US20070144944A1 - Integrated process for the conversion of feedstocks containing coal into liquid products - Google Patents

Integrated process for the conversion of feedstocks containing coal into liquid products Download PDF

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US20070144944A1
US20070144944A1 US10/579,224 US57922404A US2007144944A1 US 20070144944 A1 US20070144944 A1 US 20070144944A1 US 57922404 A US57922404 A US 57922404A US 2007144944 A1 US2007144944 A1 US 2007144944A1
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process according
stream
solvent
coal
treatment
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Alberto Del Bianco
Romolo Montanari
Nicoletta Panariti
Sergio Rosi
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SnamProgetti SpA
Eni Tecnologie SpA
Eni SpA
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SnamProgetti SpA
Eni Tecnologie SpA
Eni SpA
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Assigned to ENI S.P.A., ENITECNOLOGIE S.P.A., SNAMPROGETTI S.P.A. reassignment ENI S.P.A. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: DELBIANCO, ALBERTO, MONTANARI, ROMOLO, PANARITI, NICOLETTA, ROSI, SERGIO
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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
    • 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
    • C10G67/00—Treatment of hydrocarbon oils by at least one hydrotreatment process and at least one process for refining in the absence of hydrogen only
    • C10G67/02—Treatment of hydrocarbon oils by at least one hydrotreatment process and at least one process for refining in the absence of hydrogen only plural serial stages only
    • C10G67/04—Treatment of hydrocarbon oils by at least one hydrotreatment process and at least one process for refining in the absence of hydrogen only plural serial stages only including solvent extraction as the refining step in the absence of hydrogen
    • C10G67/0454—Solvent desasphalting
    • C10G67/049—The hydrotreatment being a hydrocracking

Definitions

  • Liquefaction is generally based on an essentially thermal reaction which causes the formation of radicals which are stabilized by hydrogen which has the function of preventing their back-grading to give large less reactive molecules, and on a catalytic hydrogenation which reduces the molecular complexity by splitting the bonds between various carbon atoms and other carbon atoms, oxygen, nitrogen and sulfur.
  • the reactions are carried out in the presence of a solvent, normally produced in the process itself.
  • the solvent has an essential role in the transformation, as it is capable of extracting products rich in hydrogen and dissolving the complex molecules which are formed due to the effect of heat and is also capable of facilitating the reaction with hydrogen as transferor and donator.
  • the ideal solvent must therefore have a high solvent capacity (and therefore consist of a strongly aromatic structure by affinity with the type of solute) and good hydrogen donor characteristics (and must therefore be easy to hydrogenate and also easily release the hydrogen received to the coal).
  • the extract is subjected to a subsequent hydrocracking step under controlled catalytic conditions, to lighten the products.
  • the overall advantage derives from a better use of the hydrogen, with a lower overall consumption and a higher process flexibility, resulting in a greater possibility of choice in the spectra of products.
  • coal liquids obtained must be heavily reprocessed with treatment units ad hoc (hydrocracking effected with conventional technologies), as they are extremely aromatic, rich in nitrogen, sulfur and with a high density, to generate distillates having commercial characteristics.
  • the hydrogenating processes for the conversion of heavy crude oils or distillation residues consist in treating the feedstock in the presence of hydrogen and suitable catalysts.
  • hydroconversion technologies currently on the market use fixed bed or ebullated bed reactors and adopt catalysts consisting of one or more transition metals (Mo, W, Ni, Co, etc.) supported on silica/alumina (or an equivalent material).
  • transition metals Mo, W, Ni, Co, etc.
  • Hydro-treatment technologies operating with catalysts in dispersed phase may constitute an attractive solution to the drawbacks which arise in the use of fixed bed or ebullated bed technologies.
  • Slurry processes in fact, combine the advantage of a wide flexibility with respect to the feedstock with high performances in terms of conversion and upgrading, proving to be, at least in principle, simpler from a technological point of view.
  • Slurry technologies are characterized by the presence of particles of catalyst having very small average dimensions and which are efficaciously dispersed in the medium; for this reason, hydrogenation processes are easier and more efficient in all points of the reactor.
  • the formation coke is greatly reduced and the upgrading of the feedstock is high.
  • the catalyst can be introduced as a powder with sufficiently reduced dimensions or as an oil-soluble precursor.
  • the active form of the catalyst generally the metal sulfide
  • the catalyst is formed in situ by the thermal decomposition of the compound used, during the reaction itself or after suitable pretreatment.
  • the metal constituents of the dispersed catalysts are generally one or more transition metals (preferably Mo, W, Ni, Co or Ru). Molybdenum and tungsten have much more satisfactory performances than nickel, cobalt or ruthenium and even more so than vanadium and iron (N. Panariti et al., Appl. Catal. A: Gen. 2000, 204, 203).
  • the catalyst can be used at a low concentration (a few hundreds of ppm) in a “once-through” configuration, but in this case, the upgrading of the reaction products is generally insufficient (A. Delbianco et al., Chemtech, November 1995, 35).
  • extremely active catalysts for example molybdenum
  • concentrations of catalyst for example molybdenum
  • the catalyst leaving the reactor can be recovered by separation from the product obtained from the hydro-treatment (preferably from the bottom of the distillation column downstream of the reactor) by the conventional methods such as decanting, centrifugation or filtration (U.S. Pat. No. 3,240,718; U.S. Pat. No. 4,762,812). Part of the catalyst can be recycled to the hydrogenation process without any further treatment.
  • the catalyst recovered using the known hydro-treatment techniques normally has a reduced activity with respect to the fresh catalyst so that a suitable regeneration step is necessary in order to restore the catalytic activity and recycle at least part of said catalyst to the hydro-treatment reactor. Furthermore, said recovery procedures of the catalyst are costly and also extremely complex from a technological point of view.
  • the application described is particularly suitable when the heavy fractions of complex hydrocarbon mixtures produced from the process (at the bottom of the distillation column) must be used as feedstock for catalytic cracking plants, both Hydrocracking (HC) and Fluid Bed Catalytic Cracking (FCC).
  • HC Hydrocracking
  • FCC Fluid Bed Catalytic Cracking
  • the integrated process, object of the present invention for the conversion of feedstocks containing coal into liquid products by the joint use of at least the following seven process units: coal liquefaction (CL), flash or distillation of the product obtained from the liquefaction (F), extraction with a solvent to remove the ashes (SDAsh), distillation to separate the solvent (RS), hydroconversion with catalysts in slurry phase (HT), distillation or flash of the product obtained from the hydroconversion (D), deasphalting with a solvent (SDA), is characterized in that it comprises the following steps:
  • the coal contained in the feedstock to be subjected to the liquefaction step can be as such or optionally beneficiated by means of the known coal beneficiation treatment techniques.
  • the feedstock essentially consisting of coal is preferably slurrified in a hydrocarbon matrix which can come from the units downstream of the liquefaction step (CL): preferably part of the stream containing asphaltenes, as well as the dispersed catalyst used in the hydro-treatment step (HT), obtained in the deasphalting step (SDA) and/or part of the stream consisting of deasphalted oil (DAO) obtained in the deasphalting step (SDA).
  • CL liquefaction step
  • HT dispersed catalyst used in the hydro-treatment step
  • DAO deasphalted oil
  • a further stream can be optionally separated, as distillate, which can be optionally added, either partly or totally, to the lighter fractions separated in the distillation or flash unit (D).
  • the direct liquefaction of the stream containing coal can be effected by adopting one of the various known coal liquefaction processes.
  • the aromatic solvent used preferably comes, at least partially, from one or more of the following recycled streams:
  • the extraction step with a solvent (SDAsh) to remove the ashes is preferably effected at a temperature ranging from 150 to 350° C. and at a pressure ranging from 20 to 60 atm in the presence of a suitable aromatic solvent.
  • the stream containing the hydro-treatment reaction product and the catalyst in dispersed phase, before being sent to one or more distillation or flash steps, is subjected to a separation pre-step effected at a high pressure in order to obtain a light fraction and a heavy fraction, said heavy fraction alone being sent to said distillation step(s) (D).
  • the hydrogenating post-treatment on a fixed bed consists in the preliminary separation of the reaction effluent of the hydro-treatment reactor (HT) using one or more separators operating at a high pressure and high temperature.
  • HT hydro-treatment reactor
  • the heavy part, extracted at the bottom is sent to the main distillation unit, the part extracted at the head, a C 2 -500° C., preferably C 5 -350° C., fraction, is sent to a secondary treatment section in the presence of hydrogen, available at a high pressure, wherein the reactor is a fixed bed reactor and contains a typical desulfuration/dearomatization catalyst, in order to obtain a product having a much lower sulfur content and also lower levels of nitrogen, a lower overall density and, at the same time, as far as the gas oil fraction is concerned, an increased cetane number.
  • the hydro-treatment section normally consists of one or more reactors in series; the product of this system can be further fractionated by distillation to obtain a totally desulfurated naphtha and a diesel gas oil according to specification as fuel.
  • the fixed bed hydro-desulfuration step generally uses typical fixed bed catalysts for the hydro-desulfuration of gas oils; said catalyst, or possibly also a mixture of catalysts or a series of reactors with several catalysts having different properties, causes a heavy refining of the light fraction, significantly reducing the sulfur and nitrogen content, increasing the hydrogenation degree of the feedstock, consequently reducing the density and increasing the cetane number of the gas oil fraction, at the same time reducing the formation of coke.
  • the quantity of hydrogen mixed with the feedstock is fed at a flow-rate ranging from 100 to 5000 Nm 3 /m 3 , preferably from 300 to 1000 Nm 3 /m 3 .
  • a further secondary post-treatment section of the flushing stream can be optionally present, alone or possibly together with the post-treatment hydrogenating section, in addition to the steps forming the integrated process.
  • Said further secondary post-treatment section consists in the post-treatment of the flushing stream in order to significantly reduce its entity and allow at least part of the catalyst, still active, to be recycled to the hydro-treatment reactor.
  • the fraction of stream containing asphaltenes, coming from the deasphalting section (SDA), called flushing stream, is sent to a treatment section with a suitable solvent for the separation of the product into a solid fraction and a liquid fraction from which said solvent can be subsequently removed.
  • the possible treatment section of the flushing effluent consists of a de-oiling step with a solvent (toluene or gas oil or other streams rich in aromatic compounds) and a separation of the solid fraction from the liquid fraction.
  • At least part of said liquid fraction can be fed:
  • the solvent and fluxing agent can coincide.
  • the solid fraction can be disposed of as such or, more advantageously, it can be sent to a selective recovery treatment of the transition metal or metals contained in the transition catalyst (for example molybdenum) (with respect to the other metals present in the starting residue, nickel and vanadium) with the optional recycling of the stream rich in transition metal (molybdenum) to the hydro-treatment reactor (HT).
  • the transition metal or metals contained in the transition catalyst for example molybdenum
  • the deoiling step consists in the treatment of the flushing stream, which represents a minimum fraction of the asphaltene stream coming from the deasphalting section (SDA) at the primary hydro-treatment plant of the heavy feedstock, with a solvent which is capable of bringing the highest possible quantity of organic compounds to liquid phase, leaving the metallic sulfides, coke and more refractory carbonaceous residues (insoluble toluene or similar products), in solid phase.
  • SDA deasphalting section
  • solvents can be advantageously used in this deoiling step; among these, aromatic solvents such as toluene and/or xylene blends, hydrocarbon feedstocks available in the plant, such as the gas oil produced therein, or in refineries, such as Light Cycle Oil coming from the FCC unit or Thermal Gas oil coming from the Visbreaker/Thermal Cracker unit, can be mentioned.
  • aromatic solvents such as toluene and/or xylene blends
  • hydrocarbon feedstocks available in the plant such as the gas oil produced therein, or in refineries, such as Light Cycle Oil coming from the FCC unit or Thermal Gas oil coming from the Visbreaker/Thermal Cracker unit, can be mentioned.
  • the operating rate is facilitated by increases in the temperature and the reaction time but an excessive increase is unadvisable for economic reasons.
  • the operating temperatures depend on the solvent used and on the pressure conditions adopted; temperatures ranging from 80 to 150° C., however, are recommended; the reaction times can vary from 0.1 to 12 h, preferably from 0.5 to 4 h.
  • volumetric ratio solvent/flushing stream is also an important variable to be taken into consideration; it can vary from 1 to 10 (v/v), preferably from 1 to 5, more preferably from 1.5 to 3.5.
  • the effluent maintained under stirring is sent to a separation section of the liquid phase from the solid phase.
  • This operation can be one of those typically used in industrial practice such as decanting, centrifugation or filtration.
  • the liquid phase can then be sent to a stripping and recovery phase of the solvent, which is recycled to the first treatment step (de-oiling) of the flushing stream.
  • the heavy fraction which remains, can be advantageously used in refineries as a stream practically free of metals and with a relatively low sulfur content. If the treatment operation is effected with a gas oil, for example, part of said gas oil can be left in the heavy product to bring it within the specification of pool fuel oil.
  • liquid phase can be recycled to the hydrogenation reactor.
  • the solid part can be disposed of as such or it can be subjected to additional treatment to selectively recover the catalyst (molybdenum) to be recycled to the hydro-treatment reactor.
  • the solid phase is dispersed in a sufficient quantity of organic phase (for example deasphalted oil coming from the same process) to which acidulated water is added.
  • organic phase for example deasphalted oil coming from the same process
  • part of the heavy feedstock and at least most of the stream containing asphaltenes, which also contains catalyst in dispersed phase and possibly coke, are mixed with a suitable hydrogenation catalyst and sent to the hydro-treatment reactor, whereas the remaining part of the quantity of the heavy feedstock is sent to the deasphalting section.
  • At least part of the remaining quantity of said distillation or flash residue can be sent to the hydro-treatment reactor, optionally together with at least part of the stream containing asphaltenes coming from the deasphalting section (SDA).
  • the catalysts used can be selected from those obtained from precursors decomposable in-situ (metallic naphthenates, metallic derivatives of phosphonic acids, metal carbonyls, etc.) or from preformed compounds based on one or more transition metals such as Ni, Co, Ru, W and Mo: the latter is preferred due to its high catalytic activity.
  • the concentration of the catalyst defined on the basis of the concentration of the metal or metals present in the hydroconversion reactor, ranges from 300 to 20,000 ppm, preferably from 1,000 to 10,000 ppm.
  • the hydro-treatment step is preferably carried out at a temperature ranging from 370 to 480° C., more preferably from 380 to 440° C., and at a pressure ranging from 3 to 30 MPa, more preferably from 10 to 20 MPa.
  • the hydrogen is fed to the reactor, which can operate with both the down-flow and, preferably, up-flow procedure. Said gas can be fed to different sections of the reactor.
  • the distillation step is preferably effected at reduced pressure ranging from 0.0001 to 0.5 MPa, preferably from 0.001 to 0.3 MPa.
  • the hydro-treatment step can consist of one or more reactors operating within the range of conditions specified above. Part of the distillates produced in the first reactor can be recycled to the subsequent reactors.
  • the deasphalting step effected by means of an extraction with a solvent, hydrocarbon or non-hydrocarbon (for example with paraffins or iso-paraffins having from 3 to 6 carbon atoms), is generally carried out at temperatures ranging from 40 to 200° C. and at a pressure ranging from 0.1 to 7 MPa. It can also consist of one or more sections operating with the same solvent or with different solvents; the recovery of the solvent can be effected under subcritical or supercritical conditions with one or more steps, thus allowing a further fractionation between deasphalted oil (DAO) and resins.
  • DAO deasphalted oil
  • the stream consisting of deasphalted oil (DAO) can be used as such, as synthetic crude oil (syncrude), optionally mixed with the distillates, or it can be used as feedstock for fluid bed Catalytic Cracking or Hydrocracking treatment.
  • DAO deasphalted oil
  • the feeding to the whole process can be advantageously varied by sending the heavy residue alternately either to the deasphalting unit or to the hydro-treatment unit, or contemporaneously to the two units, modulating:
  • the fractions of fresh feedstock to be fed to the deasphalting section and hydro-treatment section can be modulated in the best possible way.
  • the application described is particularly suitable when the heavy fractions of the complex hydrocarbon mixtures produced by the process (bottom of the distillation column) are to be used as feedstock for catalytic cracking plants, both Hydrocracking (HC) and fluid bed Catalytic Cracking (FCC).
  • HC Hydrocracking
  • FCC fluid bed Catalytic Cracking
  • HT catalytic hydrogenation unit
  • SDA extractive process
  • FIG. 1 A preferred embodiment of the present invention is provided hereunder with the help of the enclosed FIG. 1 which, however, should in no way be considered as limiting the scope of the invention itself.
  • the carbonaceous liquid stream ( 7 ) is fed to the extraction unit with a solvent (SDAsh) whereby an insoluble stream ( 8 ) is obtained, consisting of the mineral matter present in the feedstock and non-reacted coal and a liquid stream ( 9 ) consisting of the liquefied coal obtained and the solvent used, the latter stream ( 9 ) being sent in turn to a distillation step (RS) in order to separate the solvent ( 10 ) contained therein, to be recycled to the extraction unit (SDAsh), from a further liquid stream ( 11 ).
  • a solvent SDAsh
  • RS distillation step
  • An additional stream ( 12 ) can be optionally separated, as distillate, and possibly added ( 13 ) to the lighter fractions separated in the distillation or flash unit (D) and/or recycled ( 14 ), as solvent, to the liquefaction unit (CL).
  • the liquid stream ( 11 ) consisting of liquefied coal mixed with a suitable hydrogenation catalyst ( 15 ), is fed to a hydro-treatment unit (HT) introducing hydrogen or hydrogen and H 2 S ( 16 ) therein, from which a stream ( 17 ) is obtained, containing the hydrogenation product and the catalyst in dispersed phase, which is fractionated in a distillation column (D), from which the lighter fractions are separated ( 18 ) together with the distillable products ( 19 ), ( 20 ) and ( 21 ) from the distillation residue ( 22 ) containing the dispersed catalyst and coke.
  • a hydro-treatment unit introducing hydrogen or hydrogen and H 2 S ( 16 ) therein, from which a stream ( 17 ) is obtained, containing the hydrogenation product and the catalyst in dispersed phase, which is fractionated in a distillation column (D), from which the lighter fractions are separated ( 18 ) together with the distillable products ( 19 ), ( 20 ) and ( 21 ) from the distillation residue ( 22 ) containing the dis
  • Said distillation residue ( 22 ), called tar, is sent to the deasphalting unit (SDA) so as to obtain two streams: one ( 23 ) consisting of deasphalted oil (DAO), the other ( 24 ) consisting of asphaltenes which can be partly or totally added ( 25 ) to the liquid stream ( 11 ) consisting of liquefied coal and optionally partially recycled ( 26 ) to the feedstock substantially consisting of coal ( 1 ).
  • DAO deasphalted oil
  • 24 asphaltenes which can be partly or totally added
  • the coal liquefaction step was carried out according to the operating conditions indicated above.
  • the quenching of the reaction was effected; the autoclave was depressurized and the gases collected in a sampling bag for gas chromatographic analysis.
  • the non-gaseous products present in the reactor were recovered with THF and filtered on 0.5 ⁇ m Teflon filters to eliminate the THF-insoluble components consisting of the inorganic material (ashes), the non-reacted organic fraction and the catalyst.
  • Example 2 The same procedure is adopted as described in Example 1; 5.0 g of coal are treated together with 5.0 g of DAO solvent, in the presence of a solid mixture containing molybdenum sulfide, metal sulfides and heavy carbonaceous material.
  • the above mixture derives from hydro-treatment tests of heavy hydrocarbon feedstocks and represents part of the bottom of the deasphalting column (“flushing” stream of FIG. 1 ).
  • a quantity of solid mixture is introduced into the reactor, which is such as to obtain a concentration of molybdenum equal to 200 ppm.
  • Table 3 indicates the data relating to the coal liquefaction test. TABLE 3 results of the liquefaction test Conv, THFI ASFC 5 C 1 -C 4 TEST (w %) (w %) (w %) (w %) Liquefaction 79 10.6 38.2 1.5 step
  • the product was recovered from the reactor and subjected to filtration to separate the THF-insoluble components consisting of the inorganic material (ashes), from the non-reacted organic fraction and the catalyst.
  • the liquefaction step was repeated several times in order to obtain a quantity of liquid sufficient for the subsequent hydro-treatment tests.
  • the hydro-treatment reaction was effected under the conditions specified in Example 1, using the product obtained from the flash step (column bottom, 350° C.+residue).
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IT002207A ITMI20032207A1 (it) 2003-11-14 2003-11-14 Procedimento integrato per la conversione di cariche contenenti carbone in prodotti liquidi.
PCT/EP2004/012763 WO2005047425A1 (en) 2003-11-14 2004-11-10 Integrated process for the conversion of feedstocks containing coal into liquid products

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