Background
Visbreaking has the advantages of simple equipment, less investment, capability of processing inferior residual oil, mature technology and the like, can produce light oil or raw materials for further light processing, and is widely applied to oil refineries or residual oil processing plants.
Visbreaking is a shallow thermal conversion process that is primarily fed by vacuum residue. Visbreaking has been used for upgrading residua since 1930. It can not only reduce the viscosity of oil product, but also raise the yield of light fraction of gasoline, diesel oil, etc. without coking. The heavy oil not only contains extremely complex hydrocarbons, but also contains a plurality of non-hydrocarbons and a plurality of metal types, so that the processing of the heavy oil is extremely complex. However, in general, there are two main reactions in visbreaking, one is the cracking reaction and one is the condensation reaction. In recent years, there have been many studies on the improvement and combination process of visbreaking equipment, and yanogen summarized the improved visbreaking process and proposed several new combination processes, such as: catalytic hydrogenation viscosity breaking, viscosity breaking-deasphalting combined process, thickened oil demulsification-viscosity breaking combined process and the like. In the experiment of the visbreaking-residual oil hydrodesulfurization combined process, Zhoujiashun and the like, it is found that from visbreaking, not only part of light components can be obtained, but also the quality of hydrogenation products can be ensured, so that the conclusion is drawn that: the visbreaking-residual oil hydrodesulfurization combined process has certain economic benefit and feasibility.
CN101463266B and CN101463267B disclose a visbreaking method, which comprises subjecting visbreaking raw material to vacuum distillation under the condition of vacuum distillation to obtain vacuum distillate and vacuum residue with cutting temperature not less than 540 ℃; and performing visbreaking on the vacuum distillate under the visbreaking condition, mixing a product obtained after visbreaking of the vacuum distillate with the vacuum residue to obtain mixed oil, performing visbreaking on the mixed oil under the visbreaking condition, wherein the visbreaking temperature of the vacuum distillate is higher than the visbreaking temperature of the mixed oil. The visbreaking method provided by the invention can improve the visbreaking depth, namely the visbreaking conversion rate is improved, the visbreaking residual oil viscosity is reduced, and the visbreaking residual oil stability is good. However, the method only combines the existing raw materials according to the weight of fractions, and cannot fundamentally prolong the production period and solve the problem of coking of the visbreaking heating furnace tube.
CN103160308A and CN103160308B disclose a method for preventing coking of visbreaking heating furnaces for inferior heavy oil, which increases steam injection points by optimizing the arrangement type of furnace tubes of the visbreaking furnace, the temperature of the furnace outlet and the linear velocity of medium flowing in the furnace tubes, thereby reducing the coking speed in the furnace tubes of the heating furnaces and prolonging the production period. But the method only prolongs the production period by optimizing the process conditions and does not fundamentally solve the problem of coking of the visbreaking heating furnace tube.
Disclosure of Invention
Aiming at the defects of the prior art, the invention provides a processing method for reducing viscosity of high-viscosity oil. The processing method can utilize the temperature of catalytic flue gas, increase the yield of light products and effectively prevent equipment from coking.
The visbreaking processing method of the high-viscosity oil comprises the steps of carrying out visbreaking reaction on a high-viscosity oil raw material in a visbreaking tower under the action of catalytic flue gas, wherein the visbreaking reaction pressure is generally-0.03-0.3 MPa, preferably-0.01-0.1 MPa, and the reaction temperature is generally 380-550 ℃, preferably 400-450 ℃; the reaction time of the visbreaking is generally 0.01-60 min, preferably 5-20 min, the visbreaking tower adopts a three-dimensional mass transfer tower plate, the mass transfer element adopts a gas lift cylinder structure, the wall of the gas lift cylinder is provided with an opening, and at least one layer of mesh plate is arranged in the gas lift cylinder.
According to the method of the present invention, there is no special requirement on the kind of the high viscosity oil raw material, and a heavy oil raw material requiring viscosity reduction commonly used in the art can be used, specifically, the heavy oil raw material can be one or more of vacuum residue, atmospheric residue, heavy crude oil, deoiled asphalt, residue hydrogenated heavy oil, thermally cracked heavy oil, extracted oil refined from lubricating oil, catalytically cracked cycle oil, catalytically cracked decant oil, ethylene cracked tar, coal tar, shale oil, oil sand heavy oil, and natural asphalt.
According to the method, the catalytic flue gas is low-oxygen flue gas, and can be completely regenerated flue gas or incompletely regenerated flue gas. The SOx content is generally 700-4500 mg/m3The oxygen content is generally less than 3% by weight, preferably less than 1% by weight. The catalytic flue gas typically has a temperature of 180 ℃ to 230 ℃.
According to the method, the temperature of the catalytic flue gas before entering the viscosity reduction tower is preferably controlled to be 600-800 ℃, the high-viscosity heavy oil raw material in the viscosity reduction tower reaches the cracking temperature through the high-temperature catalytic flue gas, and due to the fact that the oxygen content of the catalytic flue gas is extremely low, coking can be reduced, and the liquid yield can be further improved. Because the catalytic flue gas is adopted to heat the high-viscosity oil, the process needs a larger gas-oil ratio which is generally 300-1800, and preferably 500-1200. The large gas-oil ratio can strengthen mass transfer and is beneficial to improving the cracking effect.
According to the method, the oxygen content of the catalytic flue gas entering the viscosity reduction tower is preferably controlled to be 0.5-0.8 wt%, and the coke coarse powder possibly carried to the viscosity reduction tower by the deoxidation reactor is treated by a very small amount of oxygen, so that the coke coarse powder is prevented from becoming a raw coke precursor and influencing the quality of the subsequently generated oil.
A method for processing highly viscous heavy oil, wherein one preferred embodiment comprises the following steps: the catalytic flue gas is heated to 500-850 ℃ through a heating furnace after exchanging heat with an oil gas product of a viscosity reducing tower, preferably heated to 600-800 ℃, enters the viscosity reducing tower to contact with a high-viscosity heavy oil raw material after exchanging heat with the viscosity reducing residual oil to carry out viscosity reducing reaction to obtain the oil gas product and the viscosity reducing residual oil, the temperature of the catalytic flue gas before entering the viscosity reducing tower is controlled to be 600-800 ℃, the flow is determined according to the feeding amount of the high-viscosity raw material treated by a device, the feeding ratio of the catalytic flue gas to the high-viscosity heavy oil raw material is 305-1900 ml/g, the reaction pressure of viscosity reducing cracking is-0.03-0.3 MPa, preferably-0.01-0.1 MPa, the reaction temperature is 380-550 ℃, preferably 400-450 ℃, and the reaction time of viscosity reducing cracking is generally 0.01-60 min, preferably 5-20 min.
In the method, preferably, the catalytic flue gas heated by the heating furnace enters the viscosity reduction tower after passing through an oxygen content controller, and the oxygen content controller is used for removing oxygen in the catalytic flue gas or supplementing a small amount of oxygen, so that the oxygen content in the catalytic flue gas is stably controlled to be 0.5-1 wt%. Meanwhile, the problem of oxygen content fluctuation of catalytic flue gas caused by operation fluctuation of an upstream device is solved, and the used oxygen content controller is a gas-solid fluidized bed reactor. The gas phase in the oxygen content controller is catalytic flue gas heated by a heating furnace, and the fluidized solid in the reactor is coke coarse powder added through a solid adding port of the reactor, namely oxygen and coke in the catalytic flue gas are converted into CO, so that the aim of removing oxygen is fulfilled. A gas distributor is arranged below the oxygen content controller and plays a role in supporting solids in the reactor in the initial startup period.
More preferred is a process inBefore the catalytic flue gas enters the oxygen content controller, the catalytic flue gas enters a SOx removal reactor, and the method can be a sodium-alkali washing method, a sodium-calcium double-alkali method, a seawater washing method and the like which are well known by persons skilled in the art, preferably a sodium-alkali washing method, preferably NaOH and SO2The amount of the sodium base is determined according to the mass ratio of 2: 1.
In the method, the raw material and the generated viscosity-reducing residual oil are subjected to heat exchange to 200-400 ℃, and then enter a viscosity-reducing tower, so that the energy consumption can be maximally saved.
In the method, the number of the tower plate layers in the viscosity reducing tower is determined according to the weight of the raw materials, and is generally 5-20 layers, preferably 8-15 layers. The shape of the mesh plate corresponds to that of the cap, and the mesh structure can be circular holes, strip-shaped holes, rhombic holes and other regular holes. Downward baffles can be arranged around the mesh plate to play a role in guiding flow. The angle between the baffle and the mesh plate can be 15-60 degrees, and preferably 30-45 degrees. The air lift cylinder can be in a cuboid, square, straight cylinder or conical bottom structure, and is preferably in a cuboid or square shape. The gas lift cylinder is provided with a plurality of holes on the cylinder wall above the liquid collecting and discharging plate, the opening rate of the gas lift cylinder is generally larger than that of the tower plate, and the opening rate of the cylinder wall of the gas lift cylinder/the opening rate of the tower plate is preferably more than 1.5.
According to the novel processing method of the high-viscosity heavy oil, the catalytic flue gas raw material is heated and then is used for being in contact with the heavy oil raw material for heat exchange to reach the cracking required temperature, the phenomena of serious coking and the like caused by the fact that the heavy oil raw material is directly heated to the cracking required temperature in the heating furnace in the prior art are overcome, the coking in a heating unit such as a heating furnace tube can be reduced, and the liquid yield can be improved.
The invention provides a novel high-viscosity heavy oil processing device which comprises a heating unit and a viscosity reducing unit. The catalytic flue gas raw material is heated by the heating unit, and then the heated gas raw material enters the viscosity reduction unit to exchange heat with the heavy oil raw material to the required temperature, so that the coking in the heating unit, such as a heating furnace tube, can be reduced, and the liquid yield can be improved.
The invention provides a new high-viscosity heavy oil processing device which can not only reduce coking in a heating unit such as a heating furnace tube, but also improve the liquid yield by introducing catalytic flue gas which is easily obtained by a refinery and changing the material heating mode. The specific principle is as follows: on one hand, when the heavy oil viscosity reducing device provided by the invention is used for heavy oil viscosity reducing reaction, a heating unit such as a heating furnace only plays a role of providing high-temperature gas required by the reaction, and the heavy oil raw material is not required to be heated to the viscosity reducing reaction temperature (usually 400-450 ℃) like a heating furnace of the existing heavy oil viscosity reducing device, a heat source of the viscosity reducing reaction in the invention is carried by the high-temperature gas, and the high-temperature gas is directly contacted with the heavy oil raw material (which can be properly preheated) in the viscosity reducing unit to reach the viscosity reducing temperature, so that the coking of a furnace tube of the heating furnace can be remarkably reduced.
On the other hand, in a preferred embodiment of the invention, the viscosity reducing unit is a solid mass transfer tray viscosity reducing tower, the solid mass transfer tray arranged in the viscosity reducing tower, the mass transfer element adopts a gas lift cylinder structure, the wall of the gas lift cylinder is provided with an opening, two opposite sides of the gas lift cylinder can even be completely open structures, and the opening rate of the component is large. The gas lift cylinder is internally provided with one or more layers of mesh plate structures, so that the space of the tower plates is fully utilized, and the gas flow through the mesh plates can spray liquid into fine liquid drops due to high operating gas speed, so that the two-phase contact area and the turbulence degree are large, the mass transfer process can be enhanced, and the contact area between the heavy oil raw material in unit volume and high-temperature gas is remarkably increased. The cap cover and the mesh plate are provided with downward baffles, so that the flow guide effect is achieved, the gas-liquid two-phase separation is thorough after the components pass through, the gas-liquid distribution on the tower plate is uniform, and the entrainment of liquid is reduced. And the viscosity reduction tower can be operated under negative pressure, so that the heat transfer capacity of the whole viscosity reduction reaction process is greatly enhanced, the coke formation amount is reduced, the liquid yield is increased, and the long-period operation of the heavy oil viscosity reduction process is realized. The viscosity reducing tower adopts a three-dimensional mass transfer tower plate, so that mass transfer and heat transfer are enhanced, and the viscosity reducing efficiency is improved.
In summary, compared to the prior art, the method of the present invention has the following advantages:
1. the self heat of the catalytic flue gas and the characteristic of low oxygen content are fully utilized. The catalytic flue gas raw material is heated and then is used for contacting with the heavy oil raw material to exchange heat to the cracking required temperature, so that the phenomena of serious coking and the like caused by directly heating the heavy oil raw material in a heating furnace to the cracking required temperature in the prior art are overcome, the coking in a heating unit such as a heating furnace tube can be reduced, and the liquid yield can be improved. Effectively prolongs the operation period of the device.
2. The solid mass transfer tower plate arranged in the viscosity reduction tower adopts a gas lift cylinder structure, the wall of the gas lift cylinder is provided with holes, two opposite sides of the gas lift cylinder can even be of a completely open structure, and the hole opening rate of the component is large. The gas lift cylinder is internally provided with one or more layers of mesh plate structures, so that the space of the tower plates is fully utilized, and the gas flow through the mesh plates can spray liquid into fine liquid drops due to high operating gas speed, so that the two-phase contact area and the turbulence degree are large, the mass transfer process can be enhanced, and the contact area between the heavy oil raw material in unit volume and high-temperature gas is remarkably increased. The cap cover and the mesh plate are provided with downward baffles, so that the flow guide effect is achieved, the gas-liquid two-phase separation is thorough after the components pass through, the gas-liquid distribution on the tower plate is uniform, and the entrainment of liquid is reduced. The integral use of the mass transfer element greatly enhances the heat transfer capacity of the whole viscosity reduction reaction process, reduces the coke formation amount, increases the liquid yield and further prolongs the period of the heavy oil viscosity reduction process.
Detailed Description
The method of the present invention will be described in detail below with reference to the accompanying drawings.
As shown in fig. 1, in the new processing method of high viscosity oil provided by the invention, a heavy oil raw material 17 exchanges heat with viscosity-reduced residual oil 9 generated by reaction through a heat exchanger 10 to 200-400 ℃, and then enters from the top of a viscosity-reduced tower 5 through a pump 6; the catalytic flue gas raw material 1 exchanges heat with unstable gasoline and viscosity-reducing diesel oil 8 generated by reaction through a heat exchanger 10 to 200-300 ℃, enters a gas heating unit 3 to be heated to 350-900 ℃, and then enters the bottom of a viscosity-reducing tower 5 through a heating gas 4; heavy oil 7 is in countercurrent and stepwise contact with high-temperature catalytic flue gas hot air 4 at 350-900 ℃ in a viscosity reducing tower 5, liquid drops are subjected to a thermal cracking reaction rapidly in the hot air, viscosity-reduced residual oil 7 after the reaction exchanges heat with a heavy oil raw material 17 through a viscosity reducing tower bottom outlet device, oil gas 8 generated by the reaction exchanges heat with the catalytic flue gas raw material through a side outlet of the viscosity reducing tower, and oil gas 11 after the heat exchange enters a fractionating tower 13 for separation; in the fractionating tower 13, the oil gas is divided into cracked rich gas 14, unstable gasoline 15 and visbreaking diesel oil 16, and the cracked rich gas 14 obtained by fractionation is desulfurized or directly conveyed to the heating furnace 3 to be combusted and supplied with heat.
The process of the reaction in the visbreaking column is further illustrated according to the process of the present invention, as shown in FIG. 2. The catalytic flue gas 4 passes through the plate holes from the lower layer of the tower plate upwards, the high-viscosity oil raw material 18 enters the tower plate 20 from the downcomer 19, is sucked by the upward gas phase and is carried into the gas-lift cylinder 21, and passes through the mesh plate 22 and the top cover 23, in the process, the liquid phase is pulled into a film and crushed, the gas phase and the liquid phase carry out mass transfer, and finally is sprayed out from the cylinder wall open holes 24 of the gas-lift cylinder or two sides of the gas-lift cylinder, the gas flows to the upper layer of the tower plate, the liquid falls on the liquid collecting plate 25, and.
The novel high viscosity oil processing method of the present invention is further illustrated by the following specific examples.
Examples 1 to 4
4 sets of tests were conducted on a heavy oil viscosity reduction test apparatus, which were example 1, example 2, example 3, and example 4. The experimental set-up of the examples is shown in the flow chart of FIG. 1.
After the heavy oil raw material exchanges heat with viscosity-reducing residual oil generated by reaction through a heat exchanger to 200-400 ℃, the heavy oil raw material enters from the top of a viscosity-reducing tower; the catalytic flue gas raw material exchanges heat with unstable gasoline and viscosity-reducing diesel oil generated by reaction through a heat exchanger to 200-300 ℃, enters a gas heating unit to be heated to 350-900 ℃, and then the heated gas enters the bottom of a viscosity-reducing tower; 8 layers of tower plates are arranged in the viscosity reducing tower, and each layer is provided with 4 mass transfer elements; heavy oil is in countercurrent and stepwise contact with hot air of high-temperature catalytic flue gas at 350-900 ℃ in a viscosity reducing tower, liquid drops are subjected to a thermal cracking reaction rapidly in the hot air, viscosity reducing residual oil at the bottom of the tower is collected and then exchanges heat with a heavy oil raw material, oil gas generated by the reaction exchanges heat with the catalytic flue gas raw material through a lateral outlet of the viscosity reducing tower, and the oil gas after heat exchange enters a fractionating tower for separation; the oil gas is separated into cracked rich gas, unstable gasoline and visbroken diesel in the fractionating tower.
Comparative example 1
The traditional viscosity-reducing process is adopted, the heavy oil raw material is heated by a heating furnace, and about l% of water is injected into the furnace tube to avoid coking in the furnace tube. Then the oil gas enters a reaction tower, and the oil gas at the furnace outlet enters the reaction tower to continue to react for a period of time. The reaction tower is an upflow tower type device, and 5 sieve plates are arranged in the reaction tower. Then enters a fractionating tower for separation.
The raw oils used in example 1, example 2, example 3, example 4 and comparative example 1 were all the same vacuum residue feed and had a kinematic viscosity of 595mm at 100 deg.C2The feed rate was 60kg/h, specific properties are shown in Table 1. Other operation processes are detailed in the detailed description of the specific embodiment of the specification with reference to the accompanying drawings, the main operation conditions are shown in table 2, and the product distribution is shown in table 3.
TABLE 1 Properties of the stock oils
TABLE 2 Main operating conditions
TABLE 3 product distribution
The preferred embodiments of the present invention have been described in detail, however, the present invention is not limited to the specific details of the above embodiments, and various simple modifications may be made to the technical solution of the present invention within the technical idea of the present invention, and these simple modifications are within the protective scope of the present invention.
It should be noted that the technical features described in the above embodiments can be combined in any suitable manner, and the invention is not further described in various possible combinations.
In addition, any combination of the various embodiments of the present invention is also possible, and the same should be considered as the disclosure of the present invention as long as it does not depart from the spirit of the present invention.