Background
The MAPPOL convention provides detailed regulations on the emission control region of fuel oil sulfur content used by a ship, the limit value and the implementation time of the fuel oil sulfur content, and the sulfur content of the fuel oil for the ship is not more than 0.5% when the ship sails in a general region on the sea after 1 month 1 day 2020; when sailing in the emission control area, the sulfur content of the fuel used on the ship should not exceed 0.1 percent. Research shows that the annual low-sulfur fuel oil demand is about 300 ten thousand tons if the MAPPO convention is strictly executed to meet the use requirement of the low-sulfur fuel oil, but from the current market situation, because the sulfur content of crude oil in most production places is higher, almost no refinery which can produce fuel oil with the sulfur content of 0.5 percent or even below 0.1 percent is available all over the world, the market gap of the low-sulfur fuel oil is large, and the production enterprises have urgent technical requirements on the production of the low-sulfur fuel oil.
At present, China has catalytic cracking processing capacity of more than 150Mt/a, the yield of catalytic cracking slurry oil generally accounts for 6-8% of catalytic cracking processing amount, the yield of catalytic slurry oil is very large, the catalytic slurry oil has the characteristics of high density, high sulfur content, high content of heavy components such as colloid and the like, and in addition, the catalytic slurry oil also contains a large amount of catalyst powder, so that the economic value of the catalytic slurry oil is low, and the catalytic slurry oil becomes a key problem to be solved by enterprises. If the catalytic cracking is used as a blending component of low-sulfur fuel oil, the catalytic slurry oil must be pretreated to reduce the density, sulfur content and solid content, especially to remove the solid content, so that the slurry oil de-solidification becomes a key step for realizing efficient utilization of the slurry oil, which is also an important problem in the industry at present.
The method for removing solid from catalytic slurry oil is mainly a filtering solid-removing method, and Huangfu et al, application of slurry oil filtering technology in heavy oil catalytic cracking unit, introduces a method for filtering solid from catalytic slurry oil. Wherein, the core element of the oil slurry filtering system is a porous metal powder sintered filter element. As the hot slurry passes through the filter element, the slurry liquid can pass through the filter element, clean slurry (filtrate) enters the downstream equipment, and solid catalyst particles are trapped on the inner surface of the filter element. The filtered solid catalyst filter cake is back flushed with dry gas and discharged
And a filter cake receiving tank. During the deslagging process, the rapid pressure release and the reverse flow of the filtrate can rapidly strip the solids off the inner surface of the filter element and allow all of the media inside the filter to flow out of the filter through the reject valve. The method needs to be provided with a pre-filtering device and a fine filtering device, and also needs to be provided with auxiliary equipment such as back flushing oil, so that the operation is complicated, the back flushing is frequent, and the actual operation has certain difficulty.
Patent CN 103789028A introduces a pretreatment method of raw material for producing needle coke, in which the raw material for producing needle coke is catalytic cracking slurry oil, in the patent technology, the catalytic cracking slurry oil is firstly filtered by adopting a filtering technology to remove catalyst powder in the slurry oil, then the solid removal slurry oil is hydrogenated by adopting a hydrogenation means to remove part of sulfur and saturated part of aromatic hydrocarbon, and then the ideal component is obtained by distillation and cutting to be used as the raw material for producing needle coke. In the technology, the filtering means is a relatively common oil slurry de-solidification means, but because the particle size of catalyst powder in the catalytic oil slurry is small, and the catalytic oil slurry contains certain viscosity, the catalyst powder is wrapped in the heavy component of the catalytic oil slurry and is difficult to remove through the filtering means, and meanwhile, the heavy component of the catalytic oil slurry is still easy to intercept on a filter screen in the filtering process, so that the filtering effect is poor, and meanwhile, the loss of the heavy component is also caused.
The patent CN 102888244A introduces a production method of low-sulfur marine fuel oil, and the invention relates to a production method of marine fuel oil, which comprises the following steps: heating catalytic slurry oil, filtering the catalytic slurry oil with a precise filtering device to remove tiny catalyst particles in the slurry oil, mixing the catalytic slurry oil with hydrogen, heating, contacting the mixture with a residual oil hydrofining catalyst, a distillate oil hydrofining catalyst and a distillate oil hydrocracking catalyst, reacting the hydrogenated catalytic mixture, separating and fractionating obtained reactants to obtain a tail oil fraction, and mixing the tail oil fraction with vacuum residual oil according to different proportions to obtain a finished product. The method of the invention adopts filtering equipment with larger investment and has larger liquid loss in the actual operation process.
Disclosure of Invention
The catalytic slurry oil obtained by catalytic cracking of heavy oil has the problems of high solid content and small particle size, and when the catalytic slurry oil is treated by means of conventional filtration and the like, the conditions of high liquid recovery loss, incomplete catalyst powder removal, easy blockage of a filter, frequent back washing and unstable operation of a filter device exist, so that most of the catalytic slurry oil can only be used as a coking device feed at present, a large amount of coke with low value is produced as a byproduct, and the value of the catalytic slurry oil cannot be fully exerted. Meanwhile, the residual oil is used as the heaviest component in the crude oil, and how to treat the residual oil and obtain a value-added product is also an urgent problem to be solved.
Aiming at the problems in the prior art, the invention provides a method for producing low-sulfur fuel oil, which starts from the existence state of catalyst powder in catalytic slurry oil and the property characteristics of residual oil, can reduce the solid content and the sulfur content of the catalytic slurry oil, produce high-quality purified slurry oil, and further blend with the residual oil raw material to produce the rare low-sulfur marine fuel oil.
The invention provides a production method of low-sulfur marine fuel oil, which comprises the following steps:
(1) mixing the catalytic slurry oil with a first auxiliary agent, performing sedimentation separation after mixing treatment, and obtaining a first material and residue after separation;
(2) the first material obtained by separation in the step (1) and hydrogen enter a hydrotreating unit and react under the action of a hydrotreating catalyst;
(3) the liquid phase effluent obtained in the step (2) enters a clarification unit, and clarified oil is obtained after separation;
(4) carrying out solid-liquid separation on the clarified oil obtained in the step (3), and obtaining purified oil slurry after separation;
(5) and (4) mixing the purified oil slurry obtained in the step (4) with hydrogenated tail oil to obtain the low-sulfur marine fuel oil.
In the production method of the low-sulfur marine fuel oil, the hydrogenated tail oil in the step (5) has the sulfur content of 0.1-1.0 wt% and the viscosity (50 ℃) of 300-450 mm2And s. The hydrogenated tail oil can be one or more of topping tail oil, hydrogenated normal residue and hydrogenated slag reduction obtained after hydrotreating inferior raw materials, and the inferior raw materials can be one or more of vacuum residue, atmospheric residue, extra heavy oil, oil sand asphalt, coal liquefaction oil and coal tar.
In the method for producing the low-sulfur marine fuel oil, the weight ratio of the purified oil slurry to the hydrogenated tail oil in the step (5) is 0.05-3: 1.
In the method for producing the low-sulfur marine fuel oil, a step (1.1) can be added between the step (1) and the step (2), wherein in the step (1.1), the first material obtained by separating in the step (1) and hydrogen firstly enter a hydrogenation pretreatment unit, hydrogenation reaction is carried out in the presence of a hydrogenation pretreatment catalyst, and the reaction effluent enters a hydrogenation treatment unit to carry out the step (2).
In the method for producing low-sulfur bunker fuel oil, the catalytic slurry oil referred to in step (1) is heavy oil from a catalytic cracking unit containing catalyst particles or catalyst powder, wherein the catalyst particles or catalyst powder are generated by collision and abrasion between the catalyst particles or between the catalyst particles and the reactor wall during the operation of the catalytic cracking unit. The catalytic slurry oil can be one or more of distillate oil catalytic cracking slurry oil, heavy oil catalytic cracking slurry oil, residual oil catalytic cracking slurry oil or distillate oil blending residual oil catalytic cracking slurry oil; the residual oil comprises one or more of atmospheric residual oil and vacuum residual oil, the heavy oil can be obtained by subjecting crude oil to topping treatment, and the distillate oil comprises one or more of Vacuum Gas Oil (VGO) and Atmospheric Gas Oil (AGO).
In the method for producing the low-sulfur marine fuel oil, the dry point temperature of the catalytic slurry oil in the step (1) is 300-580 ℃.
In the method for producing the low-sulfur marine fuel oil, the first auxiliary agent in the step (1) is coal tar and/or coal tar distillate oil, and specifically can be one or more of full-fraction medium-low temperature coal tar, full-fraction high-temperature coal tar, medium-low temperature coal tar distillate oil and high-temperature coal tar distillate oil.
In the production method of the low-sulfur marine fuel oil, the weight ratio of the first auxiliary agent to the catalytic slurry oil in the step (1) is 1: 10-1: 30, preferably 1: 15-1: 25; the mixing treatment temperature is 50-150 ℃, and the preferable mixing treatment temperature is 60-120 ℃; the mixing treatment time is 0.5-4 h, and preferably 1-2 h.
In the production method of the low-sulfur marine fuel oil, a second auxiliary agent can be added in the step (1), wherein the second auxiliary agent is one or more of tetrahydronaphthalene, decahydronaphthalene, formic acid, formaldehyde and methanol, and is preferably one or more of tetrahydronaphthalene and decahydronaphthalene; the weight ratio of the second auxiliary agent to the catalytic slurry oil is 1: 30-1: 100, and preferably 1: 50-1: 80.
In the method for producing the low-sulfur marine fuel oil, the hydrogenation pretreatment unit in the step (1.1) can adopt one or more of a fixed bed hydrogenation process, a boiling bed hydrogenation process, a suspended bed hydrogenation process and a moving bed hydrogenation process. The hydrogenation pretreatment unit is provided with more than 1 hydrogenation pretreatment reactor, and when more than 2 hydrogenation pretreatment reactors are arranged, more than 2 reactors can be connected in series and/or in parallel.
In the method for producing the low-sulfur marine fuel oil, the operation conditions of the hydrogenation pretreatment unit are as follows: the reaction temperature is 300-380 ℃, the reaction pressure is 4-9 Mpa, and the volume airspeed is 0.4-2.0 h-1The hydrogen-oil volume ratio is 400-1000, the preferable reaction temperature is 320-360 ℃, the reaction pressure is 6-8 Mpa, and the volume airspeed is 0.6-1.2 h-1The volume ratio of hydrogen to oil is 500-800.
In the method for producing the low-sulfur marine fuel oil, the hydrotreating unit in the step (2) can adopt one or more of a fixed bed hydrogenation process, a boiling bed hydrogenation process, a suspended bed hydrogenation process and a moving bed hydrogenation process, and preferably adopts the boiling bed hydrogenation process. The hydrotreating unit is provided with more than 1 hydrotreating reactor, and when more than 2 hydrotreating reactors are arranged, more than 2 hydrotreating reactors can be connected in series and/or in parallel.
In the method for producing the low-sulfur marine fuel oil, the operation conditions of the hydrogenation treatment unit in the step (2) are as follows: the reaction temperature is 360-420 ℃, the reaction pressure is 6.0-14.0 Mpa, and the volume airspeed is 0.5-2.5 h-1The hydrogen-oil volume ratio is 300-1000, preferably, the reaction temperature is 370-410 ℃, the reaction pressure is 7.0-11.0 Mpa, the volume space velocity is 0.8-1.5 h < -1 >, and the hydrogen-oil volume ratio is 500-800.
In the method for producing the low-sulfur marine fuel oil, the hydrogenation pretreatment unit and the hydrotreating unit can be arranged in one reactor or can be respectively provided with independent reactors.
In the method for producing low-sulfur marine fuel oil, the catalyst used in the hydrogenation pretreatment unit can be any one of the existing hydrogenation pretreatment catalysts, for example, commercially available hydrogenation pretreatment catalysts developed by the research institute of petrochemical industry can be used.
In the method for producing the low-sulfur marine fuel oil, when the hydrotreating unit adopts a boiling bed hydrogenation process, the waste catalyst discharged by the hydrotreating unit can be used as a hydrogenation pretreatment catalyst of a hydrogenation pretreatment unit.
In the method for producing the low-sulfur marine fuel oil, the catalyst used in the hydrotreating unit is a hydrotreating catalyst which is conventional in the art, wherein the active metal of the catalyst can be one or more of nickel, cobalt, molybdenum or tungsten. For example, the catalyst composition may comprise, in weight percent: 0.1-12% of nickel or cobalt (calculated according to the oxide thereof), 5-15% of molybdenum or tungsten (calculated according to the oxide thereof), and the carrier can be one or more of alumina, silica, alumina-silica or titanium oxide. The catalyst is in the shape of extrudate or sphere, and the bulk density is 0.4-0.9 g/cm3The particle diameter (spherical diameter or strip diameter) is 0.08-0.8 mm, and the specific surface area is 100-200 m2/g。
In the method for producing the low-sulfur marine fuel oil, the clarifying unit in the step (5) can be one or more of a standing clarifying unit and a forced clarifying unit by means of external force; the clarifying units are at least one, and can be operated in series or in parallel. The clarifying unit is mainly used for separating large-particle catalysts larger than 25 microns, and the separated large-particle catalysts can be treated with the waste catalysts of the catalytic cracking unit.
In the method for producing the low-sulfur marine fuel oil, the solid-liquid separation unit in the step (6) is mainly used for separating the small-particle catalyst which cannot be clarified in the step (5), the solid-liquid separation unit can adopt one of the existing methods in the field for realizing solid-liquid separation, preferably adopts an external force means of a high-speed centrifuge to forcibly realize solid-liquid separation, and the operation conditions of the centrifuge are as follows: the rotating speed is 1500-3000 r/min, the temperature is 60-80 ℃, and the operation conditions are preferably as follows: the rotating speed is 1900-2500 r/min, and the temperature is 65-75 ℃. The separated catalyst powder may be sent out for treatment together with the catalyst particles obtained in step (4).
Compared with the prior art, the method for producing the low-sulfur marine fuel oil has the following advantages:
1. the catalytic slurry oil is high in solid content and difficult to treat, and the conventional treatment means is to use the catalytic slurry oil and residual oil together as a coking device feeding material or compound the catalytic slurry oil and the residual oil with high-quality distillate oil to produce qualified fuel oil, so that the catalytic slurry oil and the residual oil cannot be fully utilized, and a large amount of high-quality distillate oil is consumed. The method not only realizes the purification treatment of the catalytic slurry oil to obtain high-quality purified slurry oil and improve the utilization value of the catalytic slurry oil, but also develops a production route of low-sulfur fuel oil, and the hydrogenated tail oil replaces high-quality distillate oil to produce the low-sulfur fuel oil, thereby greatly saving the production cost.
2. In the method for producing the low-sulfur marine fuel oil, the catalytic oil slurry is subjected to graded treatment by using the first auxiliary agent and the second auxiliary agent, and through hydrogenation pretreatment, hydrotreating, clarification treatment and solid-liquid separation, the graded removal of solid impurities with different sizes in the catalytic oil slurry is realized. Firstly, under the combined action of a first auxiliary agent and a second auxiliary agent, the aggregation, sedimentation and separation of large-particle catalyst particles in catalytic slurry oil are promoted; and then the catalytic slurry oil treated by the auxiliary agent is subjected to hydrogenation treatment through a hydrogenation pretreatment unit and a hydrogenation treatment unit, unsaturated hydrocarbons such as colloid and the like influencing the system viscosity and subsequent filtration are subjected to hydrogenation saturation, the reduction of the viscosity of heavy components is facilitated, and because the hydrogenation treatment unit uses a fluidized bed reactor, the bed layer can be prevented from being blocked by catalyst powder, and the device can be ensured to run for a long period.
3. In the method for producing the low-sulfur marine fuel oil, the second auxiliary agent can generate a synergistic effect with the first auxiliary agent to promote the settling separation of solid impurities in the catalytic slurry oil, and can release active hydrogen under the condition of hydrogenation pretreatment in the hydrogenation pretreatment unit to carry out hydrogenation saturation on the easily-coked precursor contained in the first auxiliary agent, and simultaneously carry out hydrogenation pretreatment on the catalytic slurry oil to promote the complex use of the hydrogenation treatment unit, alleviate the hydrogenation reaction of the second hydrogenation treatment unit and reduce the operation difficulty.
4. In the method for producing the low-sulfur marine fuel oil, the hydrotreating unit uses the fluidized bed reactor, the waste catalyst discharged by the fluidized bed reactor can be used as a hydrogenation pretreatment catalyst of the hydrogenation pretreatment unit, the waste catalyst discharged by the hydrotreating unit still has certain hydrogenation activity, and meanwhile, as the catalyst has passed through an initial activity period due to hydrogenation reaction, the possibility of coking and carbon deposition of aromatic hydrocarbons such as unsaturated hydrocarbons and the like on the surface of the waste catalyst is greatly reduced; on the other hand, the catalytic slurry oil has a high content of unsaturated hydrocarbons, and the structure and the content of the unsaturated hydrocarbons have a certain distribution rule, wherein the catalytic slurry oil contains a part of components which are easily condensed to form coke when heated, for example, if the catalytic slurry oil is completely and directly fed into a hydrotreating unit to carry out a hydrogenation reaction, on one hand, the hydrogenation reaction of the unsaturated hydrocarbons can release a large amount of heat, a large amount of cold hydrogen needs to be injected, the energy consumption is high, and on the other hand, the unsaturated hydrocarbons which are easily condensed to form coke when partially heated coke are coke. The waste catalyst discharged by the hydrotreating unit is adopted to carry out mild hydrotreating pretreatment on the catalytic slurry oil in advance, so that the problems can be effectively avoided, and the recycling of the waste catalyst is realized.
4. The method can obviously improve the utilization rate of the catalytic slurry oil, the traditional filtering method has low solid impurity removal efficiency, the yield of the catalytic slurry oil after filtering is damaged due to the interception and recombination of the filter screen, and meanwhile, the operation period of the filtering equipment is shortened due to the rapid increase of the pressure drop of the filter screen. The method combines the property characteristics of the catalytic slurry oil, and by adding a certain auxiliary agent, the viscosity of the catalytic slurry oil is reduced, meanwhile, the aggregation and precipitation of small particles in the catalytic slurry oil are realized, and the operation complexity is reduced; meanwhile, the heavy component wrapped with the small particle impurities is hydrogenated by adopting a hydrogenation means, so that the small particle impurities are resolved and precipitated from the heavy component, and finally the solid impurities are efficiently removed.
5. In the method for producing the low-sulfur marine fuel oil, the reaction pressure and the reaction temperature are adjusted to control the pre-hydrogenation reaction depth of the catalytic slurry oil, the catalytic slurry oil is firstly subjected to shallow hydrogenation to improve the thermal stability of the slurry oil, the hydrogenation depth is too deep, the reaction hydrogen consumption is high, and the cost is high; meanwhile, the softening point and the viscosity of the hydrogenated oil slurry are greatly reduced, and the blending proportion of high-grade road asphalt or low-sulfur fuel oil is influenced.