EP0318125B1 - Procédé de craquage d'huile lourde - Google Patents
Procédé de craquage d'huile lourde Download PDFInfo
- Publication number
- EP0318125B1 EP0318125B1 EP88202685A EP88202685A EP0318125B1 EP 0318125 B1 EP0318125 B1 EP 0318125B1 EP 88202685 A EP88202685 A EP 88202685A EP 88202685 A EP88202685 A EP 88202685A EP 0318125 B1 EP0318125 B1 EP 0318125B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- hydrogen
- catalyst
- metals
- reaction
- heavy 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.)
- Expired - Lifetime
Links
- 238000000034 method Methods 0.000 title claims description 74
- 230000008569 process Effects 0.000 title claims description 62
- 239000000295 fuel oil Substances 0.000 title claims description 14
- 238000005336 cracking Methods 0.000 title claims description 12
- 239000003054 catalyst Substances 0.000 claims description 81
- 239000001257 hydrogen Substances 0.000 claims description 47
- 229910052739 hydrogen Inorganic materials 0.000 claims description 47
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 claims description 45
- 238000006243 chemical reaction Methods 0.000 claims description 44
- 239000003921 oil Substances 0.000 claims description 23
- 238000009835 boiling Methods 0.000 claims description 19
- 230000000694 effects Effects 0.000 claims description 16
- 239000007789 gas Substances 0.000 claims description 16
- 238000004523 catalytic cracking Methods 0.000 claims description 13
- 229910052751 metal Inorganic materials 0.000 claims description 13
- 239000002184 metal Substances 0.000 claims description 13
- 230000002378 acidificating effect Effects 0.000 claims description 12
- RWSOTUBLDIXVET-UHFFFAOYSA-N Dihydrogen sulfide Chemical compound S RWSOTUBLDIXVET-UHFFFAOYSA-N 0.000 claims description 11
- 239000000463 material Substances 0.000 claims description 11
- 150000002739 metals Chemical class 0.000 claims description 10
- 239000000203 mixture Substances 0.000 claims description 10
- 239000000470 constituent Substances 0.000 claims description 8
- 239000011148 porous material Substances 0.000 claims description 7
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 6
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 6
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 claims description 6
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 claims description 6
- 230000003213 activating effect Effects 0.000 claims description 5
- 229910000510 noble metal Inorganic materials 0.000 claims description 5
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 claims description 4
- 150000002431 hydrogen Chemical class 0.000 claims description 4
- 229910052750 molybdenum Inorganic materials 0.000 claims description 4
- 239000011733 molybdenum Substances 0.000 claims description 4
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 3
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 claims description 3
- 229910052804 chromium Inorganic materials 0.000 claims description 3
- 239000011651 chromium Substances 0.000 claims description 3
- 239000010941 cobalt Substances 0.000 claims description 3
- 229910017052 cobalt Inorganic materials 0.000 claims description 3
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 claims description 3
- 229910052742 iron Inorganic materials 0.000 claims description 3
- 229910052759 nickel Inorganic materials 0.000 claims description 3
- 229910052763 palladium Inorganic materials 0.000 claims description 3
- 229910052697 platinum Inorganic materials 0.000 claims description 3
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 claims description 3
- 229910052721 tungsten Inorganic materials 0.000 claims description 3
- 239000010937 tungsten Substances 0.000 claims description 3
- 150000003568 thioethers Chemical group 0.000 claims 2
- 239000000047 product Substances 0.000 description 28
- 239000000571 coke Substances 0.000 description 23
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 22
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 20
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 20
- 229910052593 corundum Inorganic materials 0.000 description 18
- 229910001845 yogo sapphire Inorganic materials 0.000 description 18
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 17
- 239000005864 Sulphur Substances 0.000 description 17
- 238000004227 thermal cracking Methods 0.000 description 14
- 238000004517 catalytic hydrocracking Methods 0.000 description 12
- 238000002474 experimental method Methods 0.000 description 12
- 229910052757 nitrogen Inorganic materials 0.000 description 11
- 239000000377 silicon dioxide Substances 0.000 description 10
- 239000003350 kerosene Substances 0.000 description 8
- 230000008929 regeneration Effects 0.000 description 8
- 238000011069 regeneration method Methods 0.000 description 8
- 230000015572 biosynthetic process Effects 0.000 description 7
- 229910052681 coesite Inorganic materials 0.000 description 7
- 229910052906 cristobalite Inorganic materials 0.000 description 7
- 239000003502 gasoline Substances 0.000 description 7
- 235000012239 silicon dioxide Nutrition 0.000 description 7
- 229910052682 stishovite Inorganic materials 0.000 description 7
- 229910052905 tridymite Inorganic materials 0.000 description 7
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical group [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 5
- 238000004458 analytical method Methods 0.000 description 5
- 150000001336 alkenes Chemical class 0.000 description 4
- 150000001491 aromatic compounds Chemical class 0.000 description 4
- 150000001875 compounds Chemical class 0.000 description 3
- 230000008021 deposition Effects 0.000 description 3
- 229930195733 hydrocarbon Natural products 0.000 description 3
- 150000002430 hydrocarbons Chemical class 0.000 description 3
- 239000012263 liquid product Substances 0.000 description 3
- 238000002156 mixing Methods 0.000 description 3
- OFBQJSOFQDEBGM-UHFFFAOYSA-N n-pentane Natural products CCCCC OFBQJSOFQDEBGM-UHFFFAOYSA-N 0.000 description 3
- 230000035484 reaction time Effects 0.000 description 3
- IMNFDUFMRHMDMM-UHFFFAOYSA-N N-Heptane Chemical compound CCCCCCC IMNFDUFMRHMDMM-UHFFFAOYSA-N 0.000 description 2
- 229910003294 NiMo Inorganic materials 0.000 description 2
- ATUOYWHBWRKTHZ-UHFFFAOYSA-N Propane Chemical compound CCC ATUOYWHBWRKTHZ-UHFFFAOYSA-N 0.000 description 2
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 2
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 2
- 239000003575 carbonaceous material Substances 0.000 description 2
- -1 carbonium ion Chemical class 0.000 description 2
- 239000000969 carrier Substances 0.000 description 2
- 230000001419 dependent effect Effects 0.000 description 2
- 238000004821 distillation Methods 0.000 description 2
- 239000000446 fuel Substances 0.000 description 2
- 230000005484 gravity Effects 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 238000005984 hydrogenation reaction Methods 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 238000001556 precipitation Methods 0.000 description 2
- 239000002243 precursor Substances 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 238000007670 refining Methods 0.000 description 2
- BOZRCGLDOHDZBP-UHFFFAOYSA-N 2-ethylhexanoic acid;tin Chemical compound [Sn].CCCCC(CC)C(O)=O BOZRCGLDOHDZBP-UHFFFAOYSA-N 0.000 description 1
- CIWBSHSKHKDKBQ-JLAZNSOCSA-N Ascorbic acid Chemical compound OC[C@H](O)[C@H]1OC(=O)C(O)=C1O CIWBSHSKHKDKBQ-JLAZNSOCSA-N 0.000 description 1
- 238000004438 BET method Methods 0.000 description 1
- 239000004215 Carbon black (E152) Substances 0.000 description 1
- VEXZGXHMUGYJMC-UHFFFAOYSA-M Chloride anion Chemical compound [Cl-] VEXZGXHMUGYJMC-UHFFFAOYSA-M 0.000 description 1
- 229910021536 Zeolite Inorganic materials 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 230000004913 activation Effects 0.000 description 1
- ILRRQNADMUWWFW-UHFFFAOYSA-K aluminium phosphate Chemical class O1[Al]2OP1(=O)O2 ILRRQNADMUWWFW-UHFFFAOYSA-K 0.000 description 1
- APUPEJJSWDHEBO-UHFFFAOYSA-P ammonium molybdate Chemical compound [NH4+].[NH4+].[O-][Mo]([O-])(=O)=O APUPEJJSWDHEBO-UHFFFAOYSA-P 0.000 description 1
- 229940010552 ammonium molybdate Drugs 0.000 description 1
- 235000018660 ammonium molybdate Nutrition 0.000 description 1
- 239000011609 ammonium molybdate Substances 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 239000001273 butane Substances 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 238000004939 coking Methods 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 238000006482 condensation reaction Methods 0.000 description 1
- 239000010779 crude oil Substances 0.000 description 1
- 150000001923 cyclic compounds Chemical class 0.000 description 1
- 230000009849 deactivation Effects 0.000 description 1
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 230000009977 dual effect Effects 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- 230000008020 evaporation Effects 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 238000004231 fluid catalytic cracking Methods 0.000 description 1
- 238000009472 formulation Methods 0.000 description 1
- 125000005842 heteroatom Chemical group 0.000 description 1
- 238000005470 impregnation Methods 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 229910001960 metal nitrate Inorganic materials 0.000 description 1
- IJDNQMDRQITEOD-UHFFFAOYSA-N n-butane Chemical compound CCCC IJDNQMDRQITEOD-UHFFFAOYSA-N 0.000 description 1
- 229910017464 nitrogen compound Inorganic materials 0.000 description 1
- 150000002830 nitrogen compounds Chemical class 0.000 description 1
- 150000002902 organometallic compounds Chemical class 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 239000001294 propane Substances 0.000 description 1
- 238000000197 pyrolysis Methods 0.000 description 1
- 238000012216 screening Methods 0.000 description 1
- 239000010454 slate Substances 0.000 description 1
- 239000000779 smoke Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 238000001179 sorption measurement Methods 0.000 description 1
- 229910052596 spinel Inorganic materials 0.000 description 1
- 239000011029 spinel Chemical class 0.000 description 1
- 229910052717 sulfur Inorganic materials 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 238000006276 transfer reaction Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 239000013585 weight reducing agent Substances 0.000 description 1
- 239000010457 zeolite Substances 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
- C10G45/00—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds
- C10G45/44—Hydrogenation of the aromatic 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
- C10G47/00—Cracking of hydrocarbon oils, in the presence of hydrogen or hydrogen- generating compounds, to obtain lower boiling fractions
- C10G47/02—Cracking of hydrocarbon oils, in the presence of hydrogen or hydrogen- generating compounds, to obtain lower boiling fractions characterised by the catalyst used
- C10G47/10—Cracking of hydrocarbon oils, in the presence of hydrogen or hydrogen- generating compounds, to obtain lower boiling fractions characterised by the catalyst used with catalysts deposited on a carrier
- C10G47/12—Inorganic carriers
- C10G47/14—Inorganic carriers the catalyst containing platinum group metals or compounds thereof
-
- 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
- C10G47/02—Cracking of hydrocarbon oils, in the presence of hydrogen or hydrogen- generating compounds, to obtain lower boiling fractions characterised by the catalyst used
- C10G47/10—Cracking of hydrocarbon oils, in the presence of hydrogen or hydrogen- generating compounds, to obtain lower boiling fractions characterised by the catalyst used with catalysts deposited on a carrier
- C10G47/12—Inorganic carriers
Definitions
- the invention relates to a new process for the conversion of a heavy oil fraction, especially a heavy oil fraction containing a limited amount of asphaltenic constituents, into lighter components.
- heavy fractions e.g. fractions boiling between 370-520 °C
- cracking processes such as fluidized catalytic cracking, hydrocracking and thermal cracking, in order to convert these high boiling fractions into more valuable lighter fractions.
- Kerosene usually has a boiling point between about 150 and about 270 °C and is mainly used for jet fuel.
- a major quality parameter for kerosene and related to the burning properties thereof is the smoke point.
- Gas oil usually has a boiling point between about 250 and about 370 °C and is mainly used as fuel for compression-ignition engines.
- Important quality parameters comprise its ignition quality as expressed by the cetane number and its cold flow properties as expressed by the cloud point.
- Fluidized catalytic cracking is usually performed at a relatively low pressure (1.5 to 3 bar), and at relatively high temperatures (480-600 °C) in the presence of an acidic catalyst (for instance zeolite containing catalysts).
- the reaction is carried out in the absence of hydrogen and the residence time of the feed is very short (0.1-10 seconds).
- a large amount of carbonaceous materials (coke) is deposited onto the catalyst (3 to 8 %w of the feed).
- Continuous regeneration of the catalyst by burning-off coke is therefore necessary.
- the products obtained in this process contain relatively large quantities of olefins, iso-paraffins and aromatics boiling in the gasoline range.
- a major product obtained by fluidized catalytic cracking is a gasoline component of good quality.
- light cycle oils boiling in the kerosene range and some heavy cycle oils boiling in the gas oil range and above are obtained, both of a moderate to low quality for use as kerosene and gas oil.
- Hydrocracking is usually performed at a relatively high hydrogen pressure (usually 100-140 bar) and a relatively low temperature (usually 300 to 400 °C).
- the catalyst used in this reaction has a dual function: acid catalyzed cracking of the hydrocarbon molecules and activation of the hydrogen and hydrogenation.
- a long reaction time is used (usually 0.3 to 2 l/l/h liquid hourly space velocity). Due to the high hydrogen pressure only small amounts of coke are deposited on the catalyst which makes it possible to use the catalyst for 0.5 to 2 years in a fixed bed operation without regeneration.
- the products obtained in this process are dependent on the mode of operation. In one mode of operation, predominantly naphtha and lighter products are obtained.
- the naphtha fraction contains paraffins with a high iso/normal ratio, making it a valuable gasoline blending component.
- kerosene and gas oil are mainly obtained.
- the quality of these products is moderate only, due to the presence of remaining aromatics together with an undesired high iso/normal ratio of the paraffins amongst others.
- Thermal cracking is usually performed at a relatively low or moderate pressure (usually 5 to 30 bar) and at a relatively high temperature (420-520 °C) without catalysts and in the absence of hydrogen. A long reaction time is used (residence time normally 2-60 minutes).
- the middle distillates obtained from thermal cracking of high boiling distillates are of good quality as far as the ignition properties are concerned.
- the high content of olefins and heteroatoms (especially sulphur and nitrogen) requires a hydrofinishing treatment.
- a major problem in thermal cracking is the occurrence of condensation reactions which lead to the forming of polyaromatics.
- the cracked residue from thermal cracking therefore, is of a low quality (high viscosity and high carbon residue after evaporation and pyrolysis, expressed for instance by its Conradson Carbon Residue (CCR) content).
- HCTC hydrocatalytic thermal cracking
- the present invention thus relates to a process for the conversion of a heavy oil fraction into lighter fractions, comprising passing a heavy oil fraction having a content of asphaltenic constituents of less than 3%w together with a hydrogen containing gas stream through a reaction zone containing a non-acidic, hydrogen activating catalyst at a temperature of 400-550 °C, preferably 410-530 °C, more preferably 440-510 °C, and a hydrogen partial pressure of 10-60 bar, preferably 20-40 bar.
- the molecular weight reduction is essentially effected by thermal cracking of feedstock molecules.
- the novel process does not depend on the presence of acidic sites on the catalyst, which should remain active during the cracking cycle or life of the catalyst. Due to the presence of hydrogen even at relatively moderate pressure, only very small amounts of coke are deposited on the catalyst, thus making it possible to operate in a fixed bed mode (e.g. swing reactor) or a moving bed mode (e.g. bunker flow reactor).
- the middle distillates obtained are of good quality due to the high amount of n-paraffins and the low amount of olefins, in spite of the presence of a certain amount of aromatic compounds.
- the hydrogen consumption of the process is relatively low, as the aromatic compounds are hardly hydrogenated.
- a further advantage is the fact that, dependent on the catalyst, the sulphur present in the feed can be converted for a substantial part into hydrogen sulphide, thus resulting in a product, containing a relatively small amount of sulphur.
- the bottom material i.e. material boiling above the boiling point of the middle distillate products, has excellent properties (viscosity, carbon residue and sulphur content) and can be used as a valuable fuel oil blending component. Further, said heavy material is unexpectedly an excellent feedstock for a fluidized catalytic cracking reaction. When compared with a usual feedstock for a fluidized catalytic cracking reactor, for example a straight run flashed distillate, the gasoline yield and quality are similar. When compared with the bottom material obtained from a distillate thermal cracking reactor as feedstock for a fluidized catalytic cracking process a much higher gasoline yield is obtained.
- the HCTC-process does not depend on the presence of acidic sites on the catalyst.
- the HCTC process can be suitably carried out in the substantial or even complete absence of acidic sites in the catalyst.
- feeds containing a substantial amount of basic nitrogen and/or sulphur containing compounds can be processed without difficulties. Due to the presence of activated hydrogen only very small amounts of coke are deposited on the catalyst, while in fluidized catalytic cracking large amounts of coke are deposited on the catalyst, making continuous regeneration of the catalyst necessary.
- the products obtained by the present process are predominantly middle distillates of good quality together with a heavy, unconverted fraction of relatively good quality.
- the major product obtained by fluid catalytic cracking is a gasoline blending component together with a smaller amount of light cycle oil of moderate to low quality as aromatic compounds form the larger part of this light fraction.
- a gasoline blending component together with a smaller amount of light cycle oil of moderate to low quality as aromatic compounds form the larger part of this light fraction.
- HCTC is relatively insensitive to feedstock impurities, especially (basic) nitrogen and carbon residue (CCR).
- CCR carbon residue
- the process according to the present invention can be carried out during a substantial period at relatively low hydrogen pressure investment costs are considerably lower when compared with a conventional hydrocracking process.
- the hydrogen consumption in the HCTC-process is relatively low.
- iso/normal ratio of the paraffins it may be remarked that due to the radical type of cracking in the HCTC-process the iso/normal ratio of the paraffins is low, which is favourably for the ignition quality of the gas oil.
- the classic hydrocracking process results in a high iso/normal ratio due to the carbonium ion reaction mechanism, thus unfavourably affecting the quality, of the middle distillates, especially the ignition quality of the gas oil.
- a suitable feed for the HCTC-process according to the present invention is a heavy oil fraction having a content of asphaltenic constituents of less than 3%w.
- Vacuum distillates, and/or deasphalted oils of any source and almost limitless as far as the sulphur and nitrogen content is concerned can be used.
- the content of asphaltenic constituents in the feed is less than 2%w, more preferably less than 1.5%w, and most preferably less than 1.0%w.
- C7-asphaltenes are meant, i.e. the asphaltenic fraction removed from the heavy oil fraction by precipitation with heptane.
- the feed may contain a substantial amount of carbon residue (CCR), suitably below 15%w, preferably below 10%w, more preferably below 6%w.
- CCR carbon residue
- the amount of sulphur in the feed is suitably below 10%w, preferably below 6%w, more preferably below 4%w.
- the amount of nitrogen is suitably below 6%w, preferably below 4%w.
- a vacuum distillate or flashed distillate can be used as feed having a boiling range substantially between 350 and 580 °C, preferably between 370 and 520 °C.
- Another very suitable feed is a deasphaltized residual oil (DAO), for instance a propane, butane or pentane deasphalted long or short residue.
- DAO deasphaltized residual oil
- synthetic distillates and/or synthetic deasphalted oils which are available in for instance complex refineries, are suitable feeds for the present process.
- a very suitable source for producing such synthetic feeds comprises the so-called hydroconversion process of residual oil fractions, for instance short residue.
- Such a hydroconversion process preferably comprises a hydrodemetallization step, followed by a hydrodesulphurization/hydrodenitrogenation step and/or a hydrocracking step.
- usually synthetic flashed distillates or synthetic deasphalted oils are processed in a catalytic cracking process. However, this results mainly in the production of gasoline but no kerosene or gas oil of acceptable quality is obtained.
- Hydrogen conversion processes such as H-oil, LC-fining and Residfining can also be used for the production of the above-indicated synthetic feeds.
- Another very suitable feed for the HCTC-process originates from a visbreaking process of for instance short residue. Upon thermally cracking a heavy residue followed by flashing or distillation of the product, a distillate can be obtained substantially boiling in the range between 350 and 520 °C which is an excellent feedstock for the process according to the present invention.
- Mixtures of relatively heavy and relatively light feedstocks e.g. a DAO and a flashed distillate, may be used advantageously in view of reduced coke formation.
- the hydrocatalytic thermal cracking process is suitably carried out at a reaction temperature of 400-550 °C, preferably 410-530 °C, more preferably between 440-510 °C, most preferably at about 450 °C. It will be appreciated that a higher conversion will be obtained when the temperature is higher, as the rate of thermal cracking of hydrocarbons will be faster at higher temperatures. To obtain the same conversion rate a (slightly) higher temperature should be used for a feedstock which is more difficult to crack thermally, for instance a feedstock rich in cyclic compounds, than for a feedstock which cracks more easily.
- the space velocity of the feed in the novel HCTC process is suitably chosen between 0.1 to 10 l/l/h, preferably between 0.5 to 6 l/l/h, more preferably between 1.0 to 5 l/l/h.
- the hydrogen partial pressure under which the HCTC-process is carried out suitably lies between 10-60 bar, preferably 20-40 bar, more preferably about 25 bar.
- the total pressure in the reactor usually will be between 15 and 65 bar, and is preferably between 25 and 45 bar, more preferably about 30 bar.
- the hydrogen partial pressure at the reactor inlet usually will be 3-10 bar higher than at the outlet of the reactor.
- the catalysts to be used in the process according to the present invention should contain a hydrogen activating function.
- Suitable catalysts comprise one or more group IVa, group VIb or group VIII metals.
- Suitably supports such as silica, alumina, aluminium phosphates, spinel compounds, titania and zirconia can be used.
- Conventional Group VIb and VIII metal combinations can be employed.
- the term "non-acidic" in this specification relates to the substantial absence of one or more active acidic sites in the catalyst which are able to accelerate the cracking reaction of hydrocarbons via carbonium ion chemistry. Under initial reaction conditions some acidic sites may be present. However, these acidic sites rapidly deactivate due to coke formation and basic nitrogen adsorption whilst the hydrogen activating function remains substantially unchanged.
- the catalyst comprises a group VIII noble metal the use of palladium or platinum is preferred.
- the catalyst comprises a group IVa metal preferably tin is used.
- the catalyst comprises a group VIb metal, preferably molybdenum, chromium or tungsten is used.
- a group VIII non-noble metal preferably iron, cobalt or nickel is used.
- Preferred catalysts are those catalysts which show a distinct but limited hydrodesulphurization activity. These catalysts show a very low coke formation together with relatively good product properties for the middle distillate fraction.
- the second order rate constant of the hydrodesulphurization reaction under the HCTC conditions lies between 0.1 and 1.0, more preferably between 0.2 and 0.5 1/(h.%S), defined under stationary conditions at 450 °C and using Kuwait flashed distillate.
- the hydrogen/feed ratio of the process according to the present invention may be varied over a wide range.
- a suitable hydrogen/feed ratio lies between 50 Nl/kg and 5000 Nl/kg, especially between 100 Nl/kg and 2000 Nl/kg. It is preferred to use a hydrogen/feed ratio between 100 and 500 Nl/kg, more preferably between 200 Nl/kg and 400 Nl/kg. Using these preferred low hydrogen/feed ratios the coke laydown on the catalyst is surprisingly very low. Furthermore, a high cracking conversion is obtained. When compared with a conventional hydrocracking process the hydrogen/feed ratio is significantly lower for the process of the present invention, which is beneficial for process economics.
- the usual hydrogen/feed ratio in hydrocracking operations lies between 700 and 1500 Nl/kg. Generally in hydroprocessing high hydrogen/feed ratios are necessary to suppress coke-formation and to improve the conversion rate. Surprisingly, in the HCTC process a low gas rate is not only possible but also beneficial with respect to both coke formation and conversion.
- the above described preferred hydrogen/feed ratio of 200 to 400 Nl/kg is used in combination with a catalyst comprising a group VIII noble metal, preferably palladium and/or platinum.
- a catalyst comprising a group VIII noble metal, preferably palladium and/or platinum.
- the hydrogen containing stream comprises a mixture of hydrogen and hydrogen sulphide.
- Carrying out the HCTC-reaction with a mixture of hydrogen and hydrogen sulphide leads to an increase of both conversion level and the selectivity to middle distillates.
- the amount of hydrogen sulphide in the mixture present in the reactor is suitably up to 50% (v/v) of the amount of hydrogen.
- an amount of hydrogen sulphide is used between 1 and 30%, more preferably between 5 and 25%, and most preferably about 10%.
- the HCTC reaction according to the present invention is suitably carried out in a fixed bed mode, e.g. a trickle bed downflow reactor.
- a fixed bed mode e.g. a trickle bed downflow reactor.
- two or more fixed bed are used, operated in a swing-operation.
- the HCTC reaction is conveniently carried out in an upflow fixed bed reactor, especially when relatively light feedstocks are used.
- Application of an upflow reactor in that case will result in a reduced rate of coke deposition on the catalyst, thereby increasing the possible run lenght between two catalyst regenerations.
- the reduction of the amount of coke on the catalyst in the upflow mode can be 50% or more when compared with the downflow mode.
- Other preferred modes of operation the process according the present invention are moving bed operations, e.g. a bunker flow reactor, and an ebullated bed operation.
- the products produced in the HCTC process can either be used as such or can be subjected to further treatment. It is possible, for instance, to subject part or all of the product(s) obtained to a desulphurization treatment, in particular a hydrodesulphurization treatment, to adjust the sulphur amount of the product to the desired amount.
- a further possibility comprises subjecting part or all of the (hydrodesulphurized) product to a hydrofinishing treatment, optionally before or after distillation of the (hydrodesulphurized) product. It is also possible to recycle at least part of the unconverted material present in the product to the HCTC reactor.
- Catalyst regeneration is suitably carried out by burning off the carbonaceous material deposited on the catalyst using an oxygen and/or steam containing gas.
- the catalyst regeneration may be carried out in the cracking reactor itself.
- the regeneration is typically carried out in a separate regenerator.
- a Kuwait flashed distillate was subjected to the hydrocatalytic thermal cracking process according to the present invention.
- the feed properties are described in Table I.
- the reaction was carried out in an isothermally operated microflow trickle bed downflow reactor.
- the catalysts were prepared by conventional pore volume impregnation techniques, unless stated otherwise.
- Commercial available carriers silica or alumina
- Catalysts 1 to 12 and 19-21 Commercially available catalysts, either as such or slightly modified, were used in experiments 13 to 18.
- the carrier properties are described in Table II.
- Inorganic precursors were used to prepare catalysts 1-12 and 19-21 (e.g. metal nitrates, ammonium molybdate).
- Chloride precursors were omitted.
- Tin was deposited as an organometallic compound (e.g. tin(II)2-ethylhexanoate).
- NiMo/SiO2 was prepared via a deposition-precipitation technique as described in e.g. British patent specification 2,189,163. Before use, the catalysts were calcined at 350-450 °C (except for NiMo/SiO2 catalysts), followed by crushing to smaller particles (Standard sieve designation 180-550 micrometer (30-80 mesh)). An overview of the catalyst formulations is given in Table III.
- the reactions were carried out at 450 °C and a total pressure of 30 bar.
- the space velocity (LHSV) was about 1.0 l/l/h.
- the H2/feed ratio was between 850 and 1100 Nl/kg.
- the reaction time varied between 170 and 220 hours.
- the liquid product was analyzed for the boiling point distribution using TBP-GLC. Moreover, GLC analysis of the off-gas was carried out. On basis of these analyses conversions and selectivities were calculated. The conversion has been defined as the net removal (%) of material boiling above 370 °C.
- the product slate was split up into gas (C1-C4), naphtha (C5-150 °C), middle distillates (150-370 °C) and coke.
- the selectivities (%) have been calculated as the amount of the product in question, divided by the total amount of products (material boiling below 370 °C and coke).
- Hydrogen consumptions were calculated on basis of CME (Combustion Mass Spectrometric Element) analyses of both the feedstock and the liquid product and of the gas analyses.
- the hydrodesulphurization (HDS) activity was determined from the sulphur content of liquid product. The results of the experiments are summerized in Table IV.
- Example II Using the same general reaction conditions as described in Example I, three different feedstocks were compared. The feedstock properties are described in Table X.
- the Kuwait flashed distillate is described in more detail in Table I.
- the Kuwait deasphalted oil is a butane-deasphalted short residue.
- the Maya synthetic flashed distillate has been produced by hydrodemetallization and hydroconversion of Maya short residue, followed by flashing. The results of the experiments are summerized in Table XI.
- a Kuwait long residue was used as feed for an HCTC experiment carried out at a temperature of 450 °C, a pressure of 50 bar, a LHSV of 1.0 l/l/h, a H2/feed ratio of 1000 Nl/kg and a run length of 50 hours, using catalyst No. 12.
- Feedstock properties specific gravity (d 70/4): 0.9139, sulphur (%w): 3.69, nitrogen (%w): 0.15, metals (ppm): 42, RCT (%w): 5.1, C7-asphaltenes (%w): 2.4.
- the net conversion was 45%.
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- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Organic Chemistry (AREA)
- Inorganic Chemistry (AREA)
- Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)
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- Fats And Perfumes (AREA)
Claims (14)
- Procédé pour la conversion d'une fraction d'huile lourde en fractions plus légères, comprenant le passage d'une fraction d'huile lourde, ayant une teneur en constituants asphalténiques de moins de 3 % en poids, en même temps que d'un courant d'un gaz contenant de l'hydrogène, à travers une zone de réaction contenant un catalyseur non-acide activant l'hydrogène, à une température de 400-550°C, de préférence de 410-530°C, en particulier de 440-510°C, et à une pression partielle d'hydrogène de 10-60 bars, de préférence de 20-40 bars.
- Procédé selon la revendication 1, dans lequel la fraction d'huile lourde a une teneur en constituants asphalténiques de moins de 2 % en poids, de préférence de moins de 1 % en poids.
- Procédé selon la revendication 1 ou 2, dans lequel la fraction d'huile lourde est un distillat (synthétique) ayant un intervalle d'ébullition compris substantiellement entre 350 et 580°C ou une huile désasphaltée (synthétique).
- Procédé selon la revendication 1 ou 2, dans lequel la fraction d'huile lourde est un distillat bouillant substantiellement entre 350 et 520°C obtenu par craquage thermique d'un résidu lourd.
- Procédé selon les revendications 1-4, dans lequel le catalyseur comprend un ou plusieurs métaux nobles du groupe VIII, de préférence du palladium ou du platine.
- Procédé selon les revendications 1-5, dans lequel le catalyseur comprend un ou plusieurs métaux du groupe IVa, spécialement de l'étain, un ou plusieurs métaux du groupe VIb, spécialement du molybdène, du chrome ou du tungstène, et un ou plusieurs métaux du groupe VIII, spécialement du fer, du cobalt ou du nickel, les métaux étant de préférence dans leur forme sulfurée.
- Procédé selon la revendication 6, dans lequel le catalyseur comprend un ou plusieurs métaux du groupe VIb, spécialement du molybdène, du chrome ou du tungstène, en même temps qu'un ou plusieurs métaux choisis parmi le fer, le cobalt ou le nickel, les métaux étant de préférence dans leur forme sulfurée.
- Procédé selon les revendications 5-7, dans lequel le catalyseur présente une activité d'hydrodésulfuration nette, mais limitée.
- Procédé selon les revendications 5-8, dans lequel le catalyseur comprend un support sur lequel les métaux sont déposés, de préférence un catalyseur ayant un volume de pores d'au moins 0,2 ml/g, spécialement d'au moins 0,5 ml/g.
- Procédé selon les revendications 1-9, dans lequel la vitesse spatiale de la charge est de 0,1 à 5 1/1/h, de préférence de 0,5 à 3 l/l/h et le débit d'hydrogène est de 100-2000 Nl/kg, de préférence de 100-500 Nl/kg, de préférence de 200-400 Nl/kg.
- Procédé selon les revendications 1-10, dans lequel le courant contenant de l'hydrogène comprend un mélange d'hydrogène et de sulfure d'hydrogène, la quantité de sulfure d'hydrogène étant au maximum de 50 % (v/v) de la quantité d'hydrogène, de préférence comprise entre 1 et 30 %, en particulier entre 5 et 25 %.
- Procédé selon les revendications 1-11, dans lequel la réaction est conduite dans une opération à lit fixe, de préférence avec écoulement de bas en haut.
- Procédé selon les revendications 1-12, dans lequel au moins une partie de la matière non transformée présente dans le produit de la réaction est recyclée.
- Procédé selon les revendications 1-13, dans lequel la matière non transformée de la réaction est utilisée comme charge pour une réaction de craquage catalytique à lit fluidisé.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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AT88202685T ATE76893T1 (de) | 1987-11-27 | 1988-11-24 | Schweroelcrackverfahren. |
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Application Number | Priority Date | Filing Date | Title |
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GB8727777 | 1987-11-27 | ||
GB878727777A GB8727777D0 (en) | 1987-11-27 | 1987-11-27 | Heavy oil cracking process |
Publications (3)
Publication Number | Publication Date |
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EP0318125A2 EP0318125A2 (fr) | 1989-05-31 |
EP0318125A3 EP0318125A3 (en) | 1990-03-14 |
EP0318125B1 true EP0318125B1 (fr) | 1992-06-03 |
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Application Number | Title | Priority Date | Filing Date |
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EP88202685A Expired - Lifetime EP0318125B1 (fr) | 1987-11-27 | 1988-11-24 | Procédé de craquage d'huile lourde |
Country Status (25)
Country | Link |
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EP (1) | EP0318125B1 (fr) |
JP (1) | JPH01170689A (fr) |
KR (1) | KR890008302A (fr) |
CN (1) | CN1022043C (fr) |
AR (1) | AR244309A1 (fr) |
AT (1) | ATE76893T1 (fr) |
AU (1) | AU608389B2 (fr) |
BR (1) | BR8806191A (fr) |
CA (1) | CA1326464C (fr) |
DD (1) | DD283643A5 (fr) |
DE (1) | DE3871732T2 (fr) |
DK (1) | DK655488A (fr) |
ES (1) | ES2032004T3 (fr) |
FI (1) | FI885467A (fr) |
GB (1) | GB8727777D0 (fr) |
GR (1) | GR3004811T3 (fr) |
IN (1) | IN173572B (fr) |
MX (1) | MX172342B (fr) |
MY (1) | MY104114A (fr) |
NO (1) | NO172898C (fr) |
NZ (1) | NZ227067A (fr) |
PH (1) | PH25825A (fr) |
RU (1) | RU1813095C (fr) |
SG (1) | SG45793G (fr) |
ZA (1) | ZA888798B (fr) |
Cited By (1)
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US7763160B2 (en) | 2003-12-19 | 2010-07-27 | Shell Oil Company | Systems and methods of producing a crude product |
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CN1045462C (zh) * | 1996-07-22 | 1999-10-06 | 中国石油化工总公司 | 一种重质馏份油中压加氢裂化方法 |
CN1045100C (zh) * | 1996-12-26 | 1999-09-15 | 南京兴达石油化工科技工贸公司 | 特种煤油型溶剂油的生产方法 |
BRPI0405536A (pt) * | 2003-12-19 | 2005-09-20 | Shell Int Research | Métodos de produzir um produto de petróleo bruto e combustìvel de transporte, combustìvel de aquecimento, lubrificantes ou substâncias quìmicas e produto de petróleo bruto |
US20090065394A1 (en) * | 2007-09-07 | 2009-03-12 | Uop Llc, A Corporation Of The State Of Delaware | Hydrocracking process for fabricating distillate from fisher-tropsch waxes |
JP5526408B2 (ja) | 2010-01-19 | 2014-06-18 | 国立大学法人東北大学 | 燃料物性決定方法及び燃料物性決定装置 |
JP5453221B2 (ja) | 2010-11-18 | 2014-03-26 | 国立大学法人東北大学 | 燃焼実験装置 |
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US2801208A (en) * | 1954-02-04 | 1957-07-30 | Gulf Research Development Co | Process for hydrogen treatment of hydrocarbons |
FR1568754A (fr) * | 1967-06-30 | 1969-05-30 | ||
DE2504248A1 (de) * | 1974-02-07 | 1975-08-21 | Exxon Research Engineering Co | Katalysatormischung und verfahren zur umwandlung von schweren erdoelrohmaterialien |
US4298458A (en) * | 1980-02-25 | 1981-11-03 | Mobil Oil Corporation | Low pressure hydrotreating of residual fractions |
-
1987
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1988
- 1988-11-09 CA CA000582600A patent/CA1326464C/fr not_active Expired - Fee Related
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- 1988-11-24 AU AU25892/88A patent/AU608389B2/en not_active Ceased
- 1988-11-24 KR KR1019880015525A patent/KR890008302A/ko not_active Application Discontinuation
- 1988-11-24 EP EP88202685A patent/EP0318125B1/fr not_active Expired - Lifetime
- 1988-11-24 RU SU884356935A patent/RU1813095C/ru active
- 1988-11-24 JP JP63294860A patent/JPH01170689A/ja active Pending
- 1988-11-24 ES ES198888202685T patent/ES2032004T3/es not_active Expired - Lifetime
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1992
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Cited By (14)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US7763160B2 (en) | 2003-12-19 | 2010-07-27 | Shell Oil Company | Systems and methods of producing a crude product |
US7811445B2 (en) | 2003-12-19 | 2010-10-12 | Shell Oil Company | Systems and methods of producing a crude product |
US7828958B2 (en) | 2003-12-19 | 2010-11-09 | Shell Oil Company | Systems and methods of producing a crude product |
US7854833B2 (en) | 2003-12-19 | 2010-12-21 | Shell Oil Company | Systems and methods of producing a crude product |
US7879223B2 (en) | 2003-12-19 | 2011-02-01 | Shell Oil Company | Systems and methods of producing a crude product |
US7959797B2 (en) | 2003-12-19 | 2011-06-14 | Shell Oil Company | Systems and methods of producing a crude product |
US8025791B2 (en) | 2003-12-19 | 2011-09-27 | Shell Oil Company | Systems and methods of producing a crude product |
US8070936B2 (en) | 2003-12-19 | 2011-12-06 | Shell Oil Company | Systems and methods of producing a crude product |
US8163166B2 (en) | 2003-12-19 | 2012-04-24 | Shell Oil Company | Systems and methods of producing a crude product |
US8268164B2 (en) | 2003-12-19 | 2012-09-18 | Shell Oil Company | Systems and methods of producing a crude product |
US8394254B2 (en) | 2003-12-19 | 2013-03-12 | Shell Oil Company | Crude product composition |
US8608938B2 (en) | 2003-12-19 | 2013-12-17 | Shell Oil Company | Crude product composition |
US8613851B2 (en) | 2003-12-19 | 2013-12-24 | Shell Oil Company | Crude product composition |
US8663453B2 (en) | 2003-12-19 | 2014-03-04 | Shell Oil Company | Crude product composition |
Also Published As
Publication number | Publication date |
---|---|
ES2032004T3 (es) | 1993-01-01 |
DE3871732T2 (de) | 1993-01-21 |
DK655488D0 (da) | 1988-11-24 |
CN1022043C (zh) | 1993-09-08 |
FI885467A (fi) | 1989-05-28 |
NZ227067A (en) | 1990-08-28 |
JPH01170689A (ja) | 1989-07-05 |
PH25825A (en) | 1991-11-05 |
ZA888798B (en) | 1989-07-26 |
EP0318125A3 (en) | 1990-03-14 |
BR8806191A (pt) | 1989-08-15 |
MY104114A (en) | 1993-12-31 |
CN1033831A (zh) | 1989-07-12 |
ATE76893T1 (de) | 1992-06-15 |
FI885467A0 (fi) | 1988-11-24 |
NO172898B (no) | 1993-06-14 |
EP0318125A2 (fr) | 1989-05-31 |
AU608389B2 (en) | 1991-03-28 |
DE3871732D1 (de) | 1992-07-09 |
NO885257L (no) | 1989-05-29 |
GR3004811T3 (fr) | 1993-04-28 |
IN173572B (fr) | 1994-06-04 |
NO172898C (no) | 1993-09-22 |
SG45793G (en) | 1993-06-25 |
DD283643A5 (de) | 1990-10-17 |
GB8727777D0 (en) | 1987-12-31 |
RU1813095C (ru) | 1993-04-30 |
KR890008302A (ko) | 1989-07-10 |
DK655488A (da) | 1989-05-28 |
AR244309A1 (es) | 1993-10-29 |
CA1326464C (fr) | 1994-01-25 |
NO885257D0 (no) | 1988-11-24 |
AU2589288A (en) | 1989-06-01 |
MX172342B (es) | 1993-12-14 |
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