EP0035864B1 - Verfahren zum Verbessern schwerer Kohlenwasserstofföle - Google Patents
Verfahren zum Verbessern schwerer Kohlenwasserstofföle Download PDFInfo
- Publication number
- EP0035864B1 EP0035864B1 EP19810300887 EP81300887A EP0035864B1 EP 0035864 B1 EP0035864 B1 EP 0035864B1 EP 19810300887 EP19810300887 EP 19810300887 EP 81300887 A EP81300887 A EP 81300887A EP 0035864 B1 EP0035864 B1 EP 0035864B1
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- EP
- European Patent Office
- Prior art keywords
- stream
- hydrogen donor
- residuum
- boiling
- liquid
- 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.)
- Expired
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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
- C10G47/00—Cracking of hydrocarbon oils, in the presence of hydrogen or hydrogen- generating compounds, to obtain lower boiling fractions
- C10G47/32—Cracking of hydrocarbon oils, in the presence of hydrogen or hydrogen- generating compounds, to obtain lower boiling fractions in the presence of hydrogen-generating compounds
- C10G47/34—Organic compounds, e.g. hydrogenated hydrocarbons
-
- 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
- C10G2400/06—Gasoil
Definitions
- This invention relates to a process for improving the quality of heavy, viscous crude oils. More specifically, it relates to a process comprising separating the viscous crude into fractions by fractional distillation, and cracking and hydrogenating the highest boiling fraction so obtained in the presence of a recycled hydrogen donor material obtained by separating particular portions of the resulting cracked material and catalytically rehydrogenating a specific portion so produced to prepare said hydrogen donor material for recycling.
- the fractionated streams produced in separating said viscous crude and in separating said hydrogenated cracked material are suitable for further hydrogenation and/or recombining into a reconstituted crude oil, or for use in normal refinery processes without being recombined.
- Hydrogen donor materials are well known for their ability to release hydrogen to a hydrogen-deficient oil in a thermal cracking zone, and thereby to convert heavy hydrocarbon oils to more valuable lower-boiling products.
- the hydrogen donor is aromatic-naphthenic in nature and, having released hydrogen in the thermal cracking zone, can be catalytically rehydrogenated in a separate hydrogenation zone and recycled as a hydrogen donor.
- Hydrogen donor cracking processes make possible the conversion of heavy oils in the absence of a catalyst and with the formation of little, if any, coke, and at substantially lower pressures than are necessary with the use of molecular hydrogen in hydrocracking.
- U.K. Patent No. 784,136 disclosed a donor hydrocracking process in which a crude oil is fractionated by distillation into inter alia a residuum and a gas oil which is catalytically cracked with attendant production of a clarified hydrocarbon oil at least a part of which is partially hydrogenated to provide the major proportion of a hydrogen-donor diluent boiling within the range (500-1100 0 F) 260°C to 595.3°C and containing substantial proportions of condensed-ring aromatics, the remainder of the diluent being obtained from other refinery streams and/or the feed stock.
- This patent teaches that the boiling range of the diluent should be somewhat lower than but contiguous to the boiling range of the said residuum which is converted to lower-boiling products by the said diluent.
- the present invention is a process for the upgrading of heavy, viscous hydrocarbonaceous oils comprising fractionally distilling said hydrocarbonaceous oil to produce at least one distilled fraction and a residuum without substantially cracking said hydrocarbonaceous oil, contacting said residuum with a liquid hydrogen donor material stream to produce a hydrocracked stream and separating said hydrocracked stream into a gaseous stream and a liquid hydrocracked stream, characterized in that said residuum is a residuum boiling in the range from 450°C to 570°C and that:
- the invention comprises steps (a) to (c) noted above, wherein fractional distillation step (a) is carried out to produce a naphtha stream, a distillate stream and a gas oil stream as well as the aforementioned residuum, and the lower and higher boiling fractions from fractional distillation step (d) are utilized as follows: the overhead stream is combined with said naphtha stream from step (a), a heavy gas oil stream is combined with said gas oil stream from step (a) and these streams as well as a bottoms stream from step (d) are withdrawn as product streams.
- the gaseous stream obtained at step (c) can be desulphurized to produce a desulphurized gaseous stream, and said desulphurized gaseous stream can be reformed with steam to form a hydrogen-rich gaseous stream for use in step (e) and by-product carbon dioxide.
- the gaseous stream from step (c) can be used as fuel gas and the external supply of methane-rich gas can be utilized as the source of hydrogen for the reforming step.
- the aforementioned hydrogenated hydrogen donor material stream is fractionally distilled to separate, from lower and higher boiling materials, an optimized hydrogenated hydrogen donor material, which lower and higher boiling materials are combined with the appropriate product stream or streams.
- said product streams can individually be catalytically reacted with a hydrogen-rich gas, to produce more fully upgraded streams which can be used in a conventional oil refinery, or alternatively they can be combined with the bottoms stream from step (d) to produce a fully upgraded, lower viscosity synthetic crude.
- the process of the invention is applicable to upgrading various types of heavy crudes, including in-situ heavy oils (e.g. Lloydminster), oil sands bitumen (e.g. Athabasca), and generally any type of crude oil whose composition and viscosity in the raw form are such that they render it difficult or impossible to process the oil in a conventional oil refinery or to transport in a pipeline without dilution or external heating or tracing of the pipeline and consequent large-scale waste of energy.
- in-situ heavy oils e.g. Lloydminster
- oil sands bitumen e.g. Athabasca
- raw crude oil in stream 21 is distilled to remove material distillable without thermal cracking.
- the distillation is preferably carried out in two stages, the first at atmospheric pressure in fractionating column 1 with overheads going via line 22 and residue via line 25, and the second under vacuum in fractionating column 2, from which overheads go via line 26 and residue or bottoms via 27.
- the amount of absolute pressure in column 2 can be varied to as low as 2 kPa but is normally selected for minimum steam usage, and commercial operations are commonly conducted at 2.5-4 kPa.
- the bottoms stream from vacuum distillation step 2 can have an initial boiling point varying over the range from 450°C to 570°C, can be used in the process, although for reasons of economics it may be advantageous to remove as much distillate material as possible to reduce the volume of reaction mixture and consequently the size and cost of a hydrogen donor cracking zone 3.
- the bottoms stream 27 is contacted in reactor 3 with a hydrogenated recycled stream 30.
- An initial supply of hydrogen donor material for start-up is fed through line 29 until adequate flow in stream 30 is established.
- the recycled stream has the ability to donate hydrogen and is used in a weight ratio of substantially 1:0.5 to 1:4 and a temperature of substantially 350°C to 500°C, preferably 400°C to 460°C and at an absolute pressure of substantially 2 to 15 MPa, preferably 2.5 to 6 MPa, and a reaction mass liquid space velocity of substantially 0.5 to 10.0 h- 1 , preferably 0.8 to 7.0 h- 1 .
- No catalyst is necessary in the hydrogen donor cracking reaction. Under the preferred conditions no coke is produced in the reaction.
- Effluent from reactor 3 passes via line 31 to gas separator 4, which separates gases including hydrocarbons boiling at ambient room temperature or lower.
- gaseous material in stream 32 is treated to remove hydrogen sulphide in desulphurization zone 6 and is passed via line 39 into a steam reforming zone 7 juxtapos along with external steam in stream 41, forming a hydrogen-rich gas passing via line 42 to be used in catalytic hydrogenation zone 8.
- Sulphur is removed from zone 6 via line 40 and carbon dioxide-rich gas from zone 7 is discharged via line 43.
- the liquid reactor effluent 33 from separator 4 is fractionated in fractionating still 5, and the distilled portion boiling for example from substantially 180°C to substantially 350°C, preferably from 200°C to 330°C, in stream 35, is rehydrogenated in catalytic hydrogenation zone 8.
- the upper and lower limits of the boiling range of stream 35 may be adjusted as necessary to obtain an appropriate volume of hydrogen donor material for stream 30.
- Overhead fractions 22, 26 and 34, gas oil fraction 36 and residuum fraction 37 can be combined into a reconstituted "crude" in stream 53 which has sufficiently low viscosity that it is suitable for pumping.
- a portion of residuum fraction 37 can optionally be recycled through line 38 to be combined with bottoms stream 27 and reprocessed through the hydrogen donor cracking zone.
- the reaction in hydrogenation zone 8 normally does not consume all the hydrogen from stream 42 and the unused gases which are contaminated with hydrogen sulphide can be recycled to the inlet of desulphurization zone 6, via line 45.
- the hydrogen donor capability of the fraction in stream 35 is sufficient, when the latter has undergone catalytic hydrogenation in zone 8, to continue the hydrogen donor cracking without adding make-up hydrogen donor material via line 29.
- the hydrogen-rich gas in stream 42 is used to hydrogenate the fraction in stream 35 under usual catalytic hydrogenation conditions in zone 8 and the effluent stream of liquid hydrogenated material 44 is. passed either directly to line 47 thence, to line 30 where it is recycled into hydrogen donor cracking' zone 3, or via line 54 to a fractionation, hereafter described with reference to Figure 3, and return of a fraction thereof via line 55 to line 47.
- the gaseous materials formed in the hydrocracking step and separated at step 4 include methane and other hydrocarbons having up to substantially five carbon atoms in their molecules.
- the imported gas stream can be for example natural gas and can contain hydrogen; it is desulphurized if it is sour, in the desulphurization zone 6 as shown in Figure 1, or taken directly to steam reforming zone 7, as appropriate.
- the gaseous stream 32 may be desulphurized if necessary in a desulphurization zone, or taken directly to product via line 57, as shown in Figure 1.
- An optional source of hydrogen for use in hydrogenating zone 8 is the steam reforming of a residuum in steam reforming zone 7, instead of reforming the gaseous material separated at step 4.
- An advantageous source of residuum for this purpose is stream 37, the bottoms from fractionation step 5.
- Suitable hydrogen donor or hydrogen donor precursor material for starting up the process can be obtained for example, in certain refinery streams known in the art. If necessary or desirable, it can be hydrogenated in the described hydrogenation zone 8 prior to contacting with fractionating tower bottoms stream 27 in hydrogen donor cracking zone 3.
- Figure 2 employing identical numbers for parts identical to those shown in Figure 1, illustrates an optional processing scheme wherein the initial crude 21 is fractionally distilled into a plurality of cuts 22, 23 and 24 each of whose initial and final boiling points can be selected as is customary in petroleum refining to produce appropriate streams.
- Commonly used fractions are naphtha, distillate and gas oil, although fewer or more than three fractions can be taken without departing from the scope of the invention.
- the fractions resulting from the distillation step 5 in streams 34 and 36 can be combined with the appropriate fractions from the crude distillation, i.e. fractions of similar boiling ranges, to obtain a plurality of product streams 49, 51 and 50.
- the bottoms stream 37 from fractional distillation step 5 can be kept as a separate product stream.
- the hydrogenated hydrogen donor material in stream 44 from zone 8 optionally can be passed via line 54 and fractionally distilled in distillation column 9 to separate, from lower and higher boiling materials 46 and 48, a hydrogen donor heart cut 55, boiling for example in the range from substantially 220°C to substantially 295°C, which can be fed through line 47 to hydrogen donor cracking zone 3.
- the lower boiling material 46 can be combined for example with naphtha stream.49 and the higher boiling material 48 combined for example with gas oil stream 50 ( Figure 2), or if desired, both can be combined with the product stream 53 ( Figure 1).
- the hydrogen donor activity of the lower boiling and higher boiling streams 46 and 48 is lower than that of the heart cut 55 and their removal has the effect of raising the concentration of active hydrogen donor material recycled to the hydrogen donor cracking zone 3.
- FIG. 4 A modification of the embodiments of the invention outlined in Figures 1 and 2 is shown in Figure 4.
- the reconstituted naphtha, distillate and gas oil streams 49, 50 and 51,.obtained as shown in Figure 2, can optionally be further hydrogenated individually at catalytic hydrogenation steps 10, 11 and 12 by known methods.
- a hydrogen-rich gas can be introduced from an external source via line 58 and the resulting hydrogenated naphtha stream 59, hydrogenated distillate stream 60 and hydrogenated gas oil stream 61 are therefore suitable for direct use in a conventional oil refinery.
- these hydrogenated streams can be combined with the residuum stream 37 ( Figure 1) to obtain in stream 53 an upgraded, lower viscosity pipelineable synthetic crude oil suitable for use in conventional oil refineries remote from the upgrading plant. Because of its higher hydrogen:carbon ratio, the synthetic crude oil can give higher quality products with less processing than less highly hydrogenated synthetic crude oils.
- An advantage of the present process is that it can be used in a small production area to provide crude capable of being transported by pipeline to an appropriate refinery.
- a further advantage is that the process at proper operating conditions produces no coke.
- a still further advantage is that it uses as the hydrogen transfer material a fraction of the heavy crude that is generated in the process itself, and therefore no additional hydrogen transfer agent is needed after the initial start-up.
- Another advantage of this process is that it can convert as much as 90 per cent of the high boiling components in the crude, i.e. components boiling at greater than about 504°C, to components boiling at less than about 504°C.
- the products streams can be used in any of several optional ways, enabling the process to be tailored to actual field conditions.
- 497 parts of the vacuum residuum was thoroughly blended with 497 parts of a hydrocarbon stream serving as an initial hydrogen donor stream.
- This donor stream was the heart cut obtained by hydrotreating a fluid catalytically cracked fraction that boiled in the range 193°C to 343°C and fractionally distilling the hydrotreated material to obtain a heart cut boiling in the range 221°C to 293°C; the donor stream had a content of 48.7 per cent by weight of benzocycloparaffins (predominantly substituted tetrahydronaphthalenes) and 19.4 per cent naphthalenes, as determined by low resolution mass spectrometry. After sealing the autoclave, the air was displaced therefrom by nitrogen and a residual pressure of 0.65 MPa absolute left in the vessel.
- the vessel was then stirred and heated to an internal temperature of 415°C at a rate of substantially 5.3°C per minute and maintained at this temperature for a hydrogen donor cracking period of 81 minutes before cooling was begun. During this constant temperature period the pressure in the vessel increased from 3.0 MPa to 8.3 MPa. After cooling to ambient temperature (22°C, at which the pressure was 2.34 MPa) the gas was discharged from the autoclave and its volume measured (36.6 litres at NTP, including the nitrogen of the residual nitrogen pressure). The total evolved gas (nitrogen free basis) amounted to 4.6 per cent by weight of the material charged to the autoclave; on analysis the gas was found to have a composition, on a nitrogen free basis, approximately as shown in Table 1.
- 803 parts was fractionally distilled to yield three fractions, viz: (a) an initial fraction, having a boiling range up to 204°C and amounting to 102 parts, (b) a mid-fraction having a boiling range from 204°C to 316°C and amounting to 421 parts, and (c) a residue boiling above 316°C and amounting to 280 parts.
- a sample of this residue was further fractionated to separate material boiling above 491°C and amounting to 54.5 per cent by weight of the residue sample. It was thus calculated that 63.6 per cent of the original vacuum residuum (all of which boiled above 491°C) was converted to material with a boiling point below 491°C.
- the (b) fraction with a boiling range 204°C to 316°C from a duplicate operation as described above was rehydrogenated under catalytic hydrogenation conditions as follows. 459 parts of the fraction, and 50 parts of commercial hydrogenation catalyst designated as NT550 (supplied by Nalco Chemical Company) and having the composition: were sealed in a two litre autoclave, purged with nitrogen to remove air, then pressured with hydrogen to 5.62 MPa at 23°C. The stirred autoclave then was heated at a rate of 4.5°C per minute until a temperature of 305°C was reached. Pressure in the vessel rose to 9.33 MPa during heating.
- the temperature was maintained at 305°C for the next 4.7 hours during which the autoclave was further repressured with hydrogen as recorded pressure readings indicated hydrogen was consumed by reaction with the fraction, to maintain a minimum pressure at 10.5 MPa, final hydrogenation pressure being 11.47 MPa. Heating was then stopped and the vessel allowed to cool to room temperature (23°C). Pressure at this time was 4.42 MPa. The gas was discharged and on analysis was found to be predominantly hydrogen with some hydrogen sulphide and gaseous hydrocarbon. The hydrogenated liquid was recovered and found to amount to 452 parts by weight.
- the rehydrogenated material, prepared as described above, was used as the hydrogen donor stream for blending with another sample of vacuum residuum of bitumen in the autoclave, as described at the beginning of this example, and was found effective, after a hydrogen donor cracking period as described above, to convert the residuum and form additional reconstituted crude of improved properties as described above.
- a sample of hydrogen donor material as was used in Example 1 and prepared by hydrogenating a light cycle oil obtained from a fluid catalytic cracking unit, was mixed in a 1:1 ratio with the residuum from a vacuum distillation of Athabasca oil sands bitumen.
- the residuum constituted 54.5 per cent of the bitumen and had an initial boiling point of 505°C.
- the mixture was fed by a positive displacement pump at a rate of 598.8 g/hour into a tubular hydrogen donor cracking reactor of 989 ml volume and 22.9 m length, coiled into a helical shape and immersed in a fluidized sand bed maintained at constant temperature of 432°C.
- the reactor was equipped with a reciprocating mechanism to maintain turbulent flow conditions in the reactor, as disclosed in co-pending European patent application No. 80304133.4
- the reaction mixture at 5.7 MPa, flowed through a pressure control valve downstream from the reactor tube and thence into a series of flash separation zones which separated the gaseous portion from the liquids portion of the reactor effluent.
- the flow rate of the gaseous stream was measured and the composition determined using an on-line gas chromatograph.
- the hydrocarbon content of the evolved gas was found to be sufficient to provide (by steam reforming) the hydrogen requirements for hydrogenation of the hydrogen donor precursor material separated from the liquids portion of the reactor effluent.
- the liquid portion of the reactor effluent was fractionally distilled to separate a fraction boiling in the range 193°C to 332°C and amounting to 56.3% of the liquid products. This fraction was hydrogenated catalytically, over the same hydrogenation catalyst used in Example 1, at around 320°C for 5.6 hours.
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- Chemical & Material Sciences (AREA)
- Oil, Petroleum & Natural Gas (AREA)
- Engineering & Computer Science (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Organic Chemistry (AREA)
- Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)
Claims (7)
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CA347,549A CA1122914A (en) | 1980-03-04 | 1980-03-04 | Process for upgrading heavy hydrocarbonaceous oils |
CA347549 | 1980-03-04 |
Publications (3)
Publication Number | Publication Date |
---|---|
EP0035864A2 EP0035864A2 (de) | 1981-09-16 |
EP0035864A3 EP0035864A3 (en) | 1981-10-07 |
EP0035864B1 true EP0035864B1 (de) | 1985-07-03 |
Family
ID=4116462
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP19810300887 Expired EP0035864B1 (de) | 1980-03-04 | 1981-03-03 | Verfahren zum Verbessern schwerer Kohlenwasserstofföle |
Country Status (6)
Country | Link |
---|---|
EP (1) | EP0035864B1 (de) |
JP (1) | JPS56136893A (de) |
CA (1) | CA1122914A (de) |
DE (1) | DE3171175D1 (de) |
MX (1) | MX158978A (de) |
NL (1) | NL8101051A (de) |
Families Citing this family (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4363716A (en) * | 1981-02-26 | 1982-12-14 | Greene Marvin I | Cracking of heavy carbonaceous liquid feedstocks utilizing hydrogen donor solvent |
US4395324A (en) * | 1981-11-02 | 1983-07-26 | Mobil Oil Corporation | Thermal cracking with hydrogen donor diluent |
ZA845721B (en) * | 1983-08-01 | 1986-03-26 | Mobil Oil Corp | Process for visbreaking resids in the presence of hydrogen-donor materials |
CA1246481A (en) * | 1984-03-20 | 1988-12-13 | Frank Souhrada | Coking residuum in the presence of hydrogen donor |
CA1222471A (en) * | 1985-06-28 | 1987-06-02 | H. John Woods | Process for improving the yield of distillables in hydrogen donor diluent cracking |
JPH03294390A (ja) * | 1990-04-12 | 1991-12-25 | Idemitsu Kosan Co Ltd | 原油の精製方法 |
US10081769B2 (en) * | 2014-11-24 | 2018-09-25 | Husky Oil Operations Limited | Partial upgrading system and method for heavy hydrocarbons |
MX2015010173A (es) | 2015-08-06 | 2017-02-06 | Inst Mexicano Del Petróleo | Uso de polimeros como donadores de hidrogeno heterogeneos en el mejoramiento de crudos pesados y extrapesados. |
MX2017009054A (es) | 2017-07-10 | 2019-02-08 | Mexicano Inst Petrol | Procedimiento de preparacion de agentes de transferencia de hidrogeno solidos mejorados para el procesamieno de crudos pesados, extrapesados y residuos, y producto resultante. |
Family Cites Families (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB708244A (en) * | 1950-04-04 | 1954-05-05 | Anglo Iranian Oil Co Ltd | Improvements relating to the catalytic desulphurisation of petroleum hydrocarbons |
BE529891A (de) * | 1953-07-01 | |||
GB758413A (en) * | 1953-11-18 | 1956-10-03 | Exxon Research Engineering Co | Improvements in or relating to process for cracking gas oils to gasoline |
US2953513A (en) * | 1956-03-05 | 1960-09-20 | Exxon Research Engineering Co | Hydrogen donor diluent cracking process |
US4115246A (en) * | 1977-01-31 | 1978-09-19 | Continental Oil Company | Oil conversion process |
-
1980
- 1980-03-04 CA CA347,549A patent/CA1122914A/en not_active Expired
-
1981
- 1981-03-02 JP JP2852881A patent/JPS56136893A/ja active Granted
- 1981-03-03 MX MX18620681A patent/MX158978A/es unknown
- 1981-03-03 DE DE8181300887T patent/DE3171175D1/de not_active Expired
- 1981-03-03 EP EP19810300887 patent/EP0035864B1/de not_active Expired
- 1981-03-04 NL NL8101051A patent/NL8101051A/nl not_active Application Discontinuation
Also Published As
Publication number | Publication date |
---|---|
DE3171175D1 (en) | 1985-08-08 |
CA1122914A (en) | 1982-05-04 |
MX158978A (es) | 1989-04-05 |
NL8101051A (nl) | 1981-10-01 |
EP0035864A2 (de) | 1981-09-16 |
EP0035864A3 (en) | 1981-10-07 |
JPH0258316B2 (de) | 1990-12-07 |
JPS56136893A (en) | 1981-10-26 |
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