EP2751235B1 - Préchauffage des charges d'alimentation pour hydrotraitement des produits de pyrolyse d'hydrocarbures - Google Patents

Préchauffage des charges d'alimentation pour hydrotraitement des produits de pyrolyse d'hydrocarbures Download PDF

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Publication number
EP2751235B1
EP2751235B1 EP12798899.6A EP12798899A EP2751235B1 EP 2751235 B1 EP2751235 B1 EP 2751235B1 EP 12798899 A EP12798899 A EP 12798899A EP 2751235 B1 EP2751235 B1 EP 2751235B1
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Prior art keywords
mixture
utility fluid
stream
tar
hydroprocessing
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German (de)
English (en)
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EP2751235A1 (fr
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James H. Beech
Teng Xu
Keith G. REED
David T. Ferrughelli
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ExxonMobil Chemical Patents Inc
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ExxonMobil Chemical Patents Inc
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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
    • C10G69/00—Treatment of hydrocarbon oils by at least one hydrotreatment process and at least one other conversion process
    • C10G69/02—Treatment of hydrocarbon oils by at least one hydrotreatment process and at least one other conversion process plural serial stages only
    • C10G69/06—Treatment of hydrocarbon oils by at least one hydrotreatment process and at least one other conversion process plural serial stages only including at least one step of thermal cracking in the absence of hydrogen
    • 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
    • C10G49/00—Treatment of hydrocarbon oils, in the presence of hydrogen or hydrogen-generating compounds, not provided for in a single one of groups C10G45/02, C10G45/32, C10G45/44, C10G45/58 or C10G47/00
    • C10G49/18—Treatment of hydrocarbon oils, in the presence of hydrogen or hydrogen-generating compounds, not provided for in a single one of groups C10G45/02, C10G45/32, C10G45/44, C10G45/58 or C10G47/00 in the presence of hydrogen-generating compounds, e.g. ammonia, water, hydrogen sulfide
    • 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
    • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
    • C10G2300/70—Catalyst aspects
    • C10G2300/708—Coking aspect, coke content and composition of deposits

Definitions

  • the invention relates to upgraded pyrolysis products, processes for upgrading products obtained from hydrocarbon pyrolysis, equipment useful for such processes.
  • Pyrolysis processes such as steam cracking can be utilized for converting saturated hydrocarbon to higher-value products such as light olefin, e.g., ethylene and propylene. Besides these useful products, hydrocarbon pyrolysis can also produce a significant amount of relatively low-value products such as steam-cracker tar ("SCT").
  • SCT steam-cracker tar
  • SCT upgrading processes involving conventional catalytic hydroprocessing suffer from significant catalyst deactivation.
  • the process can be operated at a temperature in the range of from 250°C to 380°C, at a pressure in the range of 5400 kPa to 20,500 kPa, using catalysts containing one or more of Co, Ni, or Mo; but significant catalyst coking is observed.
  • catalyst coking can be lessened by operating the process at an elevated hydrogen partial pressure, diminished space velocity, and a temperature in the range of 200°C to 350°C; SCT hydroprocessing under these conditions is undesirable because increasing hydrogen partial pressure worsens process economics, as a result of increased hydrogen and equipment costs, and because the elevated hydrogen partial pressure, diminished space velocity, and reduced temperature range favor undesired hydrogenation reactions.
  • US 5,158,668 discloses a method involving the hydrogenation of pyrolysis tar.
  • the invention relates to a process according to claim 1. Outside of the invention is an embodiment comprising:
  • Figure 1 schematically illustrates a process configuration for a hydroprocessing reactor section that uses a utility fluid to assist hydroprocessing of SCT. Areas of high coking potential are noted.
  • Figures 2-4 schematically illustrate example of process configurations that are within the scope of the invention.
  • Figure 2 illustrates a hydroprocessing reactor section using a lower temperature first reactor stage to minimize reactor preheat train coke fouling risk.
  • Figure 3 illustrates hydroprocessor reactor section with tar feed bypassing the reactor feed/effluent heat exchanger and feed trim heater to minimize coking fouling risk.
  • Figure 4 illustrates a hydroprocessor reactor section with reactor top catalyst bed heating to minimize coke fouling risk.
  • Figure 5 shows two graphs of pressure drop across a reactor versus time at two different temperature levels.
  • SCT is generally obtained as a product of hydrocarbon pyrolysis.
  • the pyrolysis process can include, e.g., thermal pyrolysis, such as thermal pyrolysis processes utilizing water.
  • thermal pyrolysis such as thermal pyrolysis processes utilizing water.
  • steam cracking is described in more detail below.
  • the invention is based in part on the discovery that catalyst coking can be lessened by hydroprocessing the SCT in the presence of a utility fluid, the utility fluid comprising a significant amount of aromatics, e.g., single or multi ring aromatics. It is desired to heat the mixture of the SCT and utility fluid to the desired hydroprocessing temperature while avoiding coking of the preheating equipment while doing so.
  • SCT means (a) a mixture of hydrocarbons having one or more aromatic core and optionally (b) non-aromatic and/or non-hydrocarbon molecules, the mixture being derived from hydrocarbon pyrolysis and having a boiling range ⁇ about 550°F (290°C), e.g., ⁇ 90.0 wt% of the SCT molecules have an atmospheric boiling point ⁇ 550°F (290°C).
  • SCT can comprise, e.g., ⁇ 50.0 wt. %, e.g., ⁇ 75.0 wt. %, such as ⁇ 90.0 wt. %, based on the weight of the SCT, of hydrocarbon molecules (including mixtures and aggregates thereof) having (i) one or more aromatic cores and (ii) a molecular weight ⁇ about C 15 .
  • Hydroprocessing SCT improves the tar's applicability as a fuel oil by improving its compatibility with other fuel oils by lowering its viscosity, lowering its boiling point distribution, increasing its hydrogen content, and converting asphaltenes and asphaltene precursors thereby improving the thermal stability of the tar.
  • the resulting fuel oil product can be, e.g., a fungible product for global commerce of significantly higher value than untreated tar.
  • FIG. 1 schematically illustrates a hydroprocessing reactor section for hydroprocessing SCT.
  • an SCT stream 10 is combined with a utility fluid 20 in feed drum 30, is pumped by pump 40 through conduit 50, and then mixed with a hydrogen-containing stream 60.
  • This mixture 61 is then pre-heated in heat exchanger 70 against the reactor effluent 120 followed by additional preheating to reactor inlet temperature in a process trim heater 90.
  • the preheated mixture 100 is then conducted to a hydroprocessing reactor 110 having three catalyst beds 115, 116, 117 of substantially equal volume.
  • the same catalyst is utilized in each bed.
  • the catalyst can be, e.g., conventional hydroprocessing catalyst, such as RT-621, available from Albermarle.
  • the hydroprocessor effluent stream is then conducted away from heat exchanger 70 via conduit 122 to one or more separation stages 130, for separating from the hydroprocessor effluent stream (i) a purge gas stream (comprising, e.g., excess or spent treat gas) which is conducted away via conduit 132, (ii) a hydroprocessed product (comprising, e.g., hydroprocessed SCT) which is conducted away via conduit 134, and (iii) a light gas stream (comprising, e.g., methane and hydrogen sulfide) which may be conducted away via conduit 133 for upgrading and/or use, e.g., as a fuel gas.
  • a purge gas stream comprising, e.g., excess or spent treat gas
  • a hydroprocessed product comprising, e.g., hydroprocessed SCT
  • a light gas stream comprising, e.g., methane and hydrogen sulfide
  • Additional separations can be conducted in the separation stage, e.g., for separating from the hydroprocessed product a light fuel oil and/or a heavy fuel oil.
  • Make-up treat gas e.g., molecular hydrogen
  • Hydrogen-rich treat gas is conducted away from stage 130 via line 60, for recycle to the hydroprocessor 110. At least a portion of any H 2 S and NH 3 being removed in stage 130, before the treat gas enters line 60.
  • the conversion process should be capable of operating continuously without significant fouling of the hydroprocessing equipment, or excessive coking of the hydroprocessing catalyst for at least 1 day (8.6x10 4 seconds), preferably at least 1 week (6.0x10 5 seconds), more preferably at least 1 month (2.6x10 6 seconds), or most preferably at least 1 year (3.2 x10 7 seconds).
  • pressure drops across the hydroprocessing reactor or other equipment should not exceed about 3.0, 4.0 or 5.0 times the initial (SOR) pressure drop at design flow rates.
  • the desirable maximum fluid bulk temperature of the tar is set significantly below the 425°C temperature where excessive fouling is observed, e.g., in the range of 200.0°C to 400.0°C.
  • the tar stream bulk temperature is below 300°C.
  • the feed side of the reactor feed/effluent heat exchanger 70 and the reactor inlet feed trim heater 90 are at risk of fouling with coke if SCT, optionally in combination with utility fluid and/or molecular hydrogen, is preheated in this equipment at temperatures exceeding about 572°F (300°C).
  • SCT optionally in combination with utility fluid and/or molecular hydrogen
  • the tar stream 10 enters the hydroprocessor at between 200°F-572°F (90°C-300°C) and is then heated to a hydroprocessor reactor inlet temperature of 700°F-800°F (370°C-425°C).
  • Figure 1 shows the hydroprocessing configuration and the location of equipment having the potential for coking by the tar stream (or tar combined with utility fluid and/or molecular hydrogen) before it is hydrotreated.
  • the utility fluid comprises, e.g., a recycle hydroprocessed product of the conversion process, or a similar material.
  • the utility fluid is thermally-stable at typical reactor preheat temperatures of 700°F -800°F (370°C - 425°C) and unlike a fresh (untreated) tar stream, not prone to coking in the preheat equipment.
  • the location of equipment in Figure 1 highlighted with the dashed circle is at risk of coke fouling by the tar component in the feed when heated past about 572°F (300°C).
  • Certain embodiments of invention are based in part on the development of methods for preheating an untreated tar stream (such as SCT) to a hydroprocessing reactor's inlet temperature that lessen or even eliminate fouling of the preheat equipment (or mitigate the formation of catalyst coke) to allow continuous reactor operation.
  • Other embodiments of the invention are based on the development of tar hydroprocessing processes that utilize a high-activity catalyst. In these embodiments, the need to pre-heat the tar upstream of hydroprocessing is lessened or eliminated because the hydroprocessing catalyst is sufficiently active at lower temperatures.
  • TH Tar Heavies
  • the term "Tar Heavies” means a product of hydrocarbon pyrolysis
  • the TH has an atmospheric boiling point ⁇ 565°C and comprising ⁇ 5.0 wt. % of molecules having a plurality of aromatic cores based on the weight of the product.
  • the TH are typically solid at 25.0°C and generally include the fraction of SCT that is not soluble in a 5:1 (vol.:vol.) ratio of n-pentane: SCT at 25.0°C ("conventional pentane extraction").
  • the TH can include high-molecular weight molecules (e.g., MW ⁇ 600) such as asphaltenes and other high-molecular weight hydrocarbon.
  • high-molecular weight molecules e.g., MW ⁇ 600
  • asphaltenes and other high-molecular weight hydrocarbon.
  • relatively low molecular-weight alkanes and/or alkenes e.g., C 1 to C 3 alkanes and/or alkenes
  • C 5 and/or C 6 cycloparaffinic rings e.g., C 6 cycloparaffinic rings
  • thiophenic rings e.g., thiophenic rings.
  • ⁇ 60.0 wt. % of the TH's carbon atoms are included in one or more aromatic cores based on the weight of the TH's carbon atoms, e.g., in the range of 68.0 w
  • the TH form aggregates having a relatively planar morphology, as a result of Van der Waals attraction between the TH molecules.
  • the large size of the TH aggregates which can be in the range of, e.g., ten nanometers to several hundred nanometers ("nm") in their largest dimension, leads to low aggregate mobility and diffusivity under catalytic hydroprocessing conditions.
  • conventional TH conversion suffers from severe mass-transport limitations, which result in a high selectivity for TH conversion to coke.
  • the invention is also advantageous in that the SCT is not over-cracked, so that the amount of light hydrocarbons produced, e.g., C 4 or lighter, is less than 5 wt%, which further reduces the amount of hydrogen consumed in the hydroprocessing step.
  • SCT starting material differs from other relatively high-molecular weight hydrocarbon mixtures, such as crude oil residue ("resid") including both atmospheric and vacuum resids and other streams commonly encountered, e.g., in petroleum and petrochemical processing.
  • the SCT's aromatic carbon content as measured by 13 C NMR is substantially greater than that of resid.
  • the amount of aromatic carbon in SCT typically is greater than 70 wt% while the amount of aromatic carbon in resid is generally less than 40 wt%.
  • a significant fraction of SCT asphaltenes have an atmospheric boiling point that is less than 565°C, for example, only 32.5 wt% of asphaltenes in SCT 1 have an atmospheric boiling point that is greater than 565°C.
  • the total amount of metals is ⁇ 1000.0 ppmw (parts per million, weight) based on the weight of the SCT, e.g., ⁇ 100.0 ppmw, such as ⁇ 10.0 ppmw.
  • the total amount of nitrogen present in SCT is generally less than the amount of nitrogen present in a crude oil vacuum resid.
  • the SCT's kinematic viscosity (cSt) at 50°C is generally ⁇ 1000, or ⁇ 100 even though the relative amount of SCT having an atmospheric boiling point ⁇ 565°C is much less than is the case for resid.
  • SCT is generally obtained as a product of hydrocarbon pyrolysis.
  • the pyrolysis process can include, e.g., thermal pyrolysis, such as thermal pyrolysis processes utilizing water.
  • thermal pyrolysis such as thermal pyrolysis processes utilizing water.
  • steam cracking is described in more detail below.
  • Conventional steam cracking utilizes a pyrolysis furnace which has two main sections: a convection section and a radiant section.
  • the feedstock typically enters the convection section of the furnace where the first mixture's hydrocarbon component is heated and vaporized by indirect contact with hot flue gas from the radiant section and by direct contact with the first mixture's steam component.
  • the steam-vaporized hydrocarbon mixture is then introduced into the radiant section where the bulk of the cracking takes place.
  • a second mixture is conducted away from the pyrolysis furnace, the second mixture comprising products resulting from the pyrolysis of the first mixture and any unreacted components of the first mixture.
  • At least one separation stage is generally located downstream of the pyrolysis furnace, the separation stage being utilized for separating from the second mixture one or more of light olefin, SCN, SCGO, SCT, water, unreacted hydrocarbon components of the first mixture, etc.
  • the separation stage can comprise, e.g., a primary fractionator.
  • a cooling stage typically either direct quench or indirect heat exchange is located between the pyrolysis furnace and the separation stage.
  • SCT is obtained as a product of pyrolysis conducted in one or more pyrolysis furnaces, e.g., one or more steam cracking furnaces.
  • pyrolysis furnaces e.g., one or more steam cracking furnaces.
  • vapor-phase products such as one or more of acetylene, ethylene, propylene, butenes
  • liquid-phase products comprising, e.g., one or more of C 5+ molecules and mixtures thereof.
  • the liquid-phase products are generally conducted together to a separation stage, e.g., a primary fractionator, for separations of one or more of (a) overheads comprising steam-cracked naphtha ("SCN", e.g., C 5 - C 10 species) and steam cracked gas oil (“SCGO"), the SCGO comprising ⁇ 90.0 wt. % based on the weight of the SCGO of molecules (e.g., C 10 - C 17 species) having an atmospheric boiling point in the range of about 400°F to 550°F (200°C to 290°C), and (b) bottoms comprising ⁇ 90.0 wt. % SCT, based on the weight of the bottoms, the SCT having a boiling range ⁇ about 550°F (290°C) and comprising molecules and mixtures thereof having a molecular weight ⁇ about C 15 .
  • SCN steam-cracked naphtha
  • SCGO steam cracked gas oil
  • the feed to the pyrolysis furnace is a first mixture, the first mixture comprising ⁇ 10.0 wt. % hydrocarbon based on the weight of the first mixture, e.g., ⁇ 25.0 wt. %, ⁇ 50.0 wt. %, such as ⁇ 65.0 wt. %.
  • the hydrocarbon can comprise, e.g., one or more of light hydrocarbons such as methane, ethane, propane, butane etc., it can be particularly advantageous to utilize the invention in connection with a first mixture comprising a significant amount of higher molecular weight hydrocarbons because the pyrolysis of these molecules generally results in more SCT than does the pyrolysis of lower molecular weight hydrocarbons.
  • the total of the first mixtures fed to a multiplicity of pyrolysis furnaces can comprise ⁇ 1.0 wt. % or ⁇ 25.0 wt. % based on the weight of the first mixture of hydrocarbons that are in the liquid phase at ambient temperature and atmospheric pressure.
  • the first mixture can further comprise diluent, e.g., one or more of nitrogen, water, etc., e.g., ⁇ 1.0 wt. % diluent based on the weight of the first mixture, such as ⁇ 25.0 wt. %.
  • diluent e.g., one or more of nitrogen, water, etc.
  • the first mixture can be produced by combining the hydrocarbon with a diluent comprising steam, e.g., at a ratio of 0.1 to 1.0 kg steam per kg hydrocarbon, or a ratio of 0.2 to 0.6 kg steam per kg hydrocarbon.
  • the first mixture's hydrocarbon comprises ⁇ 10.0 wt. %, e.g., ⁇ 50.0 wt. %, such as ⁇ 90.0 wt. % (based on the weight of the hydrocarbon component) of one or more of naphtha, gas oil, vacuum gas oil, waxy residues, atmospheric residues, residue admixtures, or crude oil; including those comprising ⁇ about 0.1 wt. % asphaltenes.
  • Suitable crude oils include, e.g., high-sulfur virgin crude oils, such as those rich in polycyclic aromatics.
  • the first mixture's hydrocarbon comprises sulfur, e.g., ⁇ 0.1 wt.
  • the first mixture's hydrocarbon is a crude oil or crude oil fraction comprising ⁇ 0.1 wt.
  • the SCT contains a significant amount of sulfur derived from the first mixture's aromatic sulfur.
  • the SCT sulfur content can be about 3 to 4 times higher in the SCT than in the first mixture's hydrocarbon component, on a weight basis.
  • the first mixture's hydrocarbon comprises one or more crude oils and/or one or more crude oil fractions, such as those obtained from an atmospheric pipestill (“APS") and/or vacuum pipestill (“VPS").
  • the crude oil and/or fraction thereof is optionally desalted prior to being included in the first mixture.
  • An example of a crude oil fraction utilized in the first mixture is produced by combining separating APS bottoms from a crude oil and followed by VPS treatment of the APS bottoms.
  • the pyrolysis furnace has at least one vapor/liquid separation device (sometimes referred to as flash pot or flash drum) integrated therewith, for upgrading the first mixture.
  • vapor/liquid separator devices are particularly suitable when the first mixture's hydrocarbon component comprises ⁇ about 0.1 wt. % asphaltenes based on the weight of the first mixture's hydrocarbon component, e.g., ⁇ about 5.0 wt. %.
  • Conventional vapor/liquid separation devices can be utilized to do this, though the invention is not limited thereto. Examples of such conventional vapor/liquid separation devices include those disclosed in U.S. Patent Nos.
  • the composition of the vapor phase leaving the device is substantially the same as the composition of the vapor phase entering the device, and likewise the composition of the liquid phase leaving the flash drum is substantially the same as the composition of the liquid phase entering the device, i.e., the separation in the vapor/liquid separation device consists essentially of a physical separation of the two phases entering the drum.
  • At least a portion of the first mixture's hydrocarbon component is provided to the inlet of a convection section of a pyrolysis unit, wherein hydrocarbon is heated so that at least a portion of the hydrocarbon is in the vapor phase.
  • a diluent e.g., steam
  • the first mixture's diluent component is optionally (but preferably) added in this section and mixed with the hydrocarbon component to produce the first mixture.
  • the first mixture is then flashed in at least one vapor/liquid separation device in order to separate and conduct away from the first mixture at least a portion of the first mixture's high molecular-weight molecules, such as asphaltenes.
  • a bottoms fraction can be conducted away from the vapor-liquid separation device, the bottoms fraction comprising, e.g., ⁇ 10.0 % (on a wt. basis) of the first mixture's asphaltenes.
  • the steam cracking furnace can be integrated with a vapor/liquid separation device operating at a temperature in the range of from about 600°F (315°C) to about 950°F (510°C) and a pressure in the range of about 275 kPa to about 1400 kPa, e.g., a temperature in the range of from about 430°C to about 480°C and a pressure in the range of about 700 kPa to 760 kPa.
  • the overheads from the vapor/liquid separation device can be subjected to further heating in the convection section, and are then introduced via crossover piping into the radiant section where the overheads are exposed to a temperature ⁇ 760°C at a pressure ⁇ 0.5 bar (g) e.g., a temperature in the range of about 790°C to about 850°C and a pressure in the range of about 0.6 bar (g) to about 2.0 bar (g), to carry out the pyrolysis (e.g., cracking and/or reforming) of the first mixture's hydrocarbon component.
  • a pressure ⁇ 0.5 bar e.g., a temperature in the range of about 790°C to about 850°C and a pressure in the range of about 0.6 bar (g) to about 2.0 bar (g
  • pyrolysis e.g., cracking and/or reforming
  • the first mixture's hydrocarbon component can comprise ⁇ 50.0 wt. %, e.g., ⁇ 75.0 wt. %, such as ⁇ 90.0 wt. % (based on the weight of the first mixture's hydrocarbon component) of one or more crude oils, even high naphthenic acid-containing crude oils and fractions thereof.
  • Feeds having a high naphthenic acid content are among those that produce a high quantity of tar and are especially suitable when at least one vapor/liquid separation device is integrated with the pyrolysis furnace.
  • the first mixture's composition can vary over time, e.g., by utilizing a first mixture having a first hydrocarbon component during a first time period and then utilizing a first mixture having a second hydrocarbon component during a second time period, the first and second hydrocarbons being substantially different hydrocarbons or substantially different hydrocarbon mixtures.
  • the first and second periods can be of substantially equal duration, but this is not required. Alternating first and second periods can be conducted in sequence continuously or semi-continuously (e.g., in "blocked" operation) if desired.
  • This embodiment can be utilized for the sequential pyrolysis of incompatible first and second hydrocarbon components (i.e., where the first and second hydrocarbon components are mixtures that are not sufficiently compatible to be blended under ambient conditions).
  • first hydrocarbon component comprising a virgin crude oil can be utilized to produce the first mixture during a first time period and steam cracked tar utilized to produce the first mixture during a second time period.
  • the vapor/liquid separation device is not used.
  • the pyrolysis conditions can be conventional steam cracking conditions. Suitable steam cracking conditions include, e.g., exposing the first mixture to a temperature (measured at the radiant outlet) ⁇ 400°C, e.g., in the range of 400°C to 900°C, and a pressure ⁇ 0.1 bar, for a cracking residence time period in the range of from about 0.01 second to 5.0 second.
  • the first mixture comprises hydrocarbon and diluent, wherein the first mixture's hydrocarbon comprises ⁇ 50.0 wt.
  • the diluent comprises, e.g., ⁇ 95.0 wt. % water based on the weight of the diluent.
  • the first mixture comprises 10.0 wt. % to 90.0 wt.
  • the pyrolysis conditions generally include one or more of (i) a temperature in the range of 760°C to 880°C; (ii) a pressure in the range of from 1.0 to 5.0 bar (absolute), or (iii) a cracking residence time in the range of from 0.10 to 2.0 seconds.
  • a second mixture is conducted away from the pyrolysis furnace, the second mixture being derived from the first mixture by the pyrolysis.
  • the second mixture generally comprises ⁇ 1.0 wt. % of C 2 unsaturates and ⁇ 0.1 wt. % of TH, the weight percents being based on the weight of the second mixture.
  • the second mixture comprises ⁇ 5.0 wt. % of C 2 unsaturates and/or ⁇ 0.5 wt. % of TH, such as ⁇ 1.0 wt. % TH.
  • the second mixture generally contains a mixture of the desired light olefins, SCN, SCGO, SCT, and unreacted components of the first mixture (e.g., water in the case of steam cracking, but also in some cases unreacted hydrocarbon), the relative amount of each of these generally depends on, e.g., the first mixture's composition, pyrolysis furnace configuration, process conditions during the pyrolysis, etc.
  • the second mixture is generally conducted away for the pyrolysis section, e.g., for cooling and separation stages.
  • the second mixture's TH comprise ⁇ 10.0 wt. % of TH aggregates having an average size in the range of 10.0 nm to 300.0 nm in at least one dimension and an average number of carbon atoms ⁇ 50, the weight percent being based on the weight of Tar Heavies in the second mixture.
  • the aggregates comprise ⁇ 50.0 wt. %, e.g., ⁇ 80.0 wt. %, such as ⁇ 90.0 wt. % of TH molecules having a C:H atomic ratio in the range of from 1.0 to 1.8, a molecular weight in the range of 250 to 5000, and a melting point in the range of 100°C to 700°C.
  • the invention is compatible with cooling the second mixture downstream of the pyrolysis furnace, e.g., the second mixture can be cooled using a system comprising transfer line heat exchangers.
  • the transfer line heat exchangers can cool the process stream to a temperature in the range of about 700°C to 350°C, in order to efficiently generate super-high pressure steam which can be utilized by the process or conducted away.
  • the second mixture can be subjected to direct quench at a point typically between the furnace outlet and the separation stage. The quench can be accomplished by contacting the second mixture with a liquid quench stream, in lieu of, or in addition to the treatment with transfer line exchangers.
  • the quench liquid is preferably introduced at a point downstream of the transfer line exchanger(s).
  • Suitable quench liquids include liquid quench oil, such as those obtained by a downstream quench oil knock-out drum, pyrolysis fuel oil and water, which can be obtained from conventional sources, e.g., condensed dilution steam.
  • a separation stage is generally utilized downstream of the pyrolysis furnace and downstream of the transfer line exchanger and/or quench point for separating from the second mixture one or more of light olefin, SCN, SCGO, SCT, or water.
  • Conventional separation equipment can be utilized in the separation stage, e.g., one or more flash drums, fractionators, water-quench towers, indirect condensers, etc., such as those described in U.S. Patent No. 8,083,931 .
  • a third mixture which is a tar stream can be separated from the second mixture, with the third mixture tar stream comprising ⁇ 10.0 wt. % of the second mixture's TH based on the weight of the second mixture's TH.
  • the tar stream generally comprises SCT, which is obtained, e.g., from an SCGO stream and/or a bottoms stream of the steam cracker's primary fractionator, from flash-drum bottoms (e.g., the bottoms of one or more flash drums located downstream of the pyrolysis furnace and upstream of the primary fractionator), or a combination thereof.
  • SCT is obtained, e.g., from an SCGO stream and/or a bottoms stream of the steam cracker's primary fractionator, from flash-drum bottoms (e.g., the bottoms of one or more flash drums located downstream of the pyrolysis furnace and upstream of the primary fractionator), or a combination thereof.
  • the tar stream comprises ⁇ 50.0 wt. % of the second mixture's TH based on the weight of the second mixture's TH.
  • the tar stream can comprise ⁇ 90.0 wt. % of the second mixture's TH based on the weight of the second mixture's TH.
  • the tar stream can have, e.g., (i) a sulfur content in the range of 0.5 wt. to 7.0 wt. %, (ii) a TH content in the range of from 5.0 wt. % to 40.0 wt.
  • % the weight percents being based on the weight of the tar stream, (iii) a density at 15°C in the range of 1.01 g/cm 3 to 1.15 g/cm 3 , e.g., in the range of 1.07 g/cm 3 to 1.15 g/cm 3 , and (iv) a 50°C viscosity in the range of 200 cSt to 1.0 x 10 7 cSt.
  • the tar stream can comprise TH aggregates.
  • the tar stream comprises ⁇ 50.0 wt. % of the second mixture's TH aggregates based on the weight of the second mixture's TH aggregates.
  • the tar stream can comprise ⁇ 90.0 wt. % of the second mixture's TH aggregates based on the weight of the second mixture's TH aggregates.
  • the tar stream is generally conducted away from the separation stage for hydroprocessing of the tar stream in the presence of a utility fluid.
  • a utility fluid Examples of utility fluids useful in the invention will now be described in more detail.
  • the utility fluid is utilized in hydroprocessing the tar stream, e.g., for effectively increasing run-length during hydroprocessing and improving the properties of the hydroprocessed product.
  • Effective utility fluids comprise aromatics, i.e., comprise molecules having at least one aromatic core.
  • the utility fluid comprises ⁇ 40.0 wt. % aromatic carbon such as ⁇ 60.0 wt. % aromatic carbon as measured by NMR.
  • the utility fluid comprises a portion of the liquid phase of the hydroprocessed product, effectively being recycled back to the hydroprocessor. The remainder of the liquid phase of the hydroprocessed product may be conducted away from the process and optionally used as a low sulfur fuel oil blend component.
  • the hydroprocessed product may optionally pass through one or more separation stages.
  • the separation stages may include: flash drums, distillation columns, evaporators, strippers, steam strippers, vacuum flashes, or vacuum distillation columns. These separation stages allow one skilled in the art to adjust the properties of the liquid phase to be used as the utility fluid.
  • the liquid phase of the hydroprocessed product may comprise ⁇ 90.0 wt. % of the hydroprocessed product's molecules having at least four carbon atoms based on the weight of the hydroprocessed product. In other embodiments, the liquid phase comprises ⁇ 90.0 wt. % of the hydroprocessed product's molecules based on the weight of the hydroprocessed product having an atmospheric boiling point ⁇ 65.0°C, ⁇ 150.0°C, ⁇ 260.0°C.
  • the total liquid phase of the hydroprocessed product is separated into a light liquid and a heavy liquid where the heavy liquid comprises 90 wt. % of the molecules with an atmospheric boiling point of ⁇ 300°C that were present in the liquid phase.
  • the utility fluid comprises a portion of the light liquid obtained from this separation.
  • the utility fluid that comprises hydroprocessed product can be augmented or replaced by supplemental utility fluids such as described below.
  • the utility fluid comprises aromatics (i.e., comprises molecules having at least one aromatic core) and has an ASTM D86 10% distillation point ⁇ 60°C and a 90% distillation point ⁇ 350°C.
  • the utility fluid (which can be a solvent or mixture of solvents) has an ASTM D86 10% distillation point ⁇ 120°C, e.g., ⁇ 140°C, such as ⁇ 150°C and/or an ASTM D86 90% distillation point ⁇ 300°C.
  • the utility fluid has a critical temperature in the range of 285°C to 400°C and (ii) comprises ⁇ 80.0 wt. % of 1-ring aromatics and/or 2-ring aromatics, including alkyl-functionalized derivatives thereof, based on the weight of the utility fluid.
  • the utility fluid can comprise, e.g., ⁇ 90.0 wt. % of a single-ring aromatic, including those having one or more hydrocarbon substituents, such as from 1 to 3 or 1 to 2 hydrocarbon substituents.
  • Such substituents can be any hydrocarbon group that is consistent with the overall utility fluid distillation characteristics.
  • hydrocarbon groups include, but are not limited to, those selected from the group consisting of C 1 -C 6 alkyl, wherein the hydrocarbon groups can be branched or linear and the hydrocarbon groups can be the same or different.
  • the utility fluid comprises ⁇ 90.0 wt. % based on the weight of the utility fluid of one or more of benzene, ethylbenzene, trimethylbenzene, xylenes, toluene, naphthalenes, alkylnaphthalenes (e.g., methylnaphtalenes), tetralins, or alkyltetralins (e.g., methyltetralins).
  • the utility fluid comprises ⁇ 10.0 wt. % of ring compounds with C 1 -C 6 sidechains having alkenyl functionality, based on the weight of the utility fluid.
  • the utility fluid comprises SCN and/or SCGO, e.g., SCN and/or SCGO separated from the second mixture in a primary fractionator downstream of a pyrolysis furnace operating under steam cracking conditions.
  • the SCN or SCGO may be hydrotreated in different conventional hydrotreaters (e.g. not hydrotreated with the tar).
  • the utility fluid can comprise, e.g., ⁇ 50.0 wt. % of the separated gas oil, based on the weight of the utility fluid.
  • at least a portion of the utility fluid is obtained from the hydroprocessed product, e.g., by separating and re-cycling a portion of the hydroprocessed product having an atmospheric boiling point ⁇ 300°C.
  • the utility fluid contains sufficient amount of molecules having one or more aromatic cores to effectively increase run length during hydroprocessing of the tar stream.
  • the utility fluid can comprise ⁇ 50.0 wt. % of molecules having at least one aromatic core, e.g., ⁇ 60.0 wt. %, such as ⁇ 70 wt. %, based on the total weight of the utility fluid.
  • the utility fluid comprises (i) ⁇ 60.0 wt. % of molecules having at least one aromatic core and (ii) ⁇ 1.0 wt. % of C 1 -C 6 sidechains having alkenyl functionality, the weight percents being based on the weight of the utility fluid.
  • the utility fluid is utilized in hydroprocessing the tar stream, e.g., for effectively increasing run-length during hydroprocessing.
  • the relative amounts of utility fluid and tar stream during hydroprocessing are generally in the range of from about 20.0 wt. % to about 95.0 wt. % of the tar stream and from about 5.0 wt. % to about 80.0 wt. % of the utility fluid, based on total weight of utility fluid plus tar stream.
  • the relative amounts of utility fluid and tar stream during hydroprocessing can be in the range of (i) about 20.0 wt. % to about 90.0 wt. % of the tar stream and about 10.0 wt. % to about 80.0 wt.
  • the utility fluid : tar weight ratio in the hydroprocessor feed is in the range of 0.05 : 1.0 to 3.0 : 1.0.
  • At least a portion of the utility fluid can be combined with at least a portion of the tar stream within the hydroprocessing vessel or hydroprocessing zone, but this is not required, and in one or more embodiments at least a portion of the utility fluid and at least a portion of the tar stream are supplied as separate streams and combined into one feed stream prior to entering (e.g., upstream of) the hydroprocessing vessel or hydroprocessing zone).
  • the feed stream to the hydroprocessor comprises 40.0 wt. % to 90.0 wt. % of SCT and 10.0 wt. % to 60.0 wt. % of utility fluid, the weight percents being based on the weight of the feed stream.
  • Hydroprocessing of the tar stream in the presence of the utility fluid can occur in one or more hydroprocessing stages, the stages comprising one or more hydroprocessing vessels or zones.
  • Vessels and/or zones within the hydroprocessing stage in which catalytic hydroprocessing activity occurs generally include at least one hydroprocessing catalyst.
  • the catalysts can be mixed or stacked, such as when the catalyst is in the form of one or more fixed beds in a vessel or hydroprocessing zone.
  • hydroprocessing catalyst can be utilized for hydroprocessing the tar stream in the presence of the utility fluid, such as those specified for use in resid and/or heavy oil hydroprocessing, but the invention is not limited thereto.
  • Suitable hydroprocessing catalysts include those comprising (i) one or more bulk metals and/or (ii) one or more metals on a support. The metals can be in elemental form or in the form of a compound.
  • the hydroprocessing catalyst includes at least one metal from any of Groups 5 to 10 of the Periodic Table of the Elements (tabulated as the Periodic Chart of the Elements, The Merck Index, Merck & Co., Inc., 1996).
  • catalytic metals include, but are not limited to, vanadium, chromium, molybdenum, tungsten, manganese, technetium, rhenium, iron, cobalt, nickel, ruthenium, palladium, rhodium, osmium, iridium, platinum, or mixtures thereof.
  • the catalyst has a total amount of Groups 5 to 10 metals per gram of catalyst of at least 0.0001 grams, or at least 0.001 grams or at least 0.01 grams, in which grams are calculated on an elemental basis.
  • the catalyst can comprise a total amount of Group 5 to 10 metals in a range of from 0.0001 grams to 0.6 grams, or from 0.001 grams to 0.3 grams, or from 0.005 grams to 0.1 grams, or from 0.01 grams to 0.08 grams.
  • the catalyst further comprises at least one Group 15 element.
  • An example of a preferred Group 15 element is phosphorus.
  • the catalyst can include a total amount of elements of Group 15 in a range of from 0.000001 grams to 0.1 grams, or from 0.00001 grams to 0.06 grams, or from 0.00005 grams to 0.03 grams, or from 0.0001 grams to 0.001 grams, in which grams are calculated on an elemental basis.
  • the catalyst comprises at least one Group 6 metal.
  • Group 6 metals include chromium, molybdenum and tungsten.
  • the catalyst may contain, per gram of catalyst, a total amount of Group 6 metals of at least 0.00001 grams, or at least 0.01 grams, or at least 0.02 grams, in which grams are calculated on an elemental basis.
  • the catalyst can contain a total amount of Group 6 metals per gram of catalyst in the range of from 0.0001 grams to 0.6 grams, or from 0.001 grams to 0.3 grams, or from 0.005 grams to 0.1 grams, or from 0.01 grams to 0.08 grams, the number of grams being calculated on an elemental basis.
  • the catalyst includes at least one Group 6 metal and further includes at least one metal from Group 5, Group 7, Group 8, Group 9, or Group 10.
  • Such catalysts can contain, e.g., the combination of metals at a molar ratio of Group 6 metal to Group 5 metal in a range of from 0.1 to 20, 1 to 10, or 2 to 5, in which the ratio is on an elemental basis.
  • the catalyst will contain the combination of metals at a molar ratio of Group 6 metal to a total amount of Groups 7 to 10 metals in a range of from 0.1 to 20, 1 to 10, or 2 to 5, in which the ratio is on an elemental basis.
  • the catalyst includes at least one Group 6 metal and one or more metals from Groups 9 or 10, e.g., molybdenum-cobalt and/or tungsten-nickel, these metals can be present, e.g., at a molar ratio of Group 6 metal to Groups 9 and 10 metals in a range of from 1 to 10, or from 2 to 5, in which the ratio is on an elemental basis.
  • these metals can be present, e.g., at a molar ratio of Group 5 metal to Group 10 metal in a range of from 1 to 10, or from 2 to 5, where the ratio is on an elemental basis.
  • Catalysts which further comprise inorganic oxides, e.g., as a binder and/or support, are within the scope of the invention.
  • the catalyst can comprise (i) ⁇ 1.0 wt. % of one or more metals selected from Groups 6, 8, 9, and 10 of the Periodic Table and (ii) ⁇ 1.0 wt. % of an inorganic oxide, the weight percents being based on the weight of the catalyst.
  • the invention encompasses incorporating into (or depositing on) a support one or catalytic metals e.g., one or more metals of Groups 5 to 10 and/or Group 15, to form the hydroprocessing catalyst.
  • the support can be a porous material.
  • the support can comprise one or more refractory oxides, porous carbon-based materials, zeolites, or combinations thereof suitable refractory oxides include, e.g., alumina, silica, silica-alumina, titanium oxide, zirconium oxide, magnesium oxide, and mixtures thereof.
  • suitable porous carbon-based materials include, activated carbon and/or porous graphite.
  • zeolites include, e.g., Y-zeolites, beta zeolites, mordenite zeolites, ZSM-5 zeolites, and ferrierite zeolites.
  • Additional examples of support materials include gamma alumina, theta alumina, delta alumina, alpha alumina, or combinations thereof.
  • the amount of gamma alumina, delta alumina, alpha alumina, or combinations thereof, per gram of catalyst support can be in a range of from 0.0001 grams to 0.99 grams, or from 0.001 grams to 0.5 grams, or from 0.01 grams to 0.1 grams, or at most 0.1 grams, as determined by x-ray diffraction.
  • the hydroprocessing catalyst is a supported catalyst, the support comprising at least one alumina, e.g., theta alumina, in an amount in the range of from 0.1 grams to 0.99 grams, or from 0.5 grams to 0.9 grams, or from 0.6 grams to 0.8 grams, the amounts being per gram of the support.
  • the amount of alumina can be determined using, e.g., x-ray diffraction.
  • the support can comprise at least 0.1 grams, or at least 0.3 grams, or at least 0.5 grams, or at least 0.8 grams of theta alumina.
  • the support When a support is utilized, the support can be impregnated with the desired metals to form the hydroprocessing catalyst.
  • the support can be heat-treated at temperatures in a range of from 400°C to 1200°C, or from 450°C to 1000°C, or from 600°C to 900°C, prior to impregnation with the metals.
  • the hydroprocessing catalyst can be formed by adding or incorporating the Groups 5 to 10 metals to shaped heat-treated mixtures of support. This type of formation is generally referred to as overlaying the metals on top of the support material.
  • the catalyst is heat treated after combining the support with one or more of the catalytic metals, e.g., at a temperature in the range of from 150°C to 750°C, or from 200°C to 740°C, or from 400°C to 730°C.
  • the catalyst is heat treated in the presence of hot air and/or oxygen-rich air at a temperature in a range between 400°C and 1000°C to remove volatile matter such that at least a portion of the Groups 5 to 10 metals are converted to their corresponding metal oxide.
  • the catalyst can be heat treated in the presence of oxygen (e.g., air) at temperatures in a range of from 35°C to 500°C, or from 100°C to 400°C, or from 150°C to 300°C. Heat treatment can take place for a period of time in a range of from 1 to 3 hours to remove a majority of volatile components without converting the Groups 5 to 10 metals to their metal oxide form.
  • Catalysts prepared by such a method are generally referred to as "uncalcined" catalysts or "dried.”
  • Such catalysts can be prepared in combination with a sulfiding method, with the Groups 5 to 10 metals being substantially dispersed in the support.
  • the catalyst comprises a theta alumina support and one or more Groups 5 to 10 metals
  • the catalyst is generally heat treated at a temperature ⁇ 400°C to form the hydroprocessing catalyst.
  • heat treating is conducted at temperatures ⁇ 1200°C.
  • the catalyst can be in shaped forms, e.g., one or more of discs, pellets, extrudates, etc., though this is not required.
  • shaped forms include those having a cylindrical symmetry with a diameter in the range of from about 0.79 mm to about 3.2 mm (1/32 nd to 1/8 th inch), from about 1.3 mm to about 2.5 mm (1/20 th to 1/10 th inch), or from about 1.3 mm to about 1.6 mm (1/20 th to 1/16 th inch).
  • non-cylindrical shapes are within the scope of the invention, e.g., trilobe, quadralobe, etc.
  • the catalyst has a flat plate crush strength in a range of from 50-500 N/cm, or 60-400 N/cm, or 100-350 N/cm, or 200-300 N/cm, or 220-280 N/cm.
  • Porous catalysts including those having conventional pore characteristics, are within the scope of the invention.
  • the catalyst can have a pore structure, pore size, pore volume, pore shape, pore surface area, etc., in ranges that are characteristic of conventional hydroprocessing catalysts, though the invention is not limited thereto.
  • the catalyst can have a median pore size that is effective for hydroprocessing SCT molecules, such catalysts having a median pore size in the range of from 30 ⁇ to 1000 ⁇ , or 50 ⁇ to 500 ⁇ , or 60 ⁇ to 300 ⁇ .
  • Pore size can be determined according to ASTM Method D4284-07 Mercury Porosimetry.
  • the hydroprocessing catalyst has a median pore diameter in a range of from 50 ⁇ to 200 ⁇ .
  • the hydroprocessing catalyst has a median pore diameter in a range of from 90 ⁇ to 180 ⁇ , or 100 ⁇ to 140 ⁇ , or 110 ⁇ to 130 ⁇ .
  • the hydroprocessing catalyst has a median pore diameter ranging from 50 ⁇ to 150 ⁇ .
  • the hydroprocessing catalyst has a median pore diameter in a range of from 60 ⁇ to 135 ⁇ , or from 70 ⁇ to 120 ⁇ .
  • hydroprocessing catalysts having a larger median pore diameter are utilized, e.g., those having a median pore diameter in a range of from 180 ⁇ to 500 ⁇ , or 200 ⁇ to 300 ⁇ , or 230 ⁇ to 250 ⁇ .
  • the hydroprocessing catalyst has a pore size distribution that is not so great as to significantly degrade catalyst activity or selectivity.
  • the hydroprocessing catalyst can have a pore size distribution in which at least 60% of the pores have a pore diameter within 45 ⁇ , 35 ⁇ , or 25 ⁇ of the median pore diameter.
  • the catalyst has a median pore diameter in a range of from 50 ⁇ to 180 ⁇ , or from 60 ⁇ to 150 ⁇ , with at least 60% of the pores having a pore diameter within 45 ⁇ , 35 ⁇ , or 25 ⁇ of the median pore diameter.
  • the catalyst can have, e.g., a pore volume ⁇ 0.3 cm 3 /g, such ⁇ 0.7 cm 3 /g, or ⁇ 0.9 cm 3 /g.
  • pore volume can range, e.g., from 0.3 cm 3 /g to 0.99 cm 3 /g, 0.4 cm 3 /g to 0.8 cm 3 /g, or 0.5 cm 3 /g to 0.7 cm 3 /g.
  • the hydroprocessing catalyst can have a surface area ⁇ 60 m 2 /g, or ⁇ 100 m 2 /g, or ⁇ 120 m 2 /g, or ⁇ 170 m 2 /g, or ⁇ 220 m 2 /g, or ⁇ 270 m 2 /g; such as in the range of from 100 m 2 /g to 300 m 2 /g, or 120 m 2 /g to 270 m 2 /g, or 130 m 2 /g to 250 m 2 /g, or 170 m 2 /g to 220 m 2 /g.
  • Hydroprocessing the specified amounts of tar stream and utility fluid using the specified hydroprocessing catalyst leads to improved catalyst life, e.g., allowing the hydroprocessing stage to operate for at least 3 months (7.8x10 6 seconds), or at least 6 months (1.6x10 7 seconds), or at least 1 year (3.2 x10 7 seconds) without replacement of the catalyst in the hydroprocessing or contacting zone.
  • Catalyst life is generally > 10 times longer than would be the case if no utility fluid were utilized, e.g., ⁇ 100 times longer, such as ⁇ 1000 times longer.
  • the hydroprocessing is carried out in the presence of hydrogen, e.g., by (i) combining molecular hydrogen with the tar stream and/or utility fluid upstream of the hydroprocessing and/or (ii) conducting molecular hydrogen to the hydroprocessing stage in one or more conduits or lines.
  • hydrogen e.g., by (i) combining molecular hydrogen with the tar stream and/or utility fluid upstream of the hydroprocessing and/or (ii) conducting molecular hydrogen to the hydroprocessing stage in one or more conduits or lines.
  • a "treat gas" which contains sufficient molecular hydrogen for the hydroprocessing and optionally other species (e.g., nitrogen and light hydrocarbons such as methane) which generally do not adversely interfere with or affect either the reactions or the products.
  • Unused treat gas can be separated from the hydroprocessed product for re-use, generally after removing undesirable impurities, such as H 2 S and NH 3 .
  • the treat gas optionally contains ⁇ about 50 vol. % of molecular hydrogen, e.g., ⁇ about 75 vol. %, based on the total volume of treat gas conducted to the hydroprocessing stage.
  • the amount of molecular hydrogen supplied to the hydroprocessing stage is in the range of from about 300 SCF/B (standard cubic feet per barrel) (53 S m 3 /m 3 ) to 5000 SCF/B (890 S m 3 /m 3 ), in which B refers to barrel of the tar stream.
  • the molecular hydrogen can be provided in a range of from 1000 SCF/B (178 S m 3 /m 3 ) to 3000 SCF/B (534 S m 3 /m 3 ).
  • Hydroprocessing the tar stream in the presence of the specified utility fluid, molecular hydrogen, and a catalytically effective amount of the specified hydroprocessing catalyst under catalytic hydroprocessing conditions produces a hydroprocessed product including, e.g., upgraded SCT.
  • a hydroprocessed product including, e.g., upgraded SCT.
  • the hydroprocessing is generally carried out under hydroconversion conditions, e.g., under conditions for carrying out one or more of hydrocracking (including selective hydrocracking), hydrogenation, hydrotreating, hydrodesulfurization, hydrodenitrogenation, hydrodemetallation, hydrodearomatization, hydroisomerization, or hydrodewaxing of the specified tar stream.
  • the hydroprocessing reaction can be carried out in at least one vessel or zone that is located, e.g., within a hydroprocessing stage downstream of the pyrolysis stage and separation stage.
  • the specified tar stream generally contacts the hydroprocessing catalyst in the vessel or zone, in the presence of the utility fluid and molecular hydrogen.
  • Catalytic hydroprocessing conditions can include, e.g., exposing the combined diluent-tar stream to a temperature in the range from 350°C to 430°C, or 360°C to 420°C. proximate to the molecular hydrogen and hydroprocessing catalyst.
  • Weight hourly space velocity (WHSV) of the combined utility fluid tar stream will generally range from 0.1 h -1 to 30 h -1 , or 0.1 h -1 to 25 h -1 , or 0.1 h -1 to 4.0 h -1 .
  • LHSV is at least 0.1 h -1 , 5 h -1 , or at least 10 h -1 , or at least 15 h -1 .
  • Molecular hydrogen partial pressure during the hydroprocessing is generally in the range of from 0.1 MPa to 8 MPa, or 1 MPa to 7 MPa, or 2 MPa to 6 MPa, or 3 MPa to 5 MPa.
  • the partial pressure of molecular hydrogen is ⁇ 7 MPa, or ⁇ 6 MPa, or ⁇ 5 MPa, or ⁇ 4 MPa, or ⁇ 3 MPa, or ⁇ 2.5 MPa, or ⁇ 2 MPa.
  • the hydroprocessing conditions can include, e.g., one or more of a temperature in the range of 300°C to 500°C, a pressure in the range of 15 bar (absolute) to 135 bar, a space volume of tar of about 53 standard cubic meters/cubic meter (S m 3 /m 3 ) to about 445 S m 3 /m 3 (300 SCF/B to 2500 SCF/B).
  • the hydroprocessing conditions include one or more of a temperature in the range of 380°C to 430°C, a pressure in the range of 21 bar (absolute) to 81 bar (absolute), a space velocity in the range of 0.2 to 1.0, and a hydrogen consumption rate of about 71 S m 3 /m 3 to about 267 S m 3 /m 3 (400 SCF/B to 1500 SCF/B).
  • TH hydroconversion is generally ⁇ 25.0% on a weight basis, e.g., ⁇ 50.0%.
  • FIG. 2 depicts an embodiment wherein a lower temperature first reactor stage is used to minimize reactor preheat train coke fouling risk.
  • This embodiment employs additional heat sources: pre-heaters 51 and 53.
  • Heat source 51 can be, e.g., a heat exchanger utilized to further pre-heat the hydroprocessor feed by abstracting heat from the hydroprocessor effluent conducted downstream of heat exchanger 70 via line 121.
  • Heat source 53 can be, e.g., a second set of tubes in trim heater 90.
  • This embodiment also employs a first lower temperature stage 110 hydroprocessing reactor where the first reactor stage feed 54 is only heated to between 500°F-600°F (260°C - 315°C) and does not foul the reactor feed preheaters 51 and 53 at that temperature.
  • the first reactor stage (or zone) operates at a temperature of at least 100°C less than the second hydroprocessor stage (or zone) 111.
  • the first reactor stage may operate at a temperature at least 50°C or 25°C less than the second stage.
  • the effluent 55 from the first stage reactor 110 is expected to be thermally stable and optionally may then be further preheated without a risk of coke fouling.
  • the first hydroprocessing stage 110 hydrotreats the most reactive coke precursors (asphaltenes, cyclodienes, vinyl-aromatics, olefins, dienes, oxygenated species) so that the resulting first stage reactor effluent 55 can be further heated to second stage reactor inlet temperature in preheater 90 without coking.
  • the feed side of the feed/effluent heat exchanger 70 will also be protected from coking by this configuration.
  • This embodiment is further enabled by choosing a higher activity catalyst for catalyst bed 115 which allows the first stage reactor to operate at a lower temperature
  • FIG. 3 depicts an embodiment wherein the SCT feed bypasses the reactor feed/effluent heat exchanger and feed trim heater to avoid tar coking risk.
  • the SCT 10 is not heated in either the reactor feed/effluent exchanger 70 or the reactor feed trim heater 90 but rather is brought to temperature near the reactor inlet or within the reactor feed distributor when it mixes with utility fluid and hydrogen 91 that has been sufficiently overheated in the reactor feed/effluent exchanger 70 and reactor feed trim heater 90.
  • the hydrogen 60 and utility fluid 20 are mixed and conducted to the feed side of the reactor feed/effluent exchanger 70 and then to the reactor feed trim heater 90 and heated above the desired reactor inlet temperature.
  • This hot mixture 91 is then mixed with the SCT 50 and the entire mixture 100 enters the reactor 110 now at the desired reactor inlet temperature.
  • the risk of tar coke fouling in the reactor feed/effluent exchanger 70 and reactor feed trim heater 90 has been lessened or eliminated, as the SCT feed is not pre-heated.
  • only the utility fluid passes through the feed/effluent exchanger. The tar feed, the utility fluid, and recycle hydrogen can then be heated in the reactor feed trim heater.
  • the concept of this embodiment is not preheating the tar stream above the temperature at which coking becomes a problem. Rather, the preheat energy is provided by heating the utility fluid and hydrogen above the desired reactor inlet temperature and then mixing the tar stream with the hotter utility fluid and hydrogen at or in close proximity to the reactor inlet, where it will mix to the desired reactor inlet temperature and immediately contact catalyst and begin the hydroprocessing reactions.
  • reactor feed/effluent heat exchanger and feed trim heater are spared. This option mitigates the effect of whatever tar coke fouling that does occurs.
  • the sparing will allow online or offline decoking and more importantly allows continuous reactor operation.
  • a drum downstream of the feed trim heater may be included to recover the spalled coke during the decoking operation. This concept may also be applied to any of the process configurations as an added mitigation against coking risk.
  • Figure 4 depicts an embodiment wherein heat is applied to the reactor top catalyst bed to minimize the coke fouling risk.
  • SCT is not preheated in either the reactor feed/effluent exchanger 70 or the reactor feed trim heater 90, but rather is brought to temperature gradually as the reactions proceed within the reactor 110 itself by supplying external heat 102 to at least the first catalyst bed 118.
  • the first catalyst bed can be designed as a tubular reactor with catalyst in the tubes and a heat transfer fluid in the shell.
  • the heat is supplied by a heat transfer fluid in streams 102 and 101 which heat the catalyst and feed simultaneously.
  • streams 102 and 101 can represent steam or a hot process stream or any other source of heat, e.g., external electric wall heaters.
  • This methodology is observed to lessen or eliminate fouling in pilot plant studies. It is found that preheating the tar, utility fluid and hydrogen while in the presence of the catalyst results in many more successful, non-coking runs than preheating before contact with the catalyst. It should be appreciated that the design of the tubular reactor catalyst bed is within the scope of one skilled in the art of design. Similarly, a temperature control system can be designed by one skilled in the art of process control taking into account that heat is being added to an exothermic reaction zone.
  • the utility fluid and hydrogen may optionally be preheated in the reactor feed/effluent heat exchanger 70 and reactor feed trim heater 90 as required to be more energy efficient and reduce the heating requirements of the heat source in the hydroprocessor reactor.
  • the SCT is not preheated in either the reactor feed/effluent heat exchanger 70 or the reactor feed trim heater 90. In another embodiment not shown in Figure 4 the SCT may be preheated to a temperature low enough to avoid coking or fouling.
  • the recycle may de-gassed by taking the recycle from the bottom of a stabilizer distillation column. This liquid recycle can also be taken from the bottoms of a flash separator.
  • PRO/II® process simulation software is a steady-state simulator enabling improved process design and operational analysis. It is designed to perform rigorous mass and energy balance calculations for a wide range of chemical processes. Characterization of reactor feed and product used in the PRO/II® simulations were based on boiling point curves (simulated distillation GC, ASTM D2887) and density from experimental data.
  • the separation stages 130 represents conventional separation equipment for hydroprocessing comprising high temperature and low temperature separators, a stabilizer, acid gas removal, and associated equipment such as exchangers and compressors for recycle gas.
  • a light fuel and heavy fuel oil splitter is provided to produce two hydroprocessed products. In this option the light fuel oil is used as the utility fluid 20.
  • the hydroprocessor effluent stream 122 enters the separation stages 130.
  • the aforementioned equipment in the separation stages separates this stream into products and byproducts including the hydroprocessed product 134, a purge gas stream 132, and a light gas stream 133 which may be used as fuel gas. If the optional light fuel and heavy fuel oil splitter is provided then stream 134 represents two separate products, light fuel oil and heavy fuel oil.
  • Make-up hydrogen enters the separation stages 130 as stream 131.
  • Stream 60 is the recycle hydrogen rich gas. In all cases, H 2 S and NH 3 are removed in the separation stages 130, before stream 60 is sent back to the hydroprocessor.
  • the feed side of the reactor feed/effluent heat exchanger 70 and the reactor inlet feed trim heater 90 are at risk of fouling with coke.
  • the catalyst is assumed to be a conventional hydroprocessing catalyst, such as RT-621, available from Albermarle.
  • the required hydroprocessor reactor inlet 100 for this catalyst is assumed to be 750°F (400°C) and 995 psig (67 bar).
  • Figure 2 depicts an embodiment wherein a lower temperature first reactor stage is used to minimize reactor preheat train coke fouling risk.
  • This embodiment employs a first lower temperature stage 110 hydroprocessing reactor utilizing a more active catalyst such as Nebula 20 Criterion DN3651, DN3551 or Albermarle KF860 so that the first reactor stage feed 54 is only heated to 600°F (375°C).
  • the first stage reactor effluent 55 reaches 611°F (322°C).
  • the most reactive coke precursors asphaltenes, cyclodienes, vinyl-aromatics, olefins, dienes, oxygenated species
  • the first stage reactor effluent 55 is then heated to 742°F (394°C) in the feed preheat exchanger 70 and to the second stage reactor inlet temperature 750°F (400°C) is preheater 90.
  • the second stage reactor 111 contains two beds 116, 117 of RT-621 catalyst.
  • FIG. 3 depicts an embodiment wherein the SCT feed bypasses the reactor feed/effluent heat exchanger 70 and reactor feed trim heater 90.
  • the SCT feed stream 50 is at 534°F (279°C).
  • the hydrogen 60 and utility fluid 20 are mixed and conducted to the feed side of the reactor feed/effluent exchanger 70 and heated to 780°F (415°C) against the 804°F (429°C) reactor effluent 120.
  • the heated stream 80 is conducted to the reactor feed trim heater 90 and heated to 940°F (504°C).
  • This 940°F (504°C) hot mixture 91 is then mixed with the 534°F (279°C) SCT 50 and the entire mixture 100, now at the desired reactor inlet temperature of 750°F (400°C), enters the reactor 110.
  • FIG. 4 depicts an embodiment wherein heat is applied to the reactor top catalyst bed to minimize the coke fouling risk.
  • SCT is not preheated in either the reactor feed/effluent exchanger 70 or the reactor feed trim heater 90, but rather is brought to the 750°F (400°C) reaction temperature gradually as the reactions proceed within the first catalyst zone 118 of the reactor 110.
  • the hydrogen 60 and utility fluid 20 are mixed and conducted to the feed side of the reactor feed/effluent exchanger 70 and then to the reactor feed trim heater 90 and heated to 750°F (400°C).
  • the mixture 100 then enters the reactor 110.
  • the SCT feed stream 50 at 534°F (279°C) also enters the reactor 110.
  • the first catalyst bed 118 bed is designed as a tubular reactor with RT-621 catalyst in the tubes and a heat transfer fluid in the shell.
  • the mixture of heated hydrogen and utility fluid 100 mixes with the SCT feed stream and enters the tubes of 118 containing the catalyst and begins reacting.
  • the heat transfer fluid stream 102 enters the shell side of 118 at 800°F-850°F (427°C-454°C) supplying heat to the reactor and leaves as stream 101 which then can be externally heated in another coil (not shown) in the trim preheat furnace 90.
  • the mixture of SCT feed, utility fluid and hydrogen leaves the tubular reactor 118 at the desired reaction temperature 750°F (400°C) and enters the catalyst beds 116 and 117 containing RT-621 catalyst.

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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)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)

Claims (13)

  1. Procédé de conversion d'hydrocarbures, comprenant les opérations consistant à :
    (a) disposer d'un premier mélange comprenant ≥ 10,0 % en poids d'hydrocarbures par rapport au poids du premier mélange ;
    (b) pyrolyser le premier mélange pour produire un second mélange comprenant ≥ 1,0 % en poids de composés insaturés en C2 et ≥ 1,0 % en poids de goudron, les pourcentages en poids étant basés sur le poids du second mélange ;
    (c) séparer un courant de goudron du second mélange, le courant de goudron contenant ≥ 90 % en poids des molécules du second mélange ayant un point d'ébullition sous la pression atmosphérique ≥ 290 °C ;
    (d) disposer d'un fluide de service, le fluide de service comprenant ≥ 1,0 % en poids de composés aromatiques par rapport au poids du fluide de service ;
    (e) disposer d'un courant d'hydrogène comprenant de l'hydrogène moléculaire ;
    (f) chauffer le courant de goudron à une température de la masse au-dessous de 300 °C par une ou plusieurs opérations parmi (i) l'exposition du courant de goudron à une température située dans la plage de 200,0 °C à 400,0 °C, (ii) l'exposition du fluide de service à une température ≥ 400,0 °C et ensuite la combinaison du courant de goudron avec le fluide de service chauffé et/ou (iii) l'exposition du courant d'hydrogène à une température ≥ 400,0 °C et ensuite la combinaison du courant de goudron avec le courant d'hydrogène chauffé ; et
    (g) hydrotraiter dans la zone d'hydrotraitement au moins une partie du courant de goudron chauffé à une température de 350 °C à 430 °C en présence de (i) le courant d'hydrogène et/ou le courant d'hydrogène chauffé et (ii) le fluide de service et/ou le fluide de service chauffé dans des conditions d'hydrotraitement catalytique à un rapport en poids du fluide de service au courant de goudron situé dans la plage de 0,05 à 3,0 pour produire un produit hydrotraité,
    dans lequel le fluide de service comprend le produit hydrotraité en une quantité ≥ 10,0 % en poids par rapport au poids du fluide de service.
  2. Procédé selon la revendication 1, dans lequel le produit hydrotraité est produit en continu pendant au moins 6,0 x 105 secondes.
  3. Procédé selon les revendications 1 ou 2, dans lequel le produit hydrotraité est produit en continu pendant au moins 2,6 x 106 secondes.
  4. Procédé selon les revendications 1 ou 2, dans lequel le produit hydrotraité est produit en continu pendant au moins 3,2 x 107 secondes.
  5. Procédé selon l'une quelconque des revendications 1-4, dans lequel les hydrocarbures du premier mélange comprennent un ou plusieurs parmi le naphta, le gazole, le gazole sous vide, les résidus paraffiniques, les résidus atmosphériques, les mélanges de résidus et le pétrole brut.
  6. Procédé selon l'une quelconque des revendications 1-5, dans lequel le goudron du second mélange comprend (i) ≥ 10,0 % en poids de molécules ayant un point d'ébullition sous la pression atmosphérique ≥ 565 °C qui ne sont pas des asphaltènes et (ii) ≤ 1000,0 ppm en poids de métaux, les pourcentages en poids étant basés sur le poids du goudron du second mélange.
  7. Procédé selon l'une quelconque des revendications 1-6, dans lequel l'hydrotraitement est effectué à une température située dans la plage de 360 °C à 420 °C en présence d'au moins un catalyseur d'hydrotraitement.
  8. Procédé selon l'une quelconque des revendications 1-7, dans lequel le goudron est chauffé dans l'étape (f) (i) à une température située dans la plage de 200,0 °C à 300,0 °C.
  9. Procédé selon l'une quelconque des revendications 1-8, dans lequel l'étape (f) (i) comprend l'opération consistant à (A) faire passer le courant de goudron dans au moins un dispositif de chauffage, dans lequel le courant de goudron soustrait de la chaleur, (B) faire passer le courant de goudron dans des premiers canaux d'au moins un échangeur de chaleur et faire passer au moins une partie du produit hydrotraité dans des seconds canaux de l'échangeur de chaleur pour soustraire de la chaleur du produit hydrotraité vers le courant de goudron ou (C) faire réagir de façon exothermique au moins une partie du courant de goudron.
  10. Procédé selon l'une quelconque des revendications 1-9, dans lequel (i) le produit hydrotraité comprend ≥ 10,0 % en poids d'un constituant mazout léger et ≥ 10,0 % en poids d'un constituant mazout lourd par rapport au poids du produit hydrotraité, (ii) le fluide de service comprend le constituant mazout léger en une quantité ≥ 90,0 % en poids par rapport à la quantité du fluide de service et (iii) le constituant mazout léger a un point de distillation à 10 %, conformément à la norme ASTM D86, ≥ 60,0 °C et un point de distillation à 90 % ≤ 350,0 °C.
  11. Procédé selon l'une quelconque des revendications 1-8 dans lequel l'étape (f) (i) comprend l'opération consistant à faire passer le courant de goudron conjointement avec le fluide de service dans au moins un dispositif de chauffage, dans lequel le courant de goudron et le fluide de service absorbent de la chaleur émanant du dispositif de chauffage.
  12. Procédé selon l'une quelconque des revendications 1-8 dans lequel l'étape (f)(i) comprend l'opération consistant à faire passer le courant d'hydrogène, le courant de goudron, conjointement avec le fluide de service dans au moins un dispositif de chauffage, dans lequel le courant de goudron, le fluide de service et le courant d'hydrogène soustraient de la chaleur du dispositif de chauffage.
  13. Procédé selon l'une quelconque des revendications 1-8 dans lequel l'étape (f) comprend les opérations consistant à chauffer le fluide de service à une température ≥ 425,0 0 °C et combiner le courant de goudron avec le fluide de service chauffé.
EP12798899.6A 2011-08-31 2012-08-31 Préchauffage des charges d'alimentation pour hydrotraitement des produits de pyrolyse d'hydrocarbures Not-in-force EP2751235B1 (fr)

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US201161529565P 2011-08-31 2011-08-31
US201161529588P 2011-08-31 2011-08-31
US201261657299P 2012-06-08 2012-06-08
PCT/US2012/053421 WO2013033582A1 (fr) 2011-08-31 2012-08-31 Préchauffage des charges d'alimentation pour hydrotraitement des produits de pyrolyse d'hydrocarbures

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CN106414673B (zh) 2014-04-30 2018-08-03 埃克森美孚化学专利公司 提质烃热解产物
WO2015195190A1 (fr) 2014-06-20 2015-12-23 Exxonmobil Chemical Patents Inc. Valorisation de goudron de pyrolyse à l'aide de produit recyclé
US9637694B2 (en) 2014-10-29 2017-05-02 Exxonmobil Chemical Patents Inc. Upgrading hydrocarbon pyrolysis products
US9765267B2 (en) 2014-12-17 2017-09-19 Exxonmobil Chemical Patents Inc. Methods and systems for treating a hydrocarbon feed
WO2018111574A1 (fr) 2016-12-16 2018-06-21 Exxonmobil Chemical Patents Inc. Prétraitement de goudron de pyrolyse
CN110099984B (zh) 2016-12-16 2021-07-02 埃克森美孚化学专利公司 热解焦油转化
US10072218B2 (en) 2016-12-16 2018-09-11 Exxon Mobil Chemical Patents Inc. Pyrolysis tar conversion
WO2018111572A1 (fr) * 2016-12-16 2018-06-21 Exxonmobil Chemical Patents Inc. Conversion de goudron de pyrolyse
WO2019236326A1 (fr) 2018-06-08 2019-12-12 Exxonmobil Chemical Patents Inc. Valorisation de goudron de pyrolyse et de résidus de flash
CN114763497B (zh) * 2021-01-11 2023-01-10 中国石油化工股份有限公司 一种生物质临氢热解-气化联产工艺和系统
CN115957700A (zh) * 2021-10-12 2023-04-14 中国石油天然气股份有限公司 一种石油烃催化转化制丙烯/乙烯的装置及方法

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DE1645728B2 (de) * 1967-05-24 1976-11-04 Exxon Research and Engineering Co., Linden, NJ. (V.St.A.) Verfahren zur herstellung eines schweren aromatischen loesungsmittels
US4173529A (en) * 1978-05-30 1979-11-06 The Lummus Company Hydrotreating of pyrolysis gasoline
US5158668A (en) * 1988-10-13 1992-10-27 Conoco Inc. Preparation of recarburizer coke
US5215649A (en) * 1990-05-02 1993-06-01 Exxon Chemical Patents Inc. Method for upgrading steam cracker tars
WO2011006952A2 (fr) * 2009-07-15 2011-01-20 Shell Internationale Research Maatschappij B.V. Procédé d'hydrotraitement d'huile hydrocarbure

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SG2014011100A (en) 2014-05-29
WO2013033582A1 (fr) 2013-03-07
CA2845002A1 (fr) 2013-03-07
CN103764800A (zh) 2014-04-30
CA2845002C (fr) 2017-02-28
EP2751235A1 (fr) 2014-07-09

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