EP0392590B1 - Procédé de conversion d'une charge hydrocarbonée - Google Patents

Procédé de conversion d'une charge hydrocarbonée Download PDF

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Publication number
EP0392590B1
EP0392590B1 EP19900200788 EP90200788A EP0392590B1 EP 0392590 B1 EP0392590 B1 EP 0392590B1 EP 19900200788 EP19900200788 EP 19900200788 EP 90200788 A EP90200788 A EP 90200788A EP 0392590 B1 EP0392590 B1 EP 0392590B1
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EP
European Patent Office
Prior art keywords
catalyst
feedstock
process according
olefins
metal
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EP19900200788
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German (de)
English (en)
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EP0392590A1 (fr
Inventor
Ian Ernest Maxwell
Jaydeep Biswas
Johannes Petrus Van Den Berg
Jaap Erik Naber
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Shell Internationale Research Maatschappij BV
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Shell Internationale Research Maatschappij BV
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    • 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
    • C10G57/00—Treatment of hydrocarbon oils, in the absence of hydrogen, by at least one cracking process or refining process and at least one other conversion process
    • C10G57/02—Treatment of hydrocarbon oils, in the absence of hydrogen, by at least one cracking process or refining process and at least one other conversion process with polymerisation

Definitions

  • the present invention relates to a process for the conversion of a hydrocarbonaceous feedstock, and is particularly concerned with the production of olefins from hydrocarbonaceous feedstocks.
  • Ethylene and propylene are valuable starting materials for many chemical processes, while C4 olefins can find use as a starting material for alkylation and/or oligomerization procedures in order to produce high octane gasoline and/or middle distillates. Isobutene can be usefully converted to methyl t-butyl ether.
  • C2 olefins in order to meet fluctuating demand for production of C2, C3 and C4 olefins, there is a need to provide a process with a flexible product slate of lower olefins.
  • the present invention provides a process for the conversion of a hydrocarbonaceous feedstock comprising the following steps:
  • lower olefins is intended primarily to include ethylene, propylene, butene and i-butene, but may extend to other olefins having up to 6 carbon atoms.
  • the feedstock is contacted with the solid cracking catalyst in step (i) for less than 10 seconds.
  • the minimum contact time is 0.1 second. Very good results are obtainable with a process in which the feedstock is contacted with the solid cracking catalyst during 0.2 to 6 seconds.
  • the temperature during the reaction is relatively high. However, the combination of high temperature and short contact time allows a high conversion of olefins in step (i).
  • a preferred temperature range is 480 to 900 °C, more preferably 500 to 750 °C.
  • the solid cracking catalyst preferably comprises at least one zeolite with a pore diameter of from 0.3 to 0.7 nm, preferably 0.5 to 0.7 nm.
  • the catalyst suitably further comprises a refractory oxide that serves as binder material. Suitable refractory oxides include alumina, silica, silica-alumina, magnesia, titania, zirconia and mixtures thereof. Alumina is especially preferred.
  • the weight ratio of refractory oxide and zeolite suitably ranges from 10:90 to 90:10, preferably from 50:50 to 85:15.
  • the catalyst may also comprise further zeolites with a pore diameter above 0.7 nm.
  • zeolites include the faujasite-type zeolites, zeolite beta, zeolite omega and in particular zeolite X and Y.
  • the zeolitic catalyst preferably comprises as zeolite substantially only zeolites with a pore diameter of from 0.3 to 0.7 nm.
  • zeolite in this specification is not to be regarded as comprising only crystalline aluminium silicates.
  • the term also includes crystalline silica (silicalite), silicoaluminophosphates (SAPO), chromosilicates, gallium silicates, iron silicates, aluminium phosphates (ALPO), titanium aluminosilicates (TASO), boron silicates, titanium aluminophosphates (TAPO) and iron aluminosilicates.
  • Examples of zeolites that may be used in the process of the invention and that have a pore diameter of 0.3 to 0.7 nm include SAPO-4 and SAPO-11, which are described in US-A-4,440,871, ALPO-11, described in US-A-4,310,440, TAPO-11, described in US-A-4,500,651, TASO-45, described in EP-A-229,295, boron silicates, described in e.g. US-A-4,254,297, aluminium silicates like erionite, ferrierite, theta and the ZSM-type zeolites such as ZSM-5, ZSM-11, ZSM-12, ZSM-35, ZSM-23, and ZSM-38.
  • SAPO-4 and SAPO-11 which are described in US-A-4,440,871, ALPO-11, described in US-A-4,310,440, TAPO-11, described in US-A-4,500,651, TASO-45, described in EP-A-229,29
  • the zeolite is selected from the group consisting of crystalline metal silicates having a ZSM-5 structure, ferrierite, erionite and mixtures thereof.
  • crystalline metal silicates with ZSM-5 structure are aluminium, gallium, iron, rhodium and/or scandium silicates as described in e.g. GB-B-2,110,559.
  • the zeolites usually a significant amount of alkali metal oxide is present in the prepared zeolite.
  • the amount of alkali metal is removed by methods known in the art, such as ion exchange, optionally followed by calcination, to yield the zeolite in its hydrogen form.
  • the zeolite used in the present process is substantially in its hydrogen form.
  • the pressure in step (i) of the present process can be varied within wide ranges. It is, however, preferred that the pressure is such that at the prevailing temperature the feedstock is substantially in its gaseous phase or brought thereinto by contact with the catalyst. Then it is easier to achieve the short contact times envisaged. Hence, the pressure is preferably relatively low. This can be advantageous since no expensive compressors and high-pressure vessels and other equipment are necessary. A suitable pressure range is from 1 to 10 bar. Subatmospheric pressures are possible, but not preferred. It can be economically advantageous to operate at atmospheric pressure. Other gaseous materials may be present during the conversion such as steam and/or nitrogen.
  • Step (i) is carried out preferably in a moving bed.
  • the bed of catalyst, preferably fluidized may also move upwards or downwards. When the bed moves upwards a process somewhat similar to fluidized catalytic cracking process is obtained.
  • the catalyst is regenerated by subjecting it, after having been contacted with the feedstock, to a treatment with an oxidizing gas, such as air.
  • a continuous regeneration similar to the regeneration carried out in a fluidized catalytic cracking process, is especially preferred.
  • the residence time of the catalyst particles in a reaction zone is longer than the residence time of the feedstock in the reaction zone.
  • the contact time between feedstock and catalyst should be less than 10 seconds.
  • the contact time generally corresponds with the residence time of the feedstock.
  • the residence time of the catalyst is from 1 to 20 times the residence time of the feedstock.
  • the catalyst/feedstock weight ratio in step (i) may vary widely, for example up to 200 kg of catalyst per kg of feedstock including recycled material. Preferably, the catalyst/feedstock weight ratio is from 20 to 100:1.
  • feedstock which is to be converted in the process of the present invention can vary within a wide boiling range.
  • suitable feedstocks are relatively light petroleum fractions such as feedstocks comprising C3 ⁇ 4 hydrocarbons (e.g. LPG), naphtha, gasoline fractions and kerosine fractions.
  • Heavier feedstocks may comprise, for example, vacuum distillates, long residues, deasphalted residual oils and atmospheric distillates, for example gas oils and vacuum gas oils.
  • feedstock has been found to comprise hydrotreated and/or hydrocracked hydrocarbons, preferably, though not necessarily, heavy feedstocks.
  • Suitable feedstocks of this type may be obtained by hydrotreating and/or hydrocracking heavy flashed distillate fractions from long residue or deasphalted oils obtained from short residue.
  • the effluent from step (i) may be subjected to any suitable separation means dependent on the composition of the effluent which will vary somewhat dependent on the feedstock employed.
  • a fraction comprising one or more lower olefins is separated from the effluent.
  • the lower olefin-comprising fraction suitably comprises one or more of ethylene, propylene, butene and isobutene and may include other light olefinic and/or paraffinic products but is preferably free of heavier products.
  • the olefin-comprising fraction which is separated depends on the product slate desired.
  • a fraction rich in C4 olefins is separated, if it is desired to produce a final product slate rich in C2 and/or C3 olefins.
  • a preferred lower olefin rich fraction will be rich in one or two of C2, C3 and C4 olefins.
  • At least a portion of the olefin-comprising fraction is contacted with an oligomerization catalyst under oligomerization conditions.
  • an oligomerization catalyst any suitable oligomerization process can be employed. Examples of such processes include those employing solid catalysts such as ZSM-5 (e.g. US Patents 4,456,779 and 4,433,185) and fluorided silica/alumina (Ind. Pet. Gaz. - Chim 1978, (501), p 13-20), hydrocarbon-soluble catalysts such as a mixture of an organo-nickel compound and a hydrocarbyl aluminium halide (e.g.
  • a preferred catalyst employed in step (iii) of the process according to the invention comprises at least one metal (Z) selected from the group consisting of metals from Groups 1b, 2a, 2b, 3a, 4b, 5b, 6b and 8 of the Periodic Table of the Elements and a crystalline trivalent metal (Q) silicate.
  • the catalyst applied in step (iii) of the process according to the invention is prepared by using a zeolite carrier material, including such zeolites as mordenite, faujasite, omega, L, ZSM-5, -11, -12, -35, -23 and -38, ferrierite, erionite, theta, beta and mixtures thereof.
  • a zeolite carrier material including such zeolites as mordenite, faujasite, omega, L, ZSM-5, -11, -12, -35, -23 and -38, ferrierite, erionite, theta, beta and mixtures thereof.
  • a preferred zeolite is mordenite (see for example EP-A-233382).
  • the carrier comprises exchangeable cations such as alkali metal-, hydrogen- and/or preferably ammonium ions.
  • the carrier material is suitably treated one or more times with a solution of at least one metal salt such as an aqueous solution of a metal nitrate or -acetate.
  • the ion exchange treatment is suitably carried out at a temperature from 0 °C up to the boiling temperature of the solution, and preferably at a temperature from 20-100 °C.
  • the valency n of the metals Z can vary from +1 to +6.
  • at least one of the metals Z in the catalyst is bivalent or trivalent, in which case the molar ratio Z:Q is preferably greater than 0.5.
  • Z is preferably selected from the group consisting of the bivalent metals copper, zinc, cadmium, magnesium, calcium, strontium, barium, titanium, vanadium, chromium, manganese, iron, cobalt and nickel.
  • a particularly preferred metal Z is nickel.
  • the trivalent metal Q which is present in the crystal structure of the preferred metal silicate catalyst carrier used in step (iii) preferably comprises at least one metal selected from the group consisting of aluminium, iron, gallium, rhodium, chromium and scandium. Most preferably Q consists substantially of aluminium; the resulting crystalline aluminium silicate preferably comprises a major part of mordenite and most preferably consists substantially completely of mordenite.
  • the molar ratio silicon:Q in the catalyst is suitably in the range from 5:1 to 100:1 and preferably in the range from 7:1 to 30:1. This ratio is in most cases substantially identical to the molar ratio Si:Q in the crystalline metal silicate employed as carrier material, except when some of the metal Q has been removed from the crystal structure during the catalyst preparation e.g. by means of acid leaching.
  • the carrier material and/or the ready catalyst for either one of the steps of the present process can be combined with a binder material such as refractory oxide(s), clay and/or carbon.
  • a binder material such as refractory oxide(s), clay and/or carbon.
  • Suitable refractory oxides comprise alumina, silica, magnesia, zirconia, titania and combinations thereof.
  • the molar ratio Z:Q in the ready catalyst is preferably from 0.1-1.5 and most preferably from 0.2-1.2.
  • the metal Z is identical with the metal Q and is incorporated in the crystal structure of the silicate; most preferably gallium is the metal Q in the case where no additional metal Z is present in the catalyst.
  • the catalytically active composition thus obtained is preferably dried and calcined before being employed as catalyst in step (iii). Drying is suitably carried out at a temperature from 100-400 °C, and preferably from 110-300 °C, for a period of 1-24 hours; the calcination temperature is suitably from 400-800 °C and preferably from 450-650 °C.
  • the calcination treatment is suitably carried out at (sub-)atmospheric or elevated pressure for a period of 0.1-24 hours, and preferably of 0.5-5 hours in air or in an inert (e.g. nitrogen) atmosphere.
  • Step (iii) can be carried out in one or more fixed-, moving- and/or fluidized beds or in a slurry-type of reactor; preferably, the process is carried out in a fixed bed of catalyst particles such as extrudates, pellets or spheres passing sieve openings having a width from 0.05-5 mm, and preferably from 0.1-2.5 mm.
  • catalyst particles such as extrudates, pellets or spheres passing sieve openings having a width from 0.05-5 mm, and preferably from 0.1-2.5 mm.
  • Step (iii) is preferably carried out at a temperature from 180-300 °C, a pressure from 10-50 bar and a space velocity from 0.2-5 kg olefin feed/kg catalyst.hour.
  • At least a portion of the effluent from step (iii) as described above is recycled to step (i), suitably by combining it with the feed to step (i). It is not necessary that the entire effluent from step (iii) be recycled to step (i). However in a preferred mode of operation, substantially the entire C2 and/or C3 and/or C4 olefin content of the effluent from step (i) is subjected to oligomerization in step (iii) and substantially the entire effluent from step (iii) is recycled to step (i), thus achieving ultimately high conversion of the less desired lower olefin fraction to desired lower olefins.
  • the feedstock was treated in a downflow reactor 2 by passing it downwards co-currently with a flow of catalyst particles.
  • the catalyst comprised ZSM-5 in an alumina matrix (weight ratio ZSM-5/alumina 1:3).
  • the reaction was carried out at atmospheric pressure. Further process conditions are given in Table 1.
  • the product from reactor 2 was separated by distillation in unit 3.
  • the C4+ olefin fraction was withdrawn on line 4 while products including C2 and C3 olefins were withdrawn on one or more lines 5.
  • the C4+ olefin stream was passed to oligomerization unit 6 comprising a bed of nickel/mordenite catalyst prepared by ion exchange of mordenite in the ammonium form at a temperature of 100 °C with an aqueous solution containing one mol nickel(II) acetate/litre.
  • the resulting catalyst had a molar ratio of nickel:aluminium of 1.5:1 after drying at a temperature of 120 °C.
  • the nickel mordenite catalyst was mixed with 20 %wt pseudo-boehmite as a binder, 1 %wt acetic acid as peptising agent and water such that the loss on ignition amounts to 45%. After kneading the mixture was extruded into 1.5 mm extrudates and the catalyst dried at 120 °C for two hours and successively calcined in air at 500 °C for two hours.
  • the oligomerized product was recycled on line 7 to the feedstock 1 to the reactor 2.
  • Table 2 below gives (A) the results obtained for the product stream 5 from unit 2 when recycling C4 olefins from unit 2 via unit 6 as described above to give a ratio of recycled product/fresh feed entering unit 2 of 0.23 and (B) comparative results obtained for the product stream from unit 2 without recycle via unit 6.

Claims (9)

  1. Un procédé pour la conversion d'une charge hydrocarbonée comprenant les étapes suivantes :
    (1) mise en contact de la charge avec un catalyseur solide de craquage à une température d'au moins 400°C pendant moins de 10 secondes,
    (2) séparation d'une fraction comprenant une ou plusieurs oléfines de C₂ à C₆ à partir de l'effluent de l'étape (1),
    (3) mise en contact d'au moins une portion de la fraction contenant des oléfines de C₂ à C₆ avec un catalyseur d'oligomérisation dans des conditions d'oligomérisation comprenant une température de 150 à 330°C, une pression de 1 à 100 bars et une vitesse spatiale de 0,1 à 10 kg de charge d'oléfines par kg de catalyseur et par heure, et
    (4) recyclage d'au moins une portion de l'effluent de l'étape (3) à l'étape (1).
  2. Un procédé selon la revendication 1, dans lequel le catalyseur solide de craquage utilisé dans l'étape (1) comprend au moins une zéolite ayant un diamètre de pores de 0,3 à 0,7 nm.
  3. Un procédé selon la revendication 2, dans lequel ladite au moins une zéolite est choisie parmi des silicates métalliques cristallins ayant une structure de ZSM-5, la ferriérite, l'érionite et leurs mélanges.
  4. Un procédé selon l'une quelconque des revendications précédentes, dans lequel la charge est mise en contact dans l'étape (1) avec un lit mobile de catalyseur solide de craquage.
  5. Un procédé selon l'une quelconque des revendications précédentes, dans lequel la charge est mise en contact avec le catalyseur solide de craquage dans l'étape (1) pendant 0,2 à 6 secondes.
  6. Un procédé selon l'une quelconque des revendications précédentes, dans lequel la température de mise en contact dans l'étape (1) est comprise entre 500 et 750°C.
  7. Un procédé selon l'une quelconque des revendications précédentes, dans lequel le rapport en poids catalyseur/charge dans l'étape (1) est compris entre 20 et 100:1.
  8. Un procédé selon l'une quelconque des revendications précédentes, dans lequel le catalyseur d'oligomérisation utilisé dans l'étape (3) est un catalyseur solide d'oligomérisation comprenant au moins un métal choisi parmi les métaux des groupes 1b, 2a, 2b, 3a, 4b, 5b, 6b et 8 et un silicate cristallin de métal trivalent.
  9. Un procédé selon la revendication 8, dans lequel le métal comprend du nickel et le silicate cristallin comprend de la mordénite.
EP19900200788 1989-04-11 1990-03-30 Procédé de conversion d'une charge hydrocarbonée Expired - Lifetime EP0392590B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB898908081A GB8908081D0 (en) 1989-04-11 1989-04-11 Process for the conversion of a hydrocarbonaceous feedstock
GB8908081 1989-04-11

Publications (2)

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EP0392590A1 EP0392590A1 (fr) 1990-10-17
EP0392590B1 true EP0392590B1 (fr) 1993-03-10

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EP19900200788 Expired - Lifetime EP0392590B1 (fr) 1989-04-11 1990-03-30 Procédé de conversion d'une charge hydrocarbonée

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EP (1) EP0392590B1 (fr)
JP (1) JPH02298585A (fr)
AU (1) AU618464B2 (fr)
CA (1) CA2014153A1 (fr)
DE (1) DE69001035T2 (fr)
ES (1) ES2054214T3 (fr)
GB (1) GB8908081D0 (fr)

Families Citing this family (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB9114390D0 (en) * 1991-07-03 1991-08-21 Shell Int Research Hydrocarbon conversion process and catalyst composition
JPH06220461A (ja) * 1993-01-22 1994-08-09 Mazda Motor Corp 廃プラスチック又はゴム材から炭化水素油を得る方法及びその実施に使用される装置
FR2968010B1 (fr) * 2010-11-25 2014-03-14 Ifp Energies Now Procede de conversion d'une charge lourde en distillat moyen
US9914884B2 (en) 2013-12-17 2018-03-13 Uop Llc Process and apparatus for recovering oligomerate
US9732285B2 (en) 2013-12-17 2017-08-15 Uop Llc Process for oligomerization of gasoline to make diesel
US9670425B2 (en) 2013-12-17 2017-06-06 Uop Llc Process for oligomerizing and cracking to make propylene and aromatics
US9387413B2 (en) 2013-12-17 2016-07-12 Uop Llc Process and apparatus for recovering oligomerate
CN112654690A (zh) * 2018-09-06 2021-04-13 沙特基础全球技术有限公司 使用多级径向流移动床反应器系统催化裂化石脑油的方法

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB513545A (en) * 1938-04-12 1939-10-16 Standard Oil Co Indiana Improvements relating to the conversion of mineral oils into gasoline
CN1021913C (zh) * 1988-06-16 1993-08-25 国际壳牌研究有限公司 使烃类原料转化的方法
GB8814292D0 (en) * 1988-06-16 1988-07-20 Shell Int Research Process for conversion of hydrocarbonaceous feedstock

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Publication number Publication date
DE69001035T2 (de) 1993-07-01
AU5306490A (en) 1990-10-18
JPH02298585A (ja) 1990-12-10
CA2014153A1 (fr) 1990-10-11
GB8908081D0 (en) 1989-05-24
DE69001035D1 (de) 1993-04-15
EP0392590A1 (fr) 1990-10-17
AU618464B2 (en) 1991-12-19
ES2054214T3 (es) 1994-08-01

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