of the overall synthetic crude oil blend. The extent of the saturation of the various aromatics is performed to achieve the desired SCO cetane number requirement. This is however limited by reaction kinetic equilibria. By saturating the aromatics to less than 25 % volume in the final 177 C - 343 C
boiling range, an increase in the cetane number to approximately 43 in the DHTU stripper bottoms is achieved.
According to a preferred embodiment, make up hydrogen gas is supplied.
The DHTU produces a final Distillate product from the bottom of stripper column (48) and sends it to the blend station in the blending unit (52). Wild Naphtha (651) produced from the top of the stripper column is recirculated back to a naphtha hydrotreating unit (51).
According to the illustrated preferred embodiment, the first section of the reaction section is the fresh feed section which allows the coker distillate (53) and light atmospheric gas oil (LAGO) (71) to be delivered to the DHTU reactor (42) from the untreated distillate tank (35). Feed filtration can be carried out first to reduce catalyst deactivation by pore blockage. The combined stream (37) is then fed into the horizontal feed surge drum where the water phase is separated from the liquid hydrocarbon phase. The remaining distillate feed which has been separated of water then pumped through a cascade of heat exchangers before entering the DHTU reactor (40). The feed is mixed with hot recycle hydrogen stream containing greater than 92%
hydrogen (heated up to 347 C) and this mixed feed (39) enters from the top of the DHTU reactor (42).
Cold quench hydrogen is introduced at various sections to keep the reactor temperature at desirable temperatures.
In the preferred embodiment illustrated in Figure 1, the DHTU is a single reactor design reactor (42) has five catalyst beds (I42a, 142b, 142c, 142d, 242, 342, 442, 542a and 542b) each separated a quench zone (144, 244, 344, 444). The quench zones comprise: a catalyst support grid; a liquid collect tray; a splash tray and support beams; vapour/liquid distribution tray; a quench distributor and a mixing chamber.
The top bed (142) of the reactor is filled with graded layer of cayalysts (142a, I42b, 142c, I42d).
The primary function of this bed to capture impurities such as metals corrosion products, silica and other foulants, with little hydrotreating activity. Bed-2 and Bed-3 of the reator are filled with catalysts that have hydrotreating and silicon absorbing capability. High silica tolerant material was used to manage the high solica content present in coker distillate feed. The fourth catalyst bed (442) and the upper portion of the fifth catalyst bed (542a) are loaded with high activity catalyst used primarily for denitrification, desulphunzation and aromatic saturation. The cracking catalyst is loaded on the lower half of the fifth bed (542b).
One of the primary objective of the distillate reactor is to achieve sufficient aromatics saturation to meet the synthetic crude oil (SCO) cetane specification of 40 and jet cut smoke point of 18 mm. limitations for aromatic saturation favour low temperature and high pressure to achieve low concentrations and closer approaches to equilibrium point. Consequently, the distillate hydrotreater is run at a similar reactor outlet pressure (9393 kPa) to the gas oil hydrotreater, but at a lower temperature through the catalyst bed.
Inter-bed hydrogen quench is preferably used to control the catalyst bed temperatures that would otherwise increase due to the heat release from the exothermic saturation, denitrification and desulphurization reactions The reactor effluent leaves the reactor from the bottom and is sent to the reactor effluent cooling through a cascade of heat exchangers, then into the hot and cold separation sections.
According to the preferred embodiment illustrated, the reactor effluent exits the bottom of the reactor (642) and is cooled to 316 C through a cascade of heat exchangers; the condensed portion of the reactor effluent is separated from vapour in a vertical hot separator (44).
The condensed portion of reactor effluent from hot separator is let-down into the hot flash drum (46) under level control, and is subsequently sent to the stripper (48). This configuration maintains heat in the liquid phase, reducing the utility load at the stripper (48).
The vapors from hot separator goes through series of heath exchanges (600) for heat recovery. Wash water is injected upstream the hot separator vapour condenser to present deposition of ammonia salts. Final cooled stream (645) is collected in cold separator for vapor-liquid-aqueous separation. The hydrocarbon liquid from cold separator (45) is send to cold flash drum (671) and then to stripper (48), after preheating.
According to a preferred embodiment of the present invention, only the last half of the last reactor bed (542b) contains a mild hydrocracking catalyst.
Diesel blending facility The final diesel blending facility (55) can provide the necessary equipment to accomplish water separation (if necessary) (58), chemical treatment (if necessary) (60) and loading (62).
According to a preferred embodiment of the present invention, the diesel blending facility consists of 4 tanks each with 2500 bbl capacity. One tank is designated for receiving the raw treated distillate in batches. The remaining three tanks cycle through four stages: a circulation and settling stage, a testing stage, a hold stage and a loading stage. The system also contains transfer pumps, recirculation pumps, loading pumps and pump dedicated to the addition of biodiesel. In addition, a cooling system is provided to cool the disele product during circulation and chemical addition. A separate tank of biodiesel is provided to facilitate blending of biodiesel at appropriate quantities in summer, in order to meet the annual biodiesel specifications. The same tank is used as jet fuel tank during winter months.
During winter months, when biodiesel injection is stopped, the biodiesel storage tank is used to store and inject jet fuel as required to meet the cloud point specification. To that effect, there is also preferably a pump to inject biodiesel/jet fuel. Also preferably, there is an additives injection system for lubricity, cetane, and conductivity improvers as a single concoction via totes and pumps. There can also be a sump to collect water from tank dewatering & sampling, complete with vacuum out connections.
Properties of the blended product According to a preferred embodiment, the temperature of the supplied diesel product to trucks from facility is a maximum of 35 C. The water content limit in mine diesel is a maximum of 250 ppmw. In some process embodiments, the diesel product obtained meets industry CGSB
specifications and even exceeds the CGSB specifications for certain parameters (eg. CGSB specification is minimum of 40 cetane number and the diesel produced according to the present invention has typical of 42 cetane number).
Preferably, the biodiesel content is of 5% during the summer fuel period.
Design Features of blending facility Preferably, a 5 micron filter is provided in the loading line. Moreover, a prefilter (3 micron) and a coalescer (2 micron) are provided for improved water separation capability to ensure that water content in diesel product is less than 250 ppmw.
Process Description The raw treated distillate is transferred via the filling pump and passes via a fin fan cooler and then via the prefilter and coalescer and it then goes to a designated filling tank.
Recirculation & Settling Stag_e Upon completion of filling, the filling tank will transfer the fluid-to one of the three 2500 bbl tanks via the circulation pump. During recirculation through a fin-fan heat exchanger, 5 % biodiesel will be added to the recirculation product using a bio diesel pump. Other chemical additives such lubricity improver, cetane improver and conductivity improver will also be added during this stage to achieve desired product specifications.
In an embodiment of the present invention, the distillate temperature in the tank (52) is elevated at 45-50 C cooling is required to meet temperature design criteria of less than 35 C. A fin-fan air cooler can be used to cool distillate product to below 35 C. Subsequently, the tank which has received the materials after injection of biodiesel and chemicals via the circulation pump will be in a settling stage until it is required to go in loading stage. During the settling stage, dewatering of the tank is done.
After dewatering is done in the settling stage, a tank sample is collected and sent to the lab. The 2500 bbl tanks allow for the collection of samples from top middle and bottom sample points to analyze for water content. If the tank is off spec for any parameter it must be corrected at this stage or pumped back to (52) as uncorrectable. Upon lab clearance, the tank content is certified and awaits sequencing into the Loading Stage. This is the holding stage.
Once the previous 2500 bbl tank which is in the loading stage reaches a low level, the tank which is in the holding stage moves on the loading stage. It provides diesel product for loading trucks via a loading pump (preferably, one on line and one spare) loading filter (5 micron) and bottom loading arm (one on line and one spare) which is equipped with a flow meter.
It will be appreciated that variations of the above disclosed and other features and functions, or alternatives thereof, maybe desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein maybe subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.
Claims (13)
1 Method of preparing ultra low sulfur diesel, said method comprising the steps of:
- feeding bitumen into a bitumen column;
- obtaining at least two output streams from the bitumen column; said at least two streams comprising - a light atmospheric gas oil stream; and - an atmospheric bottoms stream;
- feeding the light atmospheric gas oil stream to a light atmospheric gas oil side stripper;
- monitoring the distillate from the light atmospheric gas oil side stripper to obtain a light atmospheric gas oil distillate 95% cut point at no more than 370°C;
- feeding the atmospheric bottoms stream to a coker fractionator; and - monitoring the distillate from the coker fractionator to obtain a coker distillate 95% cut point at no more than 335°C to meet a -38°C cloud point;
- monitoring and controlling the addition of cracked components to meet diesel cloud point specification (Coker Distillate 95% point);
- combining the light atmospheric gas oil distillate and coker distillate to form a combined distillate stream;
- performing a step of mild hydrocracking on the combined distillate stream, which yields an effluent comprising no more than 15 ppm sulphur.
- feeding bitumen into a bitumen column;
- obtaining at least two output streams from the bitumen column; said at least two streams comprising - a light atmospheric gas oil stream; and - an atmospheric bottoms stream;
- feeding the light atmospheric gas oil stream to a light atmospheric gas oil side stripper;
- monitoring the distillate from the light atmospheric gas oil side stripper to obtain a light atmospheric gas oil distillate 95% cut point at no more than 370°C;
- feeding the atmospheric bottoms stream to a coker fractionator; and - monitoring the distillate from the coker fractionator to obtain a coker distillate 95% cut point at no more than 335°C to meet a -38°C cloud point;
- monitoring and controlling the addition of cracked components to meet diesel cloud point specification (Coker Distillate 95% point);
- combining the light atmospheric gas oil distillate and coker distillate to form a combined distillate stream;
- performing a step of mild hydrocracking on the combined distillate stream, which yields an effluent comprising no more than 15 ppm sulphur.
2. The method according to claim 1, wherein the step of mild hydrotreatment is carried out in the presence of a mild hydrocracking catalyst in a last bed of a distillate hydrotreater (DHT) reactor along with hydrotreating in all catalyst beds.
3. The method according to claim 1 or 2, further comprising a step of maximizing naphtha in the distillate product.
4 The method according to claim 3, where in the step of maximizing the naphta distillate product is perfomed at the coker fractionator by minimizing the overhead temperature of the fractionator, and forcing the lighter components of the stream above the distillate (naphtha) into the coker distillate product.
5. The method according to claim 3, where in the step of maximizing the naphta indistillate product is perfomed at the distillate stripper column in the DHT by minimizing the overhead temperature to force the lighter components from the wild naphtha stream into the distillate product
6. The method according to claim 3, where in the step of maximizing the naphta indistillate product is perfomed at the coker fractionator by minimizing the overhead temperature of the fractionator, and forcing the lighter components of the stream above the distillate (naphtha) into the coker distillate product and at the distillate stripper column in the DHT by minimizing the overhead temperature to force the lighter components from the wild naphtha stream into the distillate product.
7. Method according to any one of claims 1 to 6, further comprising a step of filtration and coalescing of the treated distillate after the step of mild hydrocracking.
8. Method according to any one of claims 1 to 7, wherein the method further comprises a step of blending the produced diesel blend with an external source of jet fuel to improve the cloud point of the diesel blend.
9. Method according to any one of claims 1 to 8, wherein the method further comprises the blending of the produced diesel blend with the addition of at least one of the components selected from the group consisting of: off-road diesel dye, cetane additive, lubricity additive and combinations thereof
Method according to any one of claims 1 to 9, wherein the method comprises running the hydrotreatment at temperatures ranging from 287°C to 370°C.
11. Method according to claim 10, wherein the method further comprises running the inlet of the hydrocracking bed at temperatures ranging from 310°C to 370°C.
12. Method of preparing ultra low sulfur diesel, said method comprising the steps of:
- feeding bitumen into a bitumen column;
- obtaining at least two output streams from the bitumen column; said at least two streams comprising.
- a light atmospheric gas oil stream; and - an atmospheric bottoms stream;
- feeding the light atmospheric gas oil stream to a light atmospheric gas oil side stripper;
- monitoring the distillate from the light atmospheric gas oil side stripper to obtain a light atmospheric gas oil distillate 95% cut point at no more than 370°C;
- feeding the atmospheric bottoms stream to a coker fractionator; and - monitoring the distillate from the coker fractionator to obtain a coker distillate 95% cut point at no more than 335°C;
- monitoring and controlling the addition of cracked components to meet diesel cloud point specification (Coker Distillate 95% point); and - performing a step of mild hydrocracking, to yield an effluent comprising no more than 15 ppm of sulphur.
- feeding bitumen into a bitumen column;
- obtaining at least two output streams from the bitumen column; said at least two streams comprising.
- a light atmospheric gas oil stream; and - an atmospheric bottoms stream;
- feeding the light atmospheric gas oil stream to a light atmospheric gas oil side stripper;
- monitoring the distillate from the light atmospheric gas oil side stripper to obtain a light atmospheric gas oil distillate 95% cut point at no more than 370°C;
- feeding the atmospheric bottoms stream to a coker fractionator; and - monitoring the distillate from the coker fractionator to obtain a coker distillate 95% cut point at no more than 335°C;
- monitoring and controlling the addition of cracked components to meet diesel cloud point specification (Coker Distillate 95% point); and - performing a step of mild hydrocracking, to yield an effluent comprising no more than 15 ppm of sulphur.
13.
Method according to claim 12, wherein the hydrocracking yields an effluent comprising no more than 10 ppm of sulphur.
Method according to claim 12, wherein the hydrocracking yields an effluent comprising no more than 10 ppm of sulphur.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA2,941,583 | 2016-09-13 | ||
| CA2941583A CA2941583A1 (en) | 2016-09-13 | 2016-09-13 | Process to make diesel using oil sands derived distillate product |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2977388A1 true CA2977388A1 (en) | 2018-03-13 |
Family
ID=61617240
Family Applications (2)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA2941583A Abandoned CA2941583A1 (en) | 2016-09-13 | 2016-09-13 | Process to make diesel using oil sands derived distillate product |
| CA2977388A Pending CA2977388A1 (en) | 2016-09-13 | 2017-08-28 | Process to make diesel using oil sands derived distillate product |
Family Applications Before (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA2941583A Abandoned CA2941583A1 (en) | 2016-09-13 | 2016-09-13 | Process to make diesel using oil sands derived distillate product |
Country Status (1)
| Country | Link |
|---|---|
| CA (2) | CA2941583A1 (en) |
-
2016
- 2016-09-13 CA CA2941583A patent/CA2941583A1/en not_active Abandoned
-
2017
- 2017-08-28 CA CA2977388A patent/CA2977388A1/en active Pending
Also Published As
| Publication number | Publication date |
|---|---|
| CA2941583A1 (en) | 2018-03-13 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| DK2788458T3 (en) | PROCEDURE FOR HYDRO-CONVERSION OF RAW OIL CHARGES IN FIXED RENTS FOR THE PREPARATION OF FUEL OIL WITH A LOW SULFUR CONTENT | |
| TWI617661B (en) | Process with separation for treating petroleum feedstocks for the production of fuel oils with a low sulfur content | |
| KR101629047B1 (en) | Hydrotreatment and dewaxing treatments for improving freezing point of jet fuels | |
| KR101603395B1 (en) | Process and apparatus for hydroprocessing hydrocarbons | |
| CN105308158A (en) | Increased production of fuels by integration of vacuum distillation with solvent deasphalting | |
| US9394494B2 (en) | Production of lubricating oil basestocks | |
| CN101712886A (en) | Method for hydrogenating coal tar | |
| CN108699454B (en) | Process and apparatus for hydrocracking and hydroisomerizing a hydrocarbon stream | |
| US20140042056A1 (en) | Co-production of heavy and light base oils | |
| CN105694966B (en) | A kind of method that naphtha and clean gasoline are produced by catalytic cracking diesel oil | |
| US9938475B2 (en) | Catalyst configuration for increased hydrocracking activity | |
| KR20200103811A (en) | Manufacture of high quality diesel by supercritical water process | |
| US8828218B2 (en) | Pretreatment of FCC naphthas and selective hydrotreating | |
| KR20150128703A (en) | Process for improving cold flow properties and increasing yield of middle distillate feedstock through liquid full hydrotreating and dewaxing | |
| CA2977388A1 (en) | Process to make diesel using oil sands derived distillate product | |
| CN113122321B (en) | Hydrocracking method for improving aromatic hydrocarbon potential of heavy naphtha | |
| RU2741014C1 (en) | Method and device for hydroisomerisation of hydrotreated liquid flow | |
| RU2724602C1 (en) | Methods of producing fuel hydrocarbon and base lubricating oil | |
| CN103484160A (en) | Processing method for conversion of residual oil to light fractions | |
| CN110776953A (en) | Process for treating heavy hydrocarbon feedstocks comprising fixed bed hydroprocessing, two deasphalting operations and hydrocracking of the bitumen | |
| CN109988630B (en) | Wax oil hydrogenation method and system | |
| CN109988600B (en) | Flexible hydrogenation modification process for poor diesel oil | |
| RU2701526C2 (en) | Production of high-quality diesel fuel and lubricant materials from aromatic carbonaceous material with high boiling point | |
| CA2960399A1 (en) | Catalyst configuration for increased hydrocracking activity |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request |
Effective date: 20220829 |
|
| EEER | Examination request |
Effective date: 20220829 |
|
| EEER | Examination request |
Effective date: 20220829 |
|
| EEER | Examination request |
Effective date: 20220829 |
|
| EEER | Examination request |
Effective date: 20220829 |
|
| EEER | Examination request |
Effective date: 20220829 |