KR101930580B1 - Low complexity, high yield conversion of heavy hydrocarbons - Google Patents
Low complexity, high yield conversion of heavy hydrocarbons Download PDFInfo
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- KR101930580B1 KR101930580B1 KR1020147020732A KR20147020732A KR101930580B1 KR 101930580 B1 KR101930580 B1 KR 101930580B1 KR 1020147020732 A KR1020147020732 A KR 1020147020732A KR 20147020732 A KR20147020732 A KR 20147020732A KR 101930580 B1 KR101930580 B1 KR 101930580B1
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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
- C10G55/00—Treatment of hydrocarbon oils, in the absence of hydrogen, by at least one refining process and at least one cracking process
- C10G55/02—Treatment of hydrocarbon oils, in the absence of hydrogen, by at least one refining process and at least one cracking process plural serial stages only
- C10G55/04—Treatment of hydrocarbon oils, in the absence of hydrogen, by at least one refining process and at least one cracking process plural serial stages only including at least one thermal cracking step
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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
- C10G1/00—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal
- C10G1/002—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal in combination with oil conversion- or refining processes
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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
- C10G21/00—Refining of hydrocarbon oils, in the absence of hydrogen, by extraction with selective solvents
- C10G21/003—Solvent de-asphalting
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Abstract
Firstly performing moderate pyrolysis on the heavy hydrocarbons and subsequently separating the asphaltene-rich fractions from the resulting thermally-influenced fluid so that the high solvent-to-oil ratio of the process results in an asphaltene-rich fraction By using a high performance solvent extraction process for high local solvent-to-process fluid ratios by allowing only the fraction to react and to produce dry solid asphaltenes as the end-product, the low overall solvent- A process is described for producing a feedstock for pipeline or refinery from heavy hydrocarbons, with the process fluid ratio remaining.
Description
The present invention relates to the use of heavy hydrocarbons such as bitumen and the like as a hard, more fluid product, in particular as refinery-ready and as a final hydrocarbon product satisfying pipeline transport criteria without the addition of diluent To an optimized method. Solid asphaltene byproducts are produced which are easily handled and processed further. The present invention aims at improving Canadian bitumen, but has a general application to improve any heavy hydrocarbons.
A low complexity, high yield, intensive process has been developed, tested and improved to improve the feasibility and economics of the conversion of heavy viscous hydrocarbons to certain refinery feedstocks. The concept of this intensive process has already been described in US patent application Ser. Nos. 13/037185 and 13/250935 and is described in the context of a pilot plant (5 barrels per day (5BPD)) and demonstration scale facilities (1500 barrels per day). Improvements to the intensive process through shear mixing have been described in U.S. Patent Application No. 61/548915.
The present invention describes optimal working conditions for achieving the lowest complexity and highest yield for the above described intensive process. The intensive process may be carried out at any temperature, pressure, heat fluxes, residence times, sweep gas rates and solvent to oil ratios outside any disclosed technology process It is operated. Reduced capital and operating costs, along with high liquid product yields for the new intensive process from all of these conditions and the combination of solvent choices, enable a high revenue opportunity for any heavy oil producer.
Description of Prior Art
Oil Sands Bituminous Pipelines have been described as transportable and / or convertible to crude oil acceptable to refineries. In particular, thermal cracking, catalytic cracking, solvent deasphalting, and combinations of these three (e.g., visbreaking and solvent deasphalting) This bitumen has been proposed to convert its properties for use as transfer and refinery feedstocks.
pyrolysis
Visbreaking or viscosity breaking, a form of pyrolysis, is a well-known petroleum refining process in which reduced and / or attenuated crude crudes are pyrolyzed under relatively mild conditions or cracked Less viscous and costly increased requirements to achieve blending hydrocarbons, known as diluents, to improve the flowability of the crude oil, as well as lower viscosity and pour points, ), And ensures that the crude meets minimum transport pipeline specifications (API gravity of at least 9).
There are two basic visbreaking configurations: a coil-only visbreaker and a coil-and-soak visbreaker. Both require a heater to heat the crude oil, and a coil-only style employs cracking only in the heater tube. The coil-only rib breaker operates at about 900 ° F with a residence time of about 1 minute at the heater outlet. Gas oil is recycled to quench the reaction. In the coil-and-soak visbreaker, a vessel at the outlet of the furnace is used to provide a separate residence time for cracking of the crude oil. The crude oil sits and continues cracking / reaction as the temperature is slowly reduced. The coil-and-soak visbreaker operates at a heater outlet temperature of 800 ° F. The soaker drum temperature is reduced from the outlet to 700 < 0 > F over the combined residence time of one hour or more.
Examples of such visbreaking methods are described in Beuther et al., "Thermal Visbreaking of Heavy Residues ", The Oil and Gas Journal. 57: 46, Nov 9, 1959, pp. 151-157; Rhoe et al., "Visbreaking: A Flexible Process ", Hydrocarbon Processing, January 1979, pp. 131-136; And U.S. Patent No. 4,233,138. The yield structure is 1 to 3% gas ends, 5% (wt%) naphtha and 15% (vt) gas oil ). The remainder is left with heavy oil or bitumen. The products are separated in a distillation column for further processing or mixing.
Concern over standard visbreaking schemes is that for Canadian bitumen, the operating temperature is above the limit (about 700 ° F to 720 ° F) where the obvious coking affects operability (See Golden and Bartletta, Designing Vacuum Units for Canadian heavy crudes, Petroleum Technology Quarterly, Q2, 2006, pp. 105). In addition, heat may be supplied in the heater over a short period of time such that the localized heat flow is not uniform and may reach a peak above coking initiation limits; And allowing the condensation reactions to take place because the heat is not kept constant. Applying normal visbreaking to Canadian bitumen is limited by the trend towards coking and the inability of these systems to manage these problems.
In the first part of U.S. Patent Nos. 6,972,085 and 7,976,695, attempts have been made to approach the desire for constant and continuous application of heat to crude oil over an extended period of time. Essentially, the heaters and holding vessels were combined into a single vessel to produce a continuous heated bath to the crude oil. Multiple heating levels were applied to the crude oil at various times. This is an improvement to standard visbreaking but fails to remove hot spots within the processed crude oil and allows coking due to temperature climings above optimal levels for cracking.
Thermal / catalytic cracking and solvent Deasphalted Combination( Combination of Thermal / Catalytic Cracking and Solvent Deasphalting )
In U.S. Patent No. 4,454,023, a process for the treatment of heavy viscous hydrocarbon oils is disclosed, which comprises visbreaking the oil; Fractionating said visbroken oil; Solvent deasphalting the non-distilled portion of the visbreaked oil in a two-stage deasphalting process to produce separated asphaltenes, resins and deasphalted oil fractions; Mixing said deasphalted oil fraction ("DAO") with said visbreaked distillates; And recycling and combining the resin from the de-asphalt stage with the feedstock initially delivered to the visbreaker. The U.S. Patent No. 4,454,023 provides a means for upgrading the hard hydrocarbons (API specific gravity> 15) to that of the Canadian bitumen, but due to the misuse of pyrolysis which can over-crack and coke the hydrocarbon stream And the additional complexity and cost of additional solvent extraction steps to separate the resin fraction from the de-asphaltized oil fraction. In addition, the need for a recycle portion of the resin stream increases the cost of the operation and the complexity of the operation.
In U.S. Patent 4,191,636, heavy oil is continuously added to asphaltene and non-metal oil (metal) by continuously hydrotreating the heavy oil to selectively crack the asphaltenes and simultaneously removing heavy metals such as nickel and vanadium. -free oil. The liquid products are separated into a light fraction of the as-asphaltene and non-metal oil and a heavy fraction of asphaltene-containing and heavy metal-containing oil. The hard fraction is recovered into the product and the heavy fraction is recycled to the hydrotreating step. The catalytic conversion of Canadian heavy bitumen (API specific gravity <10) using the patented process 4,191,636 is believed to be a reliable catalyst for catalytic deactivation that affects selectivity and yield It is a high-intensity process that tends to have problems.
In U.S. Patent No. 4,428,824, a solvent deasphalting unit is installed upstream of the visbreaking unit to remove asphaltenes from the visbreaking operation. In this structure, since the asphaltene is completely removed from the product stream, the visbreaking unit is operated at a higher temperature to convert the heavier molecules to harder hydrocarbon molecules without fouling . However, since the initial removal of asphaltenes in the process is prevented from thermal conversion of this portion from crude oil to a refinable product, the yield of bitumen is greatly reduced (by 10 to 5%).
As in U.S. Pat. No. 4,428,824, U.S. Patent No. 6,274,032 discloses a fractionator for separating primary crude components and subsequently solvent deasphalting (SDA) that acts on heavier crude oil asphaltene-rich components, Unit and a mild thermal cracker for a non-asphaltene stream. ≪ Desc /
In U.S. Patent No. 4,686,028, a process for the treatment of whole crude oil is described, which comprises deasphalting a high boiling range hydrocarbon in a two-stage deasphalting process to separate separated asphaltenes, resins and deasphalted Producing oil fractions and subsequently upgrading only the resin fraction by hydrogenation or non-braking. The U.S. Patent No. 4,686,028 applies visbreaking to the favourable portion of the total crude oil stream to minimize coke production. However, the 4,686,028 patent is limited to the loss of most of the crude oil which may be beneficial from the optimal conversion, so that most of the crude oil does not become a pipeline product that does not require a transport diluent.
In U.S. Patent No. 5,601,697 a process for the treatment of topped crude oil is described which comprises vacuum distilling the topped crude oil and separating the bottoms product from the distillation, Deasphalting the deasphalted oil and mixing distillable catalytic cracking fractions (atmospheric equivalent boiling temperatures below 1100 ° F) to produce transportation fuels, light gases ) And slurry oil. ≪ Desc /
U.S. Patent No. 6,533,925 discloses an improvement for separating a resin phase from a gasification process of a solvent desalting process and a solvent solution comprising a solvent, deasphalted oil (DAO) and a resin. A process involving the integration of the resulting process has been described. The U.S. Patent No. 6,533,925 includes a resin extractor for a solvent raised to a temperature above the temperature of the first asphaltene extractor. The asphaltene stream is treated but is removed prior to any thermal conversion to eliminate the possibility of obtaining a value enhancement to a useful refinery feedstock. This effect is a reduction in the potential overall yield of the crude oil stream.
U.S. Patent Application No. 2007/0125686 describes a process wherein the heavy hydrocarbon stream is first separated into several fractions through distillation of heavy components sent to a moderate pyrolyzer (visbreaker). The residual heavy liquid from the moderate pyrolyzer is solvent deasphalted in a solvent prior art solvent deasphalting unit. Asphaltenes isolated from the solvent deasphalting are used as feed to the gasifier. The deasphalted oil is mixed with the condensed, moderate pyrolyzer vapor to form a blended product. As mentioned for the 4,454,023 patent, visbreaking is faced with the challenge of producing initial coke. In particular, the 2007/0125686 patent application is intended to crack the non-asphaltene material entirely with the intention of this moderate pyrolyzer, which is also not feasible for Canadian bitumen. In this application, the moderate pyrolyzer is operated at elevated pressure to inevitably increase coke formation and hence yield. In addition, separate energy is required in the distillation and extraction steps for most of the separate components combined for pipeline transportation.
In U.S. Patent No. 8,048,291, a process in which residues from an atmospheric column and / or a vacuum column are treated in a solvent deasphalting unit and subsequently treated with some form of pyrolysis or catalytic cracking, do. The purpose of this patent is to reduce the cost of cracking the deasphalted oil stream by depositing the solvent deasphalting over the upflow of the cracker. The multiple extraction steps and operating conditions of the solvent deasphalting are performed in a coherent process that provides a lower total yield as there is no significant cost to add hydrogen to increase the cost of the entire process, Lt; RTI ID = 0.0 > cracking units < / RTI > The solvent deasphalting unit removes heavy asphaltenes containing 15% or more heavy-duty bituminous streams, thus limiting the overall yield to 85% or less unless expensive contacting processes are employed. The overall result of this process is uneconomical with the restriction that the feed to be processed is above 5 APIs where the feed through which the solvent deasphalting is processed is above the API.
menstruum Deasphalting produce Aspalten -abundance Of the stream process( Treatment of SDA generated Asphaltene - Rich Stream )
In US Pat. No. 4,421,639, the solvent deasphalting process concentrates the asphaltene material (and recovers deasphalted oil) using a second asphalt extractor. The concentrated asphalt stream is delivered through a heater that raises the temperature of the stream from 18 psia to 425, and is subsequently sent to a flash drum and a steam stripper A solvent (propane in this case) is separated from the asphalt stream. Liquid asphalt products are pumped and stored. This arrangement only works if the asphalt rich stream is liquid at these conditions. The presence of significant solid asphaltene, such as bitumen, in the asphaltene-rich stream is imposed by plugging.
In US Pat. No. 3,847,751, a concentrated asphaltene product from a solvent deasphalting unit is mixed with a solvent and transferred as a liquid solution to a spray dryer. The spray nozzle design and pressure drop determine the size of the liquid droplets formed. The smaller the light hydrocarbon (solvent) droplet, the more completely the vapor will be vaporized. The smaller the heavy hydrocarbon (asphaltene) particles, the greater the surface area available for heat transfer to cool the heavy particles to achieve the goal of producing dry, non-sticky solid particles. Just as a separate cold gas is supplied to the bottom of the spray dryer to slow the droplet descent rate (through the upward cooling gas flow) to increase the droplet residence time Separate convective heat transfer improves cooling to reduce the size of the vessel (which tends to be extremely large). This arrangement is not necessary if the asphaltene particles that sink in the extractor are present in solid form in the solvent at the process operating temperature.
U.S. Patent No. 4,278,529 describes a process for separating solvents from bitumen materials by reduced pressure without carry-over of bituminous material. By passing through a pressure reduction valve, the fluid-like phase feedstock comprising the bituminous material and the solvent is depressurized and subsequently introduced into the steam stripper. The depressurization vaporizes a portion of the solvent and also disperses liquid mist of fine bitart material particles in the solvent. The problem with this approach is that the residual asphaltene remains wet and tacky and there is not enough solvent left to maintain the heavy bituminous phase (with many solids) will be.
US Patent 4,572,781 uses a centrifugal decanter to separate a liquid phase from a highly concentrated slurry of solid asphaltenes to separate substantially dry asphaltene at a high softening point (temperature) from the heavy hydrocarbon material A solvent deasphalting process is described. This process is attempting to handle an asphaltene-rich stream with solids, but the separation of solids requires solid / liquid separation where a separate solvent is required to allow the material to flow to the slope separation process, which is a highly costly process. Invariably, the separated solid material is still relatively wet and an additional drying step is required to recover the solvent as a vapor. Solvent vapors need to be compressed for reuse, which is another high energy step.
In US Pat. No. 5,009,772 there is shown a method involving a continuous, relatively low temperature de-asphaltization process wherein the heavy hydrocarbon feedstock material and the extraction solvent are introduced into the extraction zone In contact with higher subcritical temperatures and superatmospheric pressures in the light extract phase and with higher molecular weight hydrocarbon components, Conradson carbon precursors and heavy metals Producing a heavy phase. The patent 5,009,772 implies that there are advantages of working below supercritical conditions in the solvent deasphalting unit, including a reduced pressure that is continuously exerted at pressures above the first hard extraction phase produced in the extraction zone . However, additional refinement points may be used in the entire process to allow the heavier crude to be processed in a simpler and less costly manner.
In U.S. Patent No. 7,597,794, a dispersion solvent is introduced into an asphalt phase after separation by solvent extraction and the asphalt phase undergoes a rapid phase change in a gas-solid separator And while the solid particles are being dispersed, the solvent vaporizes and results in a cryogenic separation of the asphalt and the solvent accompanied by the adjustable size of the asphalt particles. Attempts to vapor / spray dryers using liquid solvents as transport media tend to leave the asphaltenes produced in this process wet before, during, and after the vaporization drying step. In addition, with this process, the asphaltenes continue to liquefy at elevated temperatures. The wetted asphaltenes are tacky to all surfaces and easily contaminate and seal process equipment. The reliability resulting from using this approach makes this operation expensive for heavy crude with high asphaltene content. Example 6 of the patent results in a total DAO yield of 83.5% and a solvent recovery of 80% or more using heavy crude oil having an API of 2. Both of these values represent an uneconomical process and can be greatly improved.
In US 7,749,378, dilute heavy oil or bitumen with a diluent comprising a hydrocarbon having from 3 to 8 carbon atoms at the production site to form a mixture; Transferring the mixture from the production site to a solvent deasphalting unit; Deasphalting said mixture in said de-asphaltening unit to recover asphaltene fraction, essentially asphaltene-free deasphalted oil fraction and solvent fraction; Separating water and salts from the asphaltene fraction, the deasphalted oil fraction and the solvent fraction in the solvent deasphalting unit; And transferring and upgrading heavy oil or bitumen comprising transferring at least a portion of the solvent fraction to the production site to dilute the heavy oil or bitumen to form the mixture. The process is limited in this patent to more than 2 API crude (2 to 15 APIs are claimed) and the heavy crude oil, such as bitumen, is limited to 15% And these conditions are entirely rejected in this process, the conditions allowed in the process limit the overall yield to less than 85% of the total barrel.
U.S. Patent No. 7,964,090 describes a method for upgrading heavy asphaltene crude using solvent deasphalting and gasification. What is interesting in this patent is that a stream to a gasifier is produced by mixing a hydrocarbon containing one or more asphaltenes and one or more non-asphaltenes with a solvent, wherein a stream to the hydrocarbon The ratio of the solvent is from about 2: 1 to about 10: 1. The asphaltene-rich stream is transferred from the solvent deasphalter to the gasifier as a liquid stream. A large amount of solvent used in the transfer is consumed in the gasifier and downgraded to the fuel gas equivalent. Because of the tendency of asphaltenes to become liquids, it can be realized to use the solvent in the stated amounts to transfer the material. For solid asphaltenes, this method may require 10 to 20 times more solvent for transfer, and expensive solvents may be consumed in large amounts in the process and its value may be reduced.
Basically, an improved process for producing crude oil and refinery feedstocks for pipeline from heavy crude oil such as Canadian oil sand bitumen is described, which process comprises: (1) Performing an optimal asphaltene conversion with offgas to produce a thermally affected asphaltene-rich fraction, a minimal non-compressible vapor stream, and an increased refinery-feed liquid stream; (2) deasphalting the thermally affected asphaltene-rich fraction into an oil refinery-feed liquid stream and a concentrated asphaltene stream; (3) selectively hydrocreating specific hydrocarbon components as required by the pipeline standard and finally combining all of the liquid streams into an oil refinery source; And (4) inertial separation of the concentrated solid asphaltene stream for conversion in a gasifier, power station or asphalt plant.
The bitumen is thermally treated to remove and convert / decompose the selected asphaltene, which is subsequently sufficiently separated in a more efficient solvent extraction process to reduce the production of coke and to remove unwanted contaminants (metal, MCR, Palettes).
Considering the relative complexity and high degree of side chains to the bitumen asphaltene of Canada, under the operating conditions of the present invention as described in the present application, the side chains are preferentially decomposed from core asphaltenes and converted into certain reduced pressure diesel vacuum gas oil is made up of components in the light hydrocarbon range. The remaining thermally affected polyaromatic asphaltene cores remain in the solid at elevated temperatures and pressures above the operating conditions and are therefore able to be used as
In addition, heavier hydrocarbons in the bitumen are also cracked moderately with reduced pressure diesel, gasoline and distillate boiling range components, all of which are desirable for separation and conversion in refineries. Any major deviations in temperature and heat fluxes in the bitumen pool in the reactor cause coking and increased gas yield and reduction in overall crude oil yield of the original bitumen and reduced reliability of operation, The operation cost can be increased.
The present invention relates to a process for the production of feedstocks from feedstocks having moderate, high asphaltene crudes (e.g., Canadian bitumen) and any virgin or feedstock having utility to the already treated hydrocarbon stream, An improved apparatus and method for producing a refinery-ready feedstock, the method and apparatus comprising preheating the process fluid to a predetermined operating temperature or near the reactor's design temperature, ≪ / RTI > Transferring the process fluid into the reactor for conversion of the process fluid and applying controlled heat to the process fluid in the reactor to maintain the process fluid at a substantially uniform temperature throughout the reactor, To produce a stream of liquid hydrocarbons vapor accompanied by a stream of the received asphaltene-rich fractions and a minimal non-condensable vapor. The stream of steam is further separated into two streams of non-condensing vapor and light liquid hydrocarbon. The thermally-affected asphaltene-rich fraction was first mixed using a high-shear mixer and subsequently subjected to a de-asphaltated oil using a single-stage solvent extraction process And deasphalted to streams of concentrated asphaltenes. The deasphalted oil liquid and the hard liquid hydrocarbons produced in the processes are mixed to form a feedstock for the pipeline and the refinery. The concentrated asphaltenes are processed in an inertial separation unit to produce a dry solid asphaltene byproduct.
A sweep gas may be used in the reactor and may be preheated to provide a heat flux source other than the heater of the reactor; The sweep gas may also assist in the removal of reactor steam organisms.
Deasphalting is achieved using at least one extraction step (further steps may be used) and a low pressure stripper under conditions outside of any known solvent extraction process. Because the initial process fluid is thermally affected, the heavy asphaltene-rich fractions have lower solvent-to-oil ratios than typically found in high-shear mixers and similar upgrader operations. Can be further separated using a single extraction process of lower complexity using a combination of temperature and pressure. By further concentrating the asphaltene-rich fraction prior to the final extraction step, even more improved solvent-extraction performance and improved DAO yield can be achieved using solvent ratios even for lower total oil. This process improves the prior art solvent deasphalting utilizing a separate solvent extraction column (rinse column) that acts on the asphaltene-rich stream from the primary solvent extraction column to produce pipeline crude oil recovery And quality.
The solvent deasphalting process may allow a portion of the heavy asphaltene-rich hydrocarbon stream to be recycled and mixed with fresh feed to the reactor.
The resulting concentrated, thermally-affected asphaltene can be successfully processed in an inertial separator such as a centrifugal collector or settling chamber to produce a dry, solid asphaltene byproduct.
BRIEF DESCRIPTION OF THE DRAWINGS Various aspects of the present invention will now be described, by way of illustration and not by way of limitation, in the figures in greater detail in the drawings with reference to the drawings, wherein like reference numerals represent like parts throughout the several views.
1 is a process diagram for forming a pipeline-transportable hydrocarbon product from a heavy hydrocarbon feedstock; And
2 is a process diagram particularly relevant to the cracking process and the liquid separation process and the solid separation process; And
Figure 3 illustrates an improved solvent tank with accompanying moderate thermal cracking and vacuum and / or coke units in accordance with one or more of the described embodiments, or with an appropriately positioned shear mixing device in an existing upgrader or refinery An exemplary application of the asphaltization process is described.
FIG. 4 illustrates a process for the production of cracked / solvent deasphalted (SDA), hydrocracking, residual hydrocracking and gasification units from an existing upgrader or refinery in accordance with one or more of the described embodiments. ) Of a concentrated, gentle pyrolysis and improved solvent deasphalting process, fed with a vacuum bottoms stream from a refinery (see Figure 3).
The detailed description set forth below in connection with the accompanying drawings is intended as a description of various embodiments of the invention and is not intended to represent the only embodiments contemplated by the inventors. The detailed description includes specific details for the purpose of providing a comprehensive understanding of the present invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these specific details.
It is to be understood that other aspects of the present invention will be readily apparent to those skilled in the art from the following detailed description, wherein various embodiments of the invention are shown and described in a manner that is illustrative of the invention. It is to be understood that the invention is capable of other embodiments and that various of its various details are capable of modifications of various other aspects without departing from the spirit and scope of the invention. Accordingly, the drawings and detailed description are to be regarded as illustrative rather than restrictive.
Figure 1 is a process flow diagram depicting a
The
In one aspect, the
The
The process fluid 14 (obtained entirely from the
In one aspect, the
Within the
The first and second parameters are determined by applying a uniform flow of heat between 7000 and 12000 BTU / hr sq. Ft (zero calorie / hour / cubic foot) to the entire tank of process fluid in the reactor, RTI ID = 0.0 > 775 F. ≪ / RTI > This can be achieved by the presence of heating devices which are suitably sized and located in the reactor. The number of heaters is determined by calculating the variance of heat between any two heaters to have a uniform temperature throughout the set and to avoid peak or spot temperatures significantly higher than the target temperature in the reactor .
The third variable, residence time, can be between 40 and 180 minutes in the reactor.
The fourth reactor parameter, operating pressure, may be at or near atmospheric pressure, in accordance with standard pressure control principles used for constant performance, and in any case less than or equal to 50 psig. The pressure range is controlled such that the low end is essentially controlled to prevent excessive premature flashing of the hydrocarbon bypassing the reactor and the high end reduces the secondary cracking and subsequent increased gas yield .
A
The
A sweep gas with a feed capacity of 20 to 80 scf / bbl is provided so that the "harder" hydrocarbon products (i.e., hydrocarbons with boiling point below methane to 750)) are immediately removed as soon as they are generated in the
The sweep gas also allows the reactor to operate closer to a predetermined working pressure (less than 50 psi) and temperature. The
1 and 2, the
[Table 1]
Each variable can be independently varied within the proposed ranges depending on the quality of the feedstock provided or the quality of the desired product. Because the five mentioned process variables are inter-related, a multi-adjustable process control scheme for the target function described above (e.g., the maximum yield that meets minimum product specifications) It may be advantageous to ensure that the process is operated at the optimum point in the event that any one of them is changed or a supply / manufacturing situation or target is changed.
Once the
The hard
The overhead
One or more liquid hydrocarbon streams may be produced from the
The
The controllable process variables allow the operator to change the performance of the reactor to meet the requirements of the end product based on the changing properties of the
The controllability of the five mutually-related variables in the
In this way, when the properties of the
The
The
The
The extracted
The
In another aspect, in FIG. 2, an optimal solvent deasphalting and solid separation scheme is depicted when operating with the five inter-related variables and thus integrating with the
The high performance
[Table 2]
The combination of
When compared with the coking upgrading process and the standard reactor and solvent extraction process,
[Table 3]
Another advantage that contributes to lowering the operating temperature and pressure, along with the lower complexity of process (10), is the low capital cost. The facility is less demanded and the flange rating that can be used is just below the "break-point", where the material standards change due to the pressure and temperature involved, which increases the cost. Considering the high sulfur concentration and TAN rating of the material, the 304L / 316LSS material is an appropriate choice for reliability. For this metallurgy,
As appropriate for the novel grassroots facilities, Figure 3 shows an example of the above described intensive, controlled pyrolyzer and improved solvent deasphalting of the present invention to existing upgraders . The proposed, intensive process,
As indicated by
As an example, FIG. 4 shows a specific embodiment for a new design or modification opportunity for refiners and / or upgraders.
As in FIG. 3, the advantages of adding the intensive unit to FIG. 4 include the reduction of demineralization or coking unit size when the maximum yield of crude oil entering the plant is present; Reduction of de-bottlenearization or residue hydrolysis size when present; De-bottlenecking or reduction of gasification unit size when present; Reduced total carbon footprint for the complex; May be included.
The intensive process of Figure 2 also allows for the acceptance of sweet, low-complexity (hydro-skimming) oil refineries that are easier to obtain, By accommodating a wide range of feedstock, it can help reposition the assets to better capture the value. The intensive process is located at the front of the refinery, To provide initial conditioning.
Comparison of working conditions
The novel arrangements and features of the intensive process of the present invention are technically feasible to provide an opportunity to operate in areas that were not previously possible in any prior art process and thereby treat heavy hydrocarbons below API of zero Possible and economically desirable / superior solutions. This low complexity process, which results in low operating and capital costs with DAO volumetric yields of 89 to 91% and solvent losses of less than 2%, is a cost effective process for producing pipeline and refinery feedstocks (Based on the ratio of revenue). Table 4 provides a comparison of the present invention with some representative existing patents. The items in bold (bold) indicate either directly limiting prior art or unfavorable conditions when compared to process (10). None of the techniques compared achieved the same yields described for the heavy hydrocarbon feedstocks in the API density range of 0 to 7. The comparison includes intensive cracker and solvent deasphalting units and also solvent deasphalting only. Since the present invention borrows some of the concepts of the pyrolyzer process outlined in U.S. Patent No. 7,957,695 as part of its operation, no comparisons have been made to pyrolyzer processes. What is important in Table 4 is that the unique combination of operating conditions for the pyrolyzer simplifies the solvent deasphalting that can be operated with the unique combination of operating conditions and the use of inertial separators handling strictly asphaltic solids and solvent vapors Allow.
[Table 4]
With this intensive process, crude oil within the API range of 0 to 12+ can be reliably processed. In addition, the
Solvent selection
In order to be economically feasible whilst being technically feasible, the solvent for de-asphaltating the heavy crude oil (below 2 API) should only contain the required asphaltenes while maintaining the DAO in solution with the solvent (Sufficiently high molecular weight). In addition, the solvent should be light enough to vaporize during transfer (solid asphaltene addition solvent) of the asphalt extractor residues without requiring a large amount of energy.
Similarly, the working temperature should be cold enough to encourage DAO dissolution in the solvent and warm enough to vaporize the solvent during transport of the solid asphaltenes. For this process, the solid asphaltene precipitation of the solution is largely insensitive to solvent selection. Table 5 provides a comparison of solvents considered when treating heavy viscous hydrocarbons (API of -7 to 0 for solvent deasphalting). Solvents with 6 carbon atoms and 7 carbon atoms provide a high yield (89-91%) with reduced complexity of the process creating new and economically feasible processes.
[Table 5]
Based on similar efficacy of the C 6 and C 7 solvents for separating asphaltenes, a mixture of these hydrocarbons can be considered to reduce cost. An approximate fraction of the transport diluent can be extracted and considered for use as the solvent in the solvent deasphalting. It has been confirmed in the test that a mixture of 5 to 8 carbon atoms (6 carbon atoms and more than 760% of the carbon) can be a low-cost choice when supplying the solvent for the process (10). This further reduces operating costs through providing readily obtainable solvents that are specified as the original diluent for the feedstock for the process.
The foregoing detailed description of the above-described embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention . Accordingly, while the invention is not intended to be limited to the embodiments shown in the present application, it is contemplated that there is a sufficient view consistent with the claims, and where the article "a" or "an" Quot; is not intended to be " one and only one "unless it is" one or more. &Quot; It is intended that all structural and functional equivalents of those elements of the various embodiments described throughout the above detailed description to be known or later known to those skilled in the art are included in the scope of the claims . In addition, nothing described in this application is intended to be dedicated to the public, regardless of whether such technology is expressly referred to in the claims.
Glossary of terms used in this application
Applicants submit the following to assist the reader in interpreting the present patent application. Of course, these definitions do not supersede the common and common meanings of these definitions as may be understood by those skilled in the art in the technical field of the present invention, In order to clearly show the difference of one or more meanings that may exist with respect to the present invention.
Asphaltene-asphaltenes are (1) insoluble in n-pentane (or n-heptane) at a dilution ratio of 40 parts alkane to 1 part crude oil, and (2) It is a substance in crude oil which is redissolved in toluene.
Bituminous - shares the properties of heavy oil but is still thicker and more viscous.
Natural bitumen is a viscous oil having a viscosity of 10,000 cP (centipoise) or more and typically an API having an API of 10 or more (< 10).
Bottoms - crude material that does not vaporize in the pyrolyzer mentioned above. It is basically composed of gas oil, resin and asphaltene.
Canadian Bitumen - crude oil with a weighted proportion of 10 or more APIs from Canadian suppliers.
Canadian Heavy Crudes - includes both conventional heavy oil and bitumen with more than 20 APIs.
Deasphalted oil (DAO) - A portion of heavy oil, most of which is removed by boiling over 500 ° F nominally.
Gas oil - Any crude oil portion boiling within the range of 520-1000 ° F.
Heavy oil - is a mixture of asphaltic, chemically defined asphaltic, low (API low specific gravity below 20 API) and viscous oil (limit of 100 cP) whose content is chemically defined as asphaltene (most sulfur and possibly 90% Very large molecules including metals).
Light ends - typically pentanes, pentylenes butanes, butylenes, propane, propylene, ethane, ethylene, and methane methane), and hydrocarbons of 5 carbon atoms or less include all the materials found in crude oil and bitumen having boiling points below 100 대기 at atmospheric conditions.
MCR refers to micro carbon residues.
Resin - A heavy oil fraction that is within the boiling point range above 800 ° F and can contain asphaltenes.
SDA means "solvent deasphalter" or "solvent deasphalting" and typically refers to a solvent deasphalting unit, which is solvent deasphalted (process using solvent (Or step) for the removal of asphalt from the fluid.
Syngas - A gaseous mixture consisting essentially of contaminants resulting from destructive distillation of hydrogen, methane, carbon monoxide and hydrocarbons.
Topped crude oil - a portion of the crude oil stream after distillation or by other means of removal of significant amounts of more volatile components (eg gas oil) of crude petroleum.
Claims (22)
(a) preheating a process fluid in a heater to a designed temperature;
(b) transferring the preheated process fluid to a reactor and converting the asphaltenes in the process fluid in the reactor to produce a first stream of thermally affected asphaltene-rich fraction (s) and a second stream of vapor ;
(c) separating the second stream of the vapor into a third stream of non-condensable vapor and a fourth stream of lighter liquid hydrocarbon (s);
(d) mixing a solvent comprising at least one of (C 4) to (C 8) C 8 in a solvent extraction step with a first stream to precipitate solid asphaltene particles, thereby thermally affecting the first stream Wherein the solvent extraction process is operated at a temperature in the range of from 40 to 130 째 F below the critical temperature of the solvent and wherein the solvent extraction process is a deasphalting process in which the deasphalting oil DAO) and a sixth stream of concentrated asphaltene which is solid at the temperature operating range of the solvent extraction process, wherein the sixth stream is present as a slurry of precipitated aspartic microparticles in a portion of the liquid solvent -;
(e) mixing the heavy DAO of the fifth stream and the liquid hydrocarbons of the fourth stream into a feedstock for pipeline or refinery; And
(f) separating said sixth stream of concentrated asphaltene into a seventh stream of solid asphaltene dried in an inertial separation unit and an eighth stream of solvent for re-use in said process;
≪ / RTI >
As a continuous process, the reactor has the following parameters:
(a) a uniform flow of between 7000 and 12000 BTU / hr sq. ft introduced into the process fluid in the reactor;
(b) 20 to 80 scf / bbl (gas / process fluid) sweep gas introduced into the reactor;
(c) residence time of the process fluid in the reactor between 40 and 180 minutes;
(d) a substantially uniform operating temperature in the reactor between 675 and 775 F;
(e) working pressure in the reactor near atmospheric pressure of 50 psig or less;
Which is a single thermal conversion reactor with an overhead partial condenser operating within the furnace.
As a continuous process, the solvent deasphalting can be accomplished by the following parameters:
(a) a solvent having a carbon number ranging from 6 to 7;
(b) a mass ratio of solvent to oil within the range of 2 to 4: 1;
(c) an asphalt extractor operated at a temperature within a range subtracted from the critical temperature of the solvent by 40 ℉ to 130;;
(d) an asphalt extractor operated at a pressure within a range of 40 to 240 psig subtracted from the critical pressure of the solvent;
, A simple asphalt extractor and a low pressure DAO / solvent recovery stripper.
(f) the step uses an inertial separation unit.
Wherein the resultant feedstock for the solvent deasphalting step has an API of -8 to 0 and the feedstock for the process in which the resulting feedstock for the inertial separator is a solid at a temperature above 700 가 is in the range of 0 to 12 Process with API within.
Wherein the solvent is a fraction of a diluent (ranging from 5 to 8 carbon atoms) used to transport the bitumen feedstock to the field.
In the step (d), the solvent deasphalting preheater, the first solvent deasphalting unit and the second solvent deasphalting unit are disposed in order, and the high shear mixing is performed in the solvent deasphalting preheater and the solvent deasphalting preheater The process being performed for a stream between the first solvent deasphalting unit or a flow between a first solvent deasphalting unit and a second solvent deasphalting unit.
a) a process fluid production element for mixing heavy hydrocarbons with other materials as required to produce the process fluid;
b) conveying means for conveying the process fluid to a preheater;
c) a preheater capable of heating the process fluid to a temperature at or near a predetermined operating temperature of the reactor;
d) conveying means for conveying the heated process fluid to said reactor;
e) a reactor having a heat exchange means for providing a predetermined flow of heat to the process fluid and maintaining the process fluid in the reactor at a substantially constant predetermined temperature for a predetermined residence time;
f) means for providing a sweep gas to the process fluid in the reactor;
g) at least
i. Non-condensable steam
ii. Light liquid hydrocarbons
iii. The thermally affected asphaltene-rich fraction
Means for removing a plurality of produced materials from the reactor at the end of the residence time;
h) means for separating the non-condensable vapor from the light liquid hydrocarbons;
i) transport means for transferring the thermally affected asphaltene-rich fraction to a solvent extraction processor;
j) from the thermally affected asphaltene-rich fraction
i. Deasphalted oil
ii. Suzy
iii. The precipitated solid, dry, thermally affected < RTI ID = 0.0 >
A solvent extraction processor involving means for removing the extracted products;
k) means for collecting the deasphalted oil, resin and light liquid hydrocarbons in an appropriate amount and mixing them together to provide a feedstock for the pipeline or refinery; And
l) recovering the solid, thermally affected precipitate from the solvent extraction processor so as to provide a solvent which can be reused in the process of the apparatus and used in a solvent extraction machine and dried and thermally affected asphaltene solid, Means for separating the solvent from the pallet. ≪ RTI ID = 0.0 > 8. < / RTI >
Wherein the reactor is a single thermal conversion reactor carrying an overhead partial condenser.
7,000 to 12,000 BTU / hr.sq.ft. Wherein the reactor is operated with a uniform flow of heat introduced into the process fluid in the reactor.
And an apparatus for processing heavy asphaltene hydrocarbons operated with sweep gas introduced into the reactor.
An apparatus for processing heavy asphaltic hydrocarbons having a ratio of sweep gas to process fluid between 20 and 80 scf / bbl.
Wherein the sweep gas is at least one of nitrogen, steam hydrogen, or light hydrocarbons.
And a heater for heating the sweep gas prior to introduction into the reactor. ≪ RTI ID = 0.0 > 8. < / RTI >
An apparatus for processing heavy asphaltene hydrocarbons operated with residence time for a working fluid in a reactor which lasts from 40 to 180 minutes.
A reactor for providing a substantially uniform temperature between about 675 and about 775 F for the process fluid in the reactor; and an apparatus for processing heavy asphaltene hydrocarbons involving an internal heater.
And for processing the heavy high asphaltene hydrocarbons at or near atmospheric pressure to the process fluid in the reactor.
Apparatus for processing heavy asphaltene hydrocarbons operating at pressures below 50 psig.
Apparatus for processing heavy asphaltene hydrocarbons in which high-shear mixing is performed on the thermally-affected asphaltene removed from the reactor in step (g).
Apparatus for processing heavy asphaltene hydrocarbons with pneumatic transport means for treating dry and solid asphaltenes.
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CN106010629A (en) * | 2016-07-16 | 2016-10-12 | 辽宁石油化工大学 | Technology method for deeper cracking and shallow coking of oil sand bitumen |
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US4454023A (en) * | 1983-03-23 | 1984-06-12 | Alberta Oil Sands Technology & Research Authority | Process for upgrading a heavy viscous hydrocarbon |
JPS60130682A (en) * | 1983-12-19 | 1985-07-12 | Toyo Eng Corp | Improved method for treating heavy oil |
US4572781A (en) * | 1984-02-29 | 1986-02-25 | Intevep S.A. | Solvent deasphalting in solid phase |
FR2602783B1 (en) * | 1986-08-12 | 1989-06-02 | Total France | PROCESS FOR DEASPHALTING A HEAVY HYDROCARBON LOAD |
GB8828335D0 (en) * | 1988-12-05 | 1989-01-05 | Shell Int Research | Process for conversion of heavy hydrocarbonaceous feedstock |
CN1167770C (en) * | 2001-09-26 | 2004-09-22 | 石油大学(北京) | Solvent extraction technology for removing high softening point asphalt in petroleum slag and its equipment |
ITMI20022713A1 (en) * | 2002-12-20 | 2004-06-21 | Enitecnologie Spa | PROCEDURE FOR THE CONVERSION OF HEAVY CHARGES SUCH AS |
CN100513520C (en) * | 2005-07-05 | 2009-07-15 | 中国石油大学(北京) | Method for realizing heavy oil deep-step separation by coupled residue granulating |
US7718839B2 (en) * | 2006-03-29 | 2010-05-18 | Shell Oil Company | Process for producing lower olefins from heavy hydrocarbon feedstock utilizing two vapor/liquid separators |
AU2011378107A1 (en) * | 2011-09-30 | 2014-04-24 | Meg Energy Corp. | Solvent de-asphalting with cyclonic separation |
EP2768927A4 (en) * | 2011-10-19 | 2015-07-22 | Meg Energy Corp | Enhanced methods for solvent deasphalting of hydrocarbons |
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CN104114677A (en) | 2014-10-22 |
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RU2014133552A (en) | 2016-03-10 |
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