RU2376340C1 - Method of crude hydrocarbon preparation for further advanced cracking - Google Patents

Abstract

FIELD: oil-and-gas production.

SUBSTANCE: invention related to method of crude hydrocarbons preparation for further advanced cracking, includes heating hydrogen and carbons up, deliver them into soaking chamber, the method differs from others in that fluid (for instance oil, oil residue) row material heats up or heats up and treats with chemical cracking, then delivers to reactor - mixer without catalyst, molecular hydrogen or light medias with hydrogen content, particularly gas and gasoline fraction cut-back products enriched with hydrogen, created during preparation process, heat up separately from crude hydrocarbons if necessary, deliver with greater pressure than in reactor - mixer to the stage of active atomic hydrogen process with heated up to required temperature catalyst, after that deliver active hydrogen into reactor - mixer to the cracking zone at stage of product under cracking and active hydrogen intensive mixing in order to create a chemical reaction, deliver chemical reaction products to separation stage, deliver reaction light desired cut, mainly with boiling temperature up to 360°C, to stage of processing light desired products (liquefied gas, gasoline, kerosene, diesel), deliver partly or totally heavy residue, mainly with a starting boiling temperature 360°C, to the stage of processing of heavy products (bitumen, chark) and/or partly or totally send to the secondary processing, according to the method to the process very beginning for mixing with row material or directly to stage of row material heating and cracking, solid hydrocarbons (such as coal, slate, plant products) send to the stage of fine dispensing and bring into raw material and/or into heavy residue before its mixing with raw material or before delivery at heating and cracking stage, gas hydrocarbons also sent into raw material and/or heavy residue before it mixed or before delivery at heating and cracking stage, in a way that stages of cracking and hydrogen heating or medias with hydrogen content and catalyst, process of active atomic hydrogen, mixing of material under cracking with hydrogen and separation on light part and heavy residue can be performed in one apparatus.

EFFECT: increase in light desired products outcome up to 100%.

5 cl, 2 tbl, 2 dwg

Description

The invention relates to the oil refining and petrochemical industry, and specifically to the field of oil preparation, including heavy, residues of oil refining and petrochemical industries, coal, oil shale, plant products and other hydrocarbon media, solid, liquid, gaseous, hereinafter raw materials, for their further in-depth processing, and can be used in the production of hydrocarbon fuels and petrochemical products. The preparation of oil, oil residues and other raw materials for processing means not only the removal of harmful impurities from the raw materials, but also, most importantly, the increase in the number of light spruce products above their potential content in the feedstock, which allows us to significantly increase the depth of processing and the profitability of the whole processing industry. Light target intermediates or fractions are understood as fractions for further processing and obtaining light target commodity products with a boiling point mainly up to 360 ° С, containing fuel, i.e. the most expensive gas, gasoline, kerosene and diesel fractions, as well as intermediates for petrochemical industries. In the future - light target fractions or intermediates, from which, upon final processing, light target products are obtained (liquefied gas, gasoline, diesel fuel, petrochemical products, etc.).

Currently, the general trend in the oil industry is a decrease in proven reserves of light oil, almost all of the increase in reserves is due to heavy viscous sulphurous oil. Reserves of high-quality raw materials at exploited fields are decreasing, and the share of heavy oil production is increasing. Coals, shales and other solid hydrocarbons are not used on a large industrial scale for the production of motor fuels and petrochemicals.

The potential of high-quality raw materials is almost 80% realized, while retaining only the prospects of small discoveries. So, for example, in Tatarstan for a long time the preparation of oil reserves is carried out at the expense of small fields and oil of deteriorated quality. More than 30% of the reserves are represented by high viscosity oil. In the Perm Region, the structure of oil reserves is generally complex due to the large share of heavy oil (58%). In the Ulyanovsk Region, 41 oil fields have been discovered, their total proven reserves amount to 50 million tons, and they are represented by heavy and highly viscous oils. A similar situation in Udmurtia, etc. In general, in the Ural-Volga region, as in other regions of the country, it will be necessary to deal more and more actively with carbon oil and natural bitumen. Reserves and production of heavy oil prevail in all countries of South America, Mexico, Canada, Africa, China and in many countries of different continents. Such oil is even transported through the pipeline with the addition of a sufficient amount of expensive solvent.

The processing of heavy viscous sulphurous oil is very difficult, energy-intensive and, as a result, unprofitable or unprofitable. It contains a low amount of "light" (fuel) fractions. In plants with a classical scheme, it is possible to select these fractions with respect to oil no more than 25-30%. The high content of sulfur, chlorides and resinous substances reduces the life of the equipment of oil refineries. For example, the properties of the "heavy" Ulyanovsk oil are as follows: density - 930-980 kg / m ³ (20-13 API), viscosity - 50-90 MPa · s, sulfur content - up to 5% wt., Chloride salts up to 2000 mg / l, resins and asphaltenes up to 35% of the mass.

The decrease in light oil reserves of traditional fields increases interest in the production and, consequently, in the processing of heavy oil (Ratov AN, Nemirovskaya GB and others. Problems of oil development in the Ulyanovsk region. "Chemistry and technology of fuels and oils", No. 4 , 1995). Heavy oil is understood to mean, as a rule, oil with a density of more than 900 kg / m ³ , with a low content of light fractions and a high content of tar-asphaltene substances and other harmful impurities. These features of the composition of heavy oil cause serious difficulties both in production and transportation: high viscosity and pour points, and during its processing: a significant content of various impurities, resins. Transportation is significantly complicated due to the high viscosity of the raw materials, the high content of resinous-asphaltene substances and paraffin, and deposits on the working surfaces of the equipment are the reason for its failure. And sulfur and metal compounds, especially vanadium, as well as chloride salts, which are usually found in such oil, have an increased corrosive effect on the equipment of oil refineries. In addition, the content of light target products in heavy oil is small, and without additional deepening processes, the processing of such oil is unprofitable.

It’s even more difficult to process oil residues, i.e. residues of oil refining and petrochemical industries, for example, still bottoms after atmospheric or vacuum distillation. There are practically no light products in them, and there are even more harmful impurities than in the feedstock.

In addition, the trend of converting plant products into gasoline and diesel fuel has recently intensified. This is a fundamentally wrong position, which can lead to serious social and environmental consequences on a global scale. It is much more promising to make efforts to increase (up to 100%) the processing depth of classical raw materials for these purposes - oil and oil residues, solid and gaseous hydrocarbons, which is what the proposed application for the invention is directed to.

The issue of deepening refining is the task of the entire world oil refining industry in the near future.

Thus, the preparation of heavy oil for refining, which can include not only the removal of harmful impurities from raw materials, but also the increase in the number of light target fractions above their potential content in the feedstock, is the process that determines the profitability of the entire oil refining industry.

Known and widely used in industry are such methods of preparing the feedstock as degassing, dehydration and desalting of oil, purification of sulfur and other harmful impurities (Erich V.N., Rasina MG, Rudin MG "Chemistry and technology of oil and gas ". Leningrad," Chemistry ", 1972. Skoblo AI, Tregubova IA, Egorov NN" Processes and apparatuses of the oil refining and petrochemical industry. Moscow, State Scientific and Technical Publishing House, 1962. Sudo M. M. “Oil and combustible gases in the modern world.” Moscow, Nedra, 1984. Rabinovich G. P., Ryabykh P. M., Khokhryakov P. A. / Under the editorship of Sudakova E.N. “Calculations of the main processes and apparatuses for oil refining.” Reference. Moscow, “Chemistry”, 1979. Dryatskaya Z.V., Mkhchiyan M.A., Zhmykhova N.M. and others. “Oil USSR. Volume 4 ". Moscow," Chemistry ", 1974. Levchenko D.N., Bergshtein N.V., Pinkovsky Y.I. Desalination of oil at oil refineries: Overview. - M .: TSNIITENeftekhim, 1973. Levchenko D .N., Bergshtein N.V., Nikolaeva N.M. Oil desalination technology at oil refineries. - M .: Chemistry, 1985. Gershuni S.Sh. Modernization of electric dehydrators, ways to increase the efficiency of their use: Overview. - M.: TSNIITENeftekhim, 1986).

However, using these methods, only the raw materials are cleaned of harmful impurities, and the fractional composition of the raw materials does not change, therefore, for cost-effective processing of heavy raw materials (oil, various oil residues, etc.), these processes are clearly not enough, processes that allow for further processing are necessary receive an increased amount of light products. In addition, there is still no way to clean the source, especially heavy raw materials, such as heavy oil or fuel oil, from sulfur and sulfur compounds. Using the well-known hydrotreating process, gasoline, kerosene and diesel fuel that have already been separated out are cleaned, but not heavy raw materials.

A known method of thermal cracking for advanced processing of raw materials (Benson S. Thermochemical kinetics, trans. From English / Ed. By N.S. Yenikolopyan, M .: Mir, 1971 Krasyukov AF, Petroleum coke. M: Chemistry 1966. Lukyanov P.I., Basistov A.G. Pyrolysis of petroleum feedstocks. M.: Gostoptekhizdat. 1962. Dekhterman A.Sh. Oil refining according to the fuel version. M.: Chemistry, 1988 and others.) . The essence of conventional thermal cracking is that, under the influence of temperature, the vibrational levels of molecules are excited and, when critical energy is reached, bonds break and two more lighter molecules are formed from a more likely heavy molecule, etc. There are a lot of gases and unsaturated hydrocarbons in thermal cracking products, which increases the requirements for further equipment in obtaining marketable products - gasoline, diesel fuel, etc. The poor quality of thermal cracking products leads to an increase in capital and operating costs. Therefore, recently, thermal cracking processes, especially in the fuel version, are rarely used. High heating temperatures of raw materials (470-550 ° C and above) and pressure (up to 7 MPa) also lead to high capital costs, and coking of equipment and low overhaul mileage of equipment - to increase operating costs and complexity of process control. The operation of thermal cracking units is characterized by a short turnaround time, sometimes no more than 20 days (Dekhterman A.Sh. Oil refining according to the fuel version. M: Chemistry, 1988, p. 51). Therefore, thermal cracking is not used in world practice as widely as catalytic processes. In addition, using thermal cracking it is not possible to achieve 100% processing depth, because heavy residues such as coke will always remain.

Known methods for processing heavy oil-containing fractions using simultaneously with thermal and wave, including cavitation, effects of various nature and a wide range of frequencies, which can be defined as methods of thermomechanical exposure or cracking.

A known method of processing by sequential extraction of fractions from hydrocarbons using electromagnetic energy with a frequency of 300 MHz-300 GHz (US patent 5055180, class C10G 1/00, 1991).

In the known method of processing fuel oil by vacuum distillation to obtain distillate fractions, the liquid phase of the still bottom is exposed to acoustic vibrations with a frequency of 0.1-200 kHz and a power of 0.2-3 W / cm ² at a residual pressure of 20-200 mm Hg (see ed. St. USSR 1377281, class C10G 7/06, 1988).

There is also a method of cracking petroleum products using an ultrasonic frequency spectrum. According to this method, the raw material (oil-containing product) and dispersant are fed into the treatment zone, ultrasonic treatment is carried out with a radiation intensity of 1-10 MW / m ² in a closed circulation circuit at a static pressure in the range from 0.2 to 5 MPa (see RF patent 2078116, C10G 15/00, 1995).

However, these methods have so far been implemented only in the laboratory version and have not found application in the industry. But even in the laboratory version, there is no need to talk about a 100% increase in the yield of light target fractions, heavy residues such as fuel oil, coke, etc. always remain. In addition, if heat is directly used to activate vibrational levels of molecules when raw materials are activated by direct heating, and to activate those But molecules with a wave action must first spend heat (energy) to create a wave effect, and this process has a very low efficiency, then the energy costs when implementing these methods are quite high . But with the proper organization of thermomechanical cracking, provided that energy costs are reduced and optimized, thermomechanical cracking has a good prospect for advanced hydrocarbon processing, since the process is not avalanche-like (as in thermal cracking), but controlled and heavy raw materials do not poison the catalysts due to their absence.

The most famous and widely used processes of deep processing are catalytic - catalytic cracking, hydrocracking, etc. (Sukhanov V.P. Catalytic processes in oil refining. Moscow: Chemistry, 1973. Prokopyuk S.G., Masagutov PM Industrial catalytic cracking plants M .: Chemistry, 1974.) The essence of catalytic cracking is that bond breaking occurs in the presence of a catalyst at high temperature (450-550 ° C and above) and pressure (up to 15 MPa), which leads to serious increase in capital costs, with g drokrekinge - in a hydrogen atmosphere. Catalytic cracking and hydrocracking in various versions (with a stationary catalyst, with a fluidized catalyst bed, etc., with various types of catalysts) are widely used in the world, one of the drawbacks is the very high cost of the process (equipment, catalysts, catalyst regeneration process etc.). In the processes of catalytic cracking, the feedstock, and during hydrocracking, the feedstock and hydrogen are heated and sent to a reactor with a catalyst, then the reaction products are sent to a rectification and preparation of commercial products. Thus, the feedstock is in direct contact with the catalyst in the reactor, hence the main drawback of these processes is the poisoning of the catalyst with harmful impurities contained in the feedstock and the coking of the catalyst surface with heavy reaction products. This leads to the fact that in order to maintain the operability of the processing complex, it is necessary to use processes and equipment for the regeneration or replacement of spent catalyst, which ultimately leads to a significant complication and cost of process equipment, current and capital costs, and complexity of the process. In addition, heavy residues such as tar, coke, i.e. talk about 100% processing depth is not necessary.

Despite the fact that currently the catalytic processes of advanced processing are the most widespread, even they cannot offer a sufficiently attractive technical and economic balance for many oil refiners when processing the most difficult types of raw materials.

Here you can see that using catalytic technologies it is impossible in principle to solve the problem of 100% processing depth, because heavy oil residues will very quickly lead to coking of the active surface of any catalyst.

The aim of the invention is to increase the yield of light target intermediates or fractions (gas, gasoline, kerosene and diesel, as well as fractions for petrochemical industries) up to 100% and, accordingly, increase the processing depth to 100%, purification of raw materials from sulfur and other harmful impurities, prevention coking and poisoning of the process catalyst with raw materials and its impurities, reduction of operating and capital costs, simplicity and reliability of equipment design and process control and regulation, process continuity, improvement improving the quality of the obtained fractions for their further transportation and processing, as well as the optimal and rational use of raw materials in their further processing and obtaining the target marketable products. Light target products are understood as refining fractions with a boiling point up to 360 ° С containing fuel, i.e. the most expensive, gas, gasoline, kerosene and diesel fractions, as well as intermediates for petrochemical industries.

The technical result, the proposed method is aimed at, and the goal is achieved by organizing the preparation process in which the raw materials and the catalyst do not contact, as a result of which the catalyst is not poisoned by harmful impurities and does not coke, which leads to an increase in the durability of the catalyst and the absence of the need for regeneration processes. To achieve a high processing depth, the raw material is subjected to the process of preparation or processing of this method repeatedly. Liquid (e.g. oil, oil residues, etc.) feedstock is heated or heated and subjected to thermal and / or thermomechanical cracking and fed to the reactor-mixer without catalyst, molecular hydrogen or light hydrogen-containing media enriched with hydrogen, for example, associated gas including gas produced during preparation, pentane fractions, xylene, toluene, light shoulder straps of gasoline fractions, including those obtained during preparation, etc., if necessary (especially if the hydrogen-containing raw material - this is a liquid and it must be transferred to the vapor-gas phase) heated separately from the feedstock, sent at a pressure higher than the pressure in the mixer reactor to the stage of production of active atomic hydrogen in a reactor with a catalyst heated to the required temperature (approximately 300-600 ° C and more ), after which the active hydrogen is sent to the mixing reactor in the cracking zone of the feed to the stage of intensive mixing of the cracked feed and active hydrogen to carry out the reaction, the reaction products after the mixing reactor are sent to After separation, light target reaction fractions, mainly with a boiling point of up to 360 ° С, are sent to the stage of obtaining target marketable products such as liquefied gas, gasoline, kerosene, diesel fuel, petrochemical products, etc., at the place of preparation of raw materials by this method or transported to a remote place of receipt of light commercial products, the heavy residue after the separation stage, mainly with a boiling point of 360 ° C, is sent to obtain heavy commercial products such as bitumen, coke, etc., or they are sent astastically or completely to the stage of purification from harmful impurities, then to the reprocessing by this method at the beginning of the process together with the feedstock or separately to the next stage of processing, solid hydrocarbon raw materials (for example, coal, shale, plant products, etc.) are sent to the stage of fine grinding and enter into the feedstock and / or heavy separation residue before processing it again, gaseous hydrocarbons are also introduced into the feedstock and / or separation residue before it After a second treatment, liquid, solid and gaseous hydrocarbons can be processed by this method simultaneously, individually or in pairs, the cracking stage, heating of hydrogen or hydrogen-containing media and a catalyst, production of active atomic hydrogen, mixing of the cracked raw material with active hydrogen and separation into the reacted light part and heavy residue can be combined in one unit. The temperature of 360 ° C is currently the boundary temperature between light and heavy target products, however, over time, guests and requirements for fractional composition for motor fuels and petrochemical products may change and the boundary temperature may change in any direction. According to this method, the changing requirements are easily satisfied by changing the process temperature accordingly at the separation stage.

This object is achieved by the fact that gaseous molecular hydrogen or light hydrogen-containing fractions enriched with hydrogen, for example associated gas or natural gas, or process gas, methane, propane - butane mixtures, pentane fractions, xylene, toluene, light gasoline fractions come into direct contact with the heated catalyst , including fractions of the process, etc., used to produce active atomic hydrogen, which then reacts with the raw material heated to a certain temperature. Hydrogen-containing fractions and the catalyst must be heated, because the reaction of detaching hydrogen atoms is endothermic and requires energy. Molecular hydrogen or light hydrogen-containing products do not contain asphaltenes, carbenes, gummy and coke-like substances, etc., as well as harmful impurities, and their interaction with the catalyst does not lead to its coking and poisoning. The process of formation of atomic hydrogen must be carried out in such modes so that when a hydrogen atom is disconnected, a hydrocarbon radical is formed, and not pure carbon. Heavy raw materials do not come into direct contact with the catalyst, poisoning and coking do not occur, there is no need for catalyst regeneration, the process is simplified and becomes more reliable, the cost of the process and equipment is significantly reduced, i.e. there is a decrease in capital and operating costs, the processing depth can be increased to 100%. In this case, there is a saving of raw materials in the development of the required number of target commodity products, in other words, the optimal and rational use of raw materials during their further processing when implementing this method.

The feed is heated separately from hydrogen or hydrogen-containing products, and it is heated to a temperature at which thermal or thermomechanical cracking of the feed is somewhat feasible.

Thermal cracking for heavy oil has features: the decomposition onset temperature is 238 ° C at a residual pressure of 0.25 kPa (Soskind D.M., Ratov A.N. Small-tonnage complex for the processing of oils of the Ulyanovsk Region with associated vanadium recovery. "Chemistry and Technology fuels and oils ", No. 1, 1996). Starting from 410-420 ° С and more, thermal cracking proceeds at a high speed, i.e. on an industrial scale. The heating temperature of the raw material is selected from the requirements for the resulting final products. The higher the temperature, the more gases and unsaturated hydrocarbons are formed, the lower the temperature of the process, the more isomers and aromatic compounds, but at the same time to achieve a greater depth of conversion of the raw material, more than one processing is necessary.

In thermomechanical cracking, the feed is heated thermally, i.e. in this case, the most economical method up to a certain temperature, which is lower than the temperature of the onset of an avalanche-like uncontrolled thermal cracking, i.e. heated so that uncontrolled thermal cracking has not yet begun. Heating can be carried out in a fire or electric furnace or another type of furnace, as well as in heat exchangers of various designs, in which the raw materials are heated by the heat carrier. The raw materials heated by (for example, heat carrier) to a subcritical temperature (vibrational levels of the molecules are already excited, but an avalanche-like breaking of the bonds between the molecules due to this excitation) are sent to the processing unit, in which the raw material is subjected to mechanical (e.g. cavitation) and wave influences of various nature (sound, ultra sonic cavitation, electromagnetic, light, radiation, etc.) and a wide range of resonant frequencies.

The raw materials processed by thermal or thermomechanical action are sent to the mixer reactor to the stage of intensive mixing with active atomic hydrogen, moreover, the thermal or thermomechanical effect can be constructively implemented in the mixer reactor, i.e. the stages of cracking the feed and mixing it with atomic hydrogen can be combined in one apparatus. The reaction products after the reactor-mixer are sent to the stage of separation into light target reaction fractions, mainly with a boiling point of up to 360 ° C, and a heavy separation residue.

When bonds are broken in hydrocarbon molecules, more likely polyatomic, smaller molecules are formed, i.e. more boiling products, but with open unsaturated bonds, i.e. poor quality products. In the future, this can lead either to the formation of unstable reaction products, or to condensation processes, i.e. to the formation of heavy molecules. The secondary formation of heavy molecules leads to a decrease in the expected processing depth. Unstable reaction products with open bonds in the future, upon receipt of marketable products or transportation, in contact with air, for example, oxygen can be added, which leads to the formation of resins. The increased resin content in the fuel leads to increased formation of soot in the engines and their premature failure. Therefore, open communications must be closed, i.e. saturate with any elements, for this topic - obtaining light target fuel components (gasoline, kerosene, diesel fractions), as well as components for further obtaining petrochemical products, it is necessary to saturate the bonds with hydrogen atoms, because molecular hydrogen is not very chemically active, and even a hydrogen molecule cannot be attached to one open bond. The quality of the obtained fractions is significantly improved. Instead of unsaturated hydrocarbons, saturated isomers with a large octane number and aromatic hydrocarbons as good raw materials for the production of petrochemical products are obtained.

Atomic hydrogen is much more active than molecular hydrogen. So, atomic hydrogen, under ordinary conditions, combines with sulfur, phosphorus, arsenic, etc., reduces the oxides of many metals, displaces some metals (Cr, Pb, Ag, etc.) from their salts and enters into other chemical reactions, which under the same conditions is not capable of ordinary molecular hydrogen. In chemical interactions involving ordinary hydrogen, its molecule must decay into atoms. But the very reaction of such a decay (dissociation into atoms) is strongly endothermic. The energy spent on the dissociation of one hydrogen molecule into two atoms is 435 kJ (kilojoules). Obviously, the energy expended on this reaction (dissociation energy) must be replenished by the energy released during the interaction of hydrogen atoms with the substance introduced into the reaction. Therefore, it can be expected that hydrogen reactions, in which less than 435 kJ / mol is released, will not occur spontaneously. In the case of the interaction of substances with atomic hydrogen, such an energy expenditure for dissociation is no longer required. Therefore, a much wider range of reactions is possible here. The large amount of energy released during the formation of a hydrogen molecule explains its stability under ordinary conditions. Noticeable thermal dissociation of hydrogen begins at about 2000 ° C and effectively occurs when the temperature reaches 5000 ° C. Naturally, to saturate the unsaturated bonds formed during the cracking of unsaturated hydrocarbons, it is impossible to apply thermal dissociation to form atomic hydrogen — too high temperatures are required. In addition to high temperatures, there are many other methods for producing active atomic hydrogen. The rate of reactions of the formation of atomic hydrogen from molecular and light hydrogen-containing media increases when using catalysts (platinum group metals, transition or heavy metal oxides), methods of excitation by means of wave action with a wide range of frequencies of various nature and intensity (light, electric discharge, electric arc, etc. .), as well as through chemical reactions. In an atomic form, hydrogen reacts with almost any elements and molecules, except for noble gases (B. Nekrasov, Fundamentals of General Chemistry. M., 1973). Therefore, it reacts with hydrocarbon molecules, and not just with radicals. Those. the process of preparing hydrocarbon feedstock for further in-depth processing can be carried out without cracking the feedstock, but this process is still poorly understood, but has broad prospects, as can take place at lower temperatures and energy costs than with the implementation of thermal and / or thermomechanical cracking.

The production of atomic hydrogen using the methods of wave excitation and chemical reactions under industrial conditions of the oil refining complex is not yet the most efficient way, although with the further development and optimization of such processes it has a good prospect.

The most real results in industrial conditions can be achieved using catalysts. For this, gaseous molecular hydrogen, hydrogen-containing media and / or a reactor with a catalyst are heated to a temperature of 300-600 ° C or more. In this case, the interaction of hydrogen and hydrogen-containing media with molybdenum, cobalt, zinc, vanadium, nickel and other catalysts, for example, based on alumina, or other type of catalyst, atomic hydrogen is formed, which effectively saturates open bonds of light radicals obtained as a result of the cracking reaction hydrocarbon feedstock, resulting in the formation of saturated light target fractions of good quality. Light radicals obtained by detaching active atomic hydrogen from used hydrogen-containing media also attach to light cracking radicals of the feed, saturate their open bonds and form target fractions. If they (or atomic hydrogen) are attached to the heavy radicals of the cracking of the feedstock, then after the separation stage the heavy residue of the reactions is sent either partially or completely to the reprocessing by this method, or partially or completely to obtain heavy commercial products such as coke, bitumen, etc. (depending on the task). However, much more light radicals are formed during cracking of raw materials than heavy ones, because most likely, a long raw material molecule breaks in about the middle, and with a much lesser probability is a very small and very large radical. This is evidenced, for example, by thermal cracking processes, as a result of which lighter fractions in larger quantities are obtained from heavy raw materials than heavy ones. Therefore, a significantly smaller amount of separation residue is sent for reprocessing than raw materials. In this case, the separation residue can be sent for re-processing at the beginning of the process together with the feedstock or separately for an additional processing unit according to this method. The separation residue may be heated together with the raw material or separately, in a separate furnace coil or in a separate heater (furnace). In the latter case, the temperature of the residue can be much higher than the temperature of the feedstock, and thermal or thermomechanical cracking of the feedstock is carried out through interaction, for example direct mixing, with a heated heavy separation residue. If the feedstock is not sufficiently purified, for example, of mechanical impurities, then in the heavy separation residue their concentration increases significantly and it is necessary to clean it before re-processing the residue. With repeated reprocessing of the heavy separation residue, the feed will be processed into light target products with an efficiency of up to 100%.

Hydrogen-containing media and a reactor with a catalyst can be heated to produce atomic hydrogen using separate heaters of various types, but it is most economical to use the heat of a heated feedstock or separation residue. The temperature of the raw materials for carrying out the reaction of thermal and / or thermomechanical cracking usually exceeds 400 ° C and lies in the temperature range of the use of catalysts for the dissociation of hydrogen. For this purpose, widely known heat exchangers of various types and designs are used.

In addition to increasing the depth of processing during the implementation of the proposed method, the feedstock is purified from sulfur and other impurities. The carbon-heteroatom bond energies (carbon-sulfur, carbon-nitrogen, etc.) are lower than the carbon-carbon and carbon-hydrogen bonds (T.V. Bukharkina, I.G. Digurov. Chemistry of natural energy carriers and carbon materials. M. , 1998). Therefore, for example, sulfur atoms, the purification of the feedstock from which is problematic, are more likely to disconnect from the hydrocarbon molecule during cracking, and when this method is implemented, they form hydrogen sulfide. Hydrogen sulfide is easily released in a gaseous form and disposed of to produce atomic sulfur or other sulfur-containing commercial products.

The light target reaction fractions after the separation stage, mainly with a boiling point of up to 360 ° С, which are mainly in gas-vapor and droplet form, contain gas, gasoline, kerosene and diesel fractions, as well as fractions for producing petrochemical products. The gas fractions are purified, for example, of hydrogen sulfide, then sent to obtain marketable products, such as liquefied gas, or used as fuel for their own needs on the spot. In addition, the gas part of the separation is a light product surrounded by hydrogen, and can be partially or fully used at the stage of producing atomic hydrogen together with molecular hydrogen or light hydrogen-containing fractions enriched with hydrogen coming from outside the process. For the same purpose, the lightest part of the obtained gasoline fractions obtained in the preparation of raw materials by this method can be used. This leads to a partial saving of molecular hydrogen and hydrogen-containing fractions coming from outside the process. The remaining target fractions are sent to the stage of obtaining the target marketable products such as gasoline, kerosene, diesel fuel, petrochemical products, etc. at the place of preparation of the raw materials according to this method or, after cooling and condensation, they are transported to a remote place for receiving light marketable products.

The proposed method can be used to prepare for further in-depth processing of solid and gaseous hydrocarbons.

Solid hydrocarbon feedstocks (for example, coal, shale, vegetable products, etc.) are preliminarily crushed into fine powder and introduced into the liquid feedstock and / or into the separation residue before it is processed again by this method.

For solid hydrocarbons, the liquid feed or residue in this case is heat and carrier. In this case, under the influence of temperatures and in the presence of active atomic hydrogen, hydrocarbon molecules of various sizes are formed. Light hydrocarbons will be separated out at the separation stage and used to produce light target commercial products, heavy ones will be returned for reprocessing and, when processed using this method several times, solid hydrocarbon raw materials with an efficiency of up to 100% will be processed into target fractions and products. The prospects for this approach to the preparation of solid hydrocarbons are obvious, because reserves of, for example, coal exceed oil reserves by hundreds of times, however, oil is used for the production of fuel products, because so far there are no satisfactory coal processing technologies for these purposes. Because solid hydrocarbons contain harmful impurities, mainly inorganic, the separation residue must be cleaned from them before re-processing.

The situation with the processing of gaseous hydrocarbons is much better, but even here all the problems have not been resolved. For example, during oil production, a huge amount of associated gas is burned, while doing great harm to the environment and destroying valuable hydrocarbons. This method allows you to effectively use such hydrocarbons, mixing them into the original liquid raw materials and / or heavy separation residue during its reprocessing by this method (similar to the preparation of solid hydrocarbon raw materials in the form of a fine powder for further in-depth processing), or use as hydrogen-containing products in production of atomic hydrogen. Such low-cost complexes can be used at the site of oil production to improve the quality and cost of raw materials before transportation.

In addition, gaseous hydrocarbons can be used as an independent feedstock to prepare for further processing similar to liquid feedstock. In this case, gaseous hydrocarbons can be used as heat and mass carrier in the processing of solid hydrocarbons in the form of fine powders.

Depending on the task in this method, it is possible to process liquid, solid, gaseous raw materials at the same time, or in pairs, or separately liquid or gaseous hydrocarbons.

It is easy to implement the proposed process of preparing raw materials for further deep processing both in industrial and in laboratory and bench conditions. The raw materials used were oil from the Vishenskoye deposit in the Ulyanovsk Region (Ratov AN, Nemirovskaya GB and other problems of oil development in the Ulyanovsk Region. "Chemistry and Technology of Fuels and Oils", No. 4, 1995), and heavy oil from other fields and oil residues.

In laboratory conditions, the feedstock is heated under pressure in a cylindrical tank apparatus (reactor-mixer) with a diameter of 96 millimeters and a height of 400 millimeters, the apparatus is thermally insulated. At the bottom of its housing is a built-in electric heater. Schematic diagram of the reactor is shown in figure 1, which indicates: 1 - reactor-mixer; 2 - electric heater; 3 - reactor with a catalyst for producing atomic hydrogen. The feedstock was poured into the reactor-mixer 1 and heated by an electric heater 2. In these experiments, to reach the cracking stage, the temperature of the feedstock was predominantly up to 430-470 ° C, although some heavy media such as tar had to be heated above this temperature, pressure up to 1 MPa. Molecular hydrogen is supplied from the cylinder (at a higher pressure than the pressure in the mixing reactor, so that the feed does not enter the reactor with the catalyst) into the reactor 3 with the nickel, molybdenum or platinum catalyst in it (in the form of granules with a diameter of 1-3 mm). Hydrogen and a reactor with a catalyst are heated in this embodiment to the required temperature due to the heat of the heated feedstock. The reactor with the catalyst is arranged in the form of a flat cylinder (with a diameter of 85 millimeters and a height of 75 millimeters), into which the catalyst is placed horizontally in the cross section of the reactor-mixer, with a hydrogen supply pipe for the distribution of hydrogen over the cross section of the reactor and distributed over the entire upper plane the reactor with holes with a diameter of 0.1 mm to distribute the resulting atomic hydrogen over the cross section of the reactor-mixer. The design of the reactor with the catalyst can be double-sided, spherical, etc., this is not of fundamental importance. Atomic hydrogen generated in a reactor with a catalyst is distributed over the entire cross section of the mixer reactor and enters directly into the cracking zone of the feedstock, where the saturation reaction of open radical bonds takes place. Light reaction fractions are discharged through the upper nozzle with a valve from the reactor-mixer, cooled and analyzed. The heavy separation residue remains in the mixing reactor and is also analyzed at the end of the experiment. The mixing reactor is equipped with thermocouples for measuring temperature and a manometer for measuring pressure. In this embodiment, the stages of cracking the feed, heating hydrogen or hydrogen-containing media and a catalyst, producing active atomic hydrogen, mixing the cracked feed with active hydrogen and separating the reacted light portion and the heavy residue are combined in one apparatus. Some results obtained at the laboratory facility are shown in Table 1. The processing depth reaches 87%, and the sulfur content decreased by almost 10 times. With the addition of 5% shale crushed to oil sizes of 0.05-2 micrometer, the yield of light target fractions increased to 89%, i.e. part of the solid hydrocarbons was processed into light liquid hydrocarbons. With repeated processing, the yield of the target fractions will increase to almost 100%. To achieve almost the same results in this method, instead of hydrogen, you can use a propane-butane mixture from a balloon and other light, hydrogen-enriched products or fractions. This approach is not a prototype of the industrial process, but allows you to easily demonstrate the specific implementation of the proposed method.

Table 1 Selection limits The output of fractions for oil,% of the mass. Source oil Reaction products The beginning of the boil, ° C 79 46 up to 200 ° C 10.6 38,4 up to 250 ° C 15.1 47.9 up to 300 ° C 22.2 71.2 up to 360 ° С 29.9 87.2 The sulfur content,% of the mass. up to 5.0 up to 0.6

In conditions as close to industrial as possible, the proposed method is implemented on a pilot plant with a capacity of up to 30 kg / h. Figure 2 shows the step-by-step scheme for the preparation of raw materials for further in-depth processing by this method. Figure 2 indicates: 1 - stage of heating and cracking of raw materials (furnace, heater, thermomechanical processing devices of various types); 2 - the stage of mixing raw materials and active atomic hydrogen (reactor-mixer without catalyst); 3 - stage heating of hydrogen or light hydrogen-containing fractions; 4 - stage for the production of active atomic hydrogen (heated reactor with a catalyst); 5 - stage separation of raw materials into light non-left fractions and heavy residue. Raw materials are pumped into the coil of an electric heater 1 (analogous to an industrial furnace), then the heated raw materials are fed into the mixer reactor 2. The hydrogen from the cylinder is heated (stage 3), passed through the heated reactor with catalyst 4, and also fed into the mixer reactor (stage 2), the reacted mixture is sent to the separation stage 5, for example, dispersed with decreasing pressure in a capacitive apparatus. In this embodiment, stage 2 (reactor-mixer) and stage 5 (separator) can be combined in one apparatus. Simultaneously with or in front of the dispersion, in order to initiate cracking, it is advisable to expose the product stream sequentially or simultaneously to cavitation, sound, and ultrasonic action created by the movement of the stream, moreover, a mixture of hydrocarbons can be exposed to this effect repeatedly and active hydrogen is supplied to cavitation, sound, and ultrasonic devices exposure. Special devices are also used for cavitation oil treatment and application of acoustic impact on it, the action of which is based on the hydrodynamic effects of medium moving at high speed through channels with obstacles of various shapes and different curvatures. The heavy separation residue may be mixed with the feed before reprocessing and heated together or separately heated (indicated by a dotted line in FIG. 2) from the feed in the same or separate heater. In this case, it can be heated to higher temperatures than raw materials, because in the heavy residue is much less light fractions than in the raw material. In this case, the cracking stage of the raw material can be carried out due to its interaction with the separation residue heated to a high temperature, for example, by direct mixing and further joint movement with high speeds along the channels with obstacles of various shapes and curvatures. In addition, hydrogen or hydrogen-containing fractions and a reactor with a catalyst for producing atomic hydrogen can be heated due to the temperature of the feedstock and the separation residue, therefore, the steps of cracking the feedstock, heating hydrogen or hydrogen-containing media and a catalyst, producing active atomic hydrogen, mixing the cracked feedstock with active hydrogen and separation of the unreacted light portion and the unreacted heavy residue can be combined in one apparatus.

The light part of the separation with a boiling point predominantly up to 360 ° C after the separation stage can be immediately sent further for processing to the rectification unit and, further, to the unit for obtaining marketable products (gasoline, diesel fuel, petrochemical products, etc.), i.e. . to obtain marketable products on site, or refrigerate and send to the place of further processing. The heavy part of the separation serves as a raw material for obtaining heavy commercial products - bitumen, bitumen emulsions, coke, etc., i.e. also sent to the unit for the preparation of marketable products. Greater processing depth and better results can be achieved if a heavy residue of separation of reaction products or part of it (if there is a need for heavy commercial products such as bitumen, bitumen emulsions, etc.), mainly with a boiling point above 360 ° C, after Separation stages should be sent for reprocessing in order to increase the processing depth at the beginning of the process together with the raw materials (see Fig. 2) or separately for the next processing step. The process is continuous. Some results obtained at the bench installation for the implementation of the proposed method are shown in table 2. The processing depth reaches 96%. Given the generated non-condensed gases, one can confidently talk about 100% depth of processing of raw materials using this method.

table 2 Selection limits The output of fractions for oil,% of the mass. Source oil Reaction products The beginning of the boil, ° C 79 39 up to 200 ° C 10.6 41.2 up to 250 ° C 15.1 49.6 up to 300 ° C 22.2 78.1 up to 360 ° С 29.9 96.3 The sulfur content,% of the mass. up to 5.0 up to 0.1

Thus, the technical result is an increase in the yield of light target intermediates or fractions (gas, gasoline, kerosene and diesel, as well as fractions for petrochemical industries) to 100% and, accordingly, an increase in the processing depth to 100%, an improvement in the quality of the obtained fractions for their further transportation and processing with a simultaneous reduction in operating and capital costs - this is achieved by organizing the preparation process in which the raw materials and the catalyst do not contact, as a result of which the catalyst it is not poisoned by harmful impurities and does not coke, which leads to an increase in the durability of the catalyst and the absence of the need for regeneration processes, and further processing can be achieved up to 100% by this method by repeated, possibly multiple, processing of the heavy part of the separation of reaction products.

Claims (5)

1. A method of preparing hydrocarbon feedstocks for further in-depth processing, comprising heating the feedstock and hydrogen, supplying them to a reaction chamber, characterized in that the liquid feed (for example, oil, oil residues) is heated or heated and subjected to thermal and / or thermomechanical cracking and fed into the reactor-mixer without catalyst, molecular hydrogen or light hydrogen-containing media enriched with hydrogen, in particular gas and light shoulder straps of gasoline fractions obtained in the preparation process, if necessary the springs are heated separately from the feedstock, sent at a higher pressure than the pressure in the mixing reactor to the stage of producing active atomic hydrogen in the reactor with the catalyst heated to the required temperature, after which the active hydrogen is sent to the mixing reactor in the cracking zone of the raw material to the intensive mixing stage cracked raw materials and active hydrogen for carrying out the reaction, reaction products after the reactor-mixer are sent to the separation stage, light target reaction fractions, mainly with a temperature the end of boiling up to 360 ° C, is sent to the stage of obtaining light target commercial products (liquefied gas, gasoline, kerosene, diesel fuel), the heavy residue after the separation stage, mainly with a boiling point of 360 ° C, is partially or completely sent to obtain heavy commodity products (bitumen, coke) and / or partially or completely sent for re-processing according to this method at the beginning of the process for mixing with the feedstock or separately for the stage of heating and cracking of raw materials, solid hydrocarbons (e.g. al, oil shale, vegetable products) are sent to the stage of fine grinding and introduced into the feedstock and / or into the heavy separation residue before mixing it with the feedstock or before feeding the feedstock to the heating and cracking stage, gaseous hydrocarbons are also introduced into the feedstock and / or in the heavy separation residue before mixing it with the feedstock or before feeding the raw materials to the heating and cracking step, the cracking, heating of hydrogen or hydrogen-containing media and catalyst, obtaining active atomic hydrogen, mixing cracked raw materials with active hydrogen and separation into the light part and the heavy residue can be combined in one device. 2. The method according to claim 1, characterized in that the heating of hydrogen or hydrogen-containing media and the catalyst at the stage of production of active atomic hydrogen is carried out due to the heat of the heated feedstock and / or separation residue. 3. The method according to claim 1, characterized in that the stage of producing atomic active hydrogen is carried out using a wave action on hydrogen and hydrogen-containing media with a wide range of frequencies of various nature and intensity, as well as using chemical reactions. 4. The method according to claim 1, characterized in that gaseous hydrocarbons are used as feedstock, and gaseous hydrocarbons can be used as heat and mass carrier in the processing of solid hydrocarbons in the form of fine powders. 5. The method according to claim 1, characterized in that the separation residue before reprocessing is subjected to purification from harmful impurities and compounds, in particular from inorganic ones.

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