US20130184505A1 - Methods for Producing Hydrocarbon Products from Bio-Oils and/or Coal-Oils - Google Patents

Methods for Producing Hydrocarbon Products from Bio-Oils and/or Coal-Oils Download PDF

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US20130184505A1
US20130184505A1 US13/504,383 US201013504383A US2013184505A1 US 20130184505 A1 US20130184505 A1 US 20130184505A1 US 201013504383 A US201013504383 A US 201013504383A US 2013184505 A1 US2013184505 A1 US 2013184505A1
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oil
hydroprocessing
reaction
bio
plant
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Ian Ernest Maxwell
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Ignite Resources Pty Ltd
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Ignite Energy Resources Pty Ltd
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    • 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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    • C10G1/00—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal
    • C10G1/02—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal by distillation
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    • C10G1/00—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal
    • C10G1/06—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal by destructive hydrogenation
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    • C10G11/00—Catalytic cracking, in the absence of hydrogen, of hydrocarbon oils
    • C10G11/14—Catalytic cracking, in the absence of hydrogen, of hydrocarbon oils with preheated moving solid catalysts
    • C10G11/18—Catalytic cracking, in the absence of hydrogen, of hydrocarbon oils with preheated moving solid catalysts according to the "fluidised-bed" technique
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    • C10G3/42—Catalytic treatment
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    • C10G3/44—Catalytic treatment characterised by the catalyst used
    • C10G3/45—Catalytic treatment characterised by the catalyst used containing iron group metals or compounds thereof
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    • C10G3/00—Production of liquid hydrocarbon mixtures from oxygen-containing organic materials, e.g. fatty oils, fatty acids
    • C10G3/50—Production of liquid hydrocarbon mixtures from oxygen-containing organic materials, e.g. fatty oils, fatty acids in the presence of hydrogen, hydrogen donors or hydrogen generating compounds
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    • C10G45/00—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds
    • C10G45/02—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to eliminate hetero atoms without changing the skeleton of the hydrocarbon involved and without cracking into lower boiling hydrocarbons; Hydrofinishing
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    • C10G45/00—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds
    • C10G45/02—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to eliminate hetero atoms without changing the skeleton of the hydrocarbon involved and without cracking into lower boiling hydrocarbons; Hydrofinishing
    • C10G45/04—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to eliminate hetero atoms without changing the skeleton of the hydrocarbon involved and without cracking into lower boiling hydrocarbons; Hydrofinishing characterised by the catalyst used
    • C10G45/06—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to eliminate hetero atoms without changing the skeleton of the hydrocarbon involved and without cracking into lower boiling hydrocarbons; Hydrofinishing characterised by the catalyst used containing nickel or cobalt metal, or compounds thereof
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    • 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
    • C10G45/00—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds
    • C10G45/02—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to eliminate hetero atoms without changing the skeleton of the hydrocarbon involved and without cracking into lower boiling hydrocarbons; Hydrofinishing
    • C10G45/04—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to eliminate hetero atoms without changing the skeleton of the hydrocarbon involved and without cracking into lower boiling hydrocarbons; Hydrofinishing characterised by the catalyst used
    • C10G45/06—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to eliminate hetero atoms without changing the skeleton of the hydrocarbon involved and without cracking into lower boiling hydrocarbons; Hydrofinishing characterised by the catalyst used containing nickel or cobalt metal, or compounds thereof
    • C10G45/08—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to eliminate hetero atoms without changing the skeleton of the hydrocarbon involved and without cracking into lower boiling hydrocarbons; Hydrofinishing characterised by the catalyst used containing nickel or cobalt metal, or compounds thereof in combination with chromium, molybdenum, or tungsten metals, or compounds thereof
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    • C10G45/00—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds
    • C10G45/02—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to eliminate hetero atoms without changing the skeleton of the hydrocarbon involved and without cracking into lower boiling hydrocarbons; Hydrofinishing
    • C10G45/04—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to eliminate hetero atoms without changing the skeleton of the hydrocarbon involved and without cracking into lower boiling hydrocarbons; Hydrofinishing characterised by the catalyst used
    • C10G45/12—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to eliminate hetero atoms without changing the skeleton of the hydrocarbon involved and without cracking into lower boiling hydrocarbons; Hydrofinishing characterised by the catalyst used containing crystalline alumino-silicates, e.g. molecular sieves
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    • C10G69/00—Treatment of hydrocarbon oils by at least one hydrotreatment process and at least one other conversion process
    • C10G69/02—Treatment of hydrocarbon oils by at least one hydrotreatment process and at least one other conversion process plural serial stages only
    • C10G69/04—Treatment of hydrocarbon oils by at least one hydrotreatment process and at least one other conversion process plural serial stages only including at least one step of catalytic cracking in the absence of hydrogen
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    • C10G9/00—Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils
    • C10G9/34—Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils by direct contact with inert preheated fluids, e.g. with molten metals or salts
    • C10G9/36—Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils by direct contact with inert preheated fluids, e.g. with molten metals or salts with heated gases or vapours
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    • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
    • C10L1/00—Liquid carbonaceous fuels
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    • Y02P30/00—Technologies relating to oil refining and petrochemical industry
    • Y02P30/20—Technologies relating to oil refining and petrochemical industry using bio-feedstock

Definitions

  • the cracking reaction is a catalytic cracking reaction utilizing a powdered catalyst at a reaction temperature of between about 500° C. and 600° C., and a reaction pressure of between about 1400 KPa and 2000 KPa.
  • the method comprises additional step of oxidizing the lower olefins, wherein the oxidising produces an organic chemical product selected from any one or more of glycerine, methionine and glutaraldehyde.
  • FIGS. 8 a and 8 b show flow charts representative of processes according to embodiments of the invention.
  • the word “comprising” is to be understood in its “open” sense, that is, in the sense of “including”, and thus not limited to its “closed” sense, that is the sense of “consisting only of”.
  • a corresponding meaning is to be attributed to variations of the words “comprising” such as “comprise”, “comprised” and “comprises”.
  • a method “comprising” two steps may consist exclusively of those two steps or may include one or more additional steps.
  • the present invention provides methods for producing hydrocarbon products which may have reduced adverse effects on the environment and/or provide hydrocarbon products of comparable or increased quality compared to existing processes that rely on the use of crude oil.
  • the methods of the present invention may also provide hydrocarbon products for reduced economic cost in comparison to existing processes that rely on the use of crude oil.
  • the biomass can be derived from any suitable source.
  • a variety of animal and plant sources such as plants, trees, forestry waste, corn waste, algae, crops, landfill gas, garbage, palm oil and other vegetable oils. Waste products from animal processing such as tallow may also be considered as renewable sources of biomass suitable for use in the methods of the present invention.
  • Coal-oil can be produced from coal using any suitable method known in the art.
  • feedstock as used herein with respect to a hydroprocessing plant is defined as a feedstock including any one of a bio-oil feedstock produced from biomass, a coal oil feedstock produced from coal, a combination of bio-oil and coal oil feedstock and/or a combination of any one of these feedstocks with other hydrocarbon mixtures such as crude oil and/or a gas condensate.
  • the effluent mixture may be piped through heat exchangers to assist in preheating the feedstock 360 and cooling the effluent mixture (not shown). Wash water may also be mixed with the effluent mixture to assist in removing the impurities such as sulfur, nitrogen and oxygen, by converting the impurities to aqueous compounds.
  • the effluent mixture may then be fed to a condenser 356 to condense the hydrocarbons in the effluent mixture.
  • the condensed mixture may then be separated from the hydrogen gas present in the mixture in a separator 374 .
  • the hydrogen gas may be fed back as indicated by arrow 346 to the reactor and optionally to compressor 342 to increase the pressure of the hydrogen.
  • the water soluble aqueous compounds containing the impurities may be removed as sour water.
  • FIG. 2 shows a series flow hydroprocessing plant according to an exemplary embodiment of the invention.
  • a first reactor 550 and a second reactor 551 In the illustrated hydroprocessing plant configuration there is shown a first reactor 550 and a second reactor 551 , although it is noted that there may be three, four, five, six or more reactors if desired.
  • Each reactor 550 , 551 may comprise the same or different catalyst beds.
  • the first reactor 550 or earlier reactors if more than two reactors, comprises catalysts bed(s) to adapted to remove oxygen and/or nitrogen and/or sulphur from oil feedstock 360 .
  • the first catalyst bed or beds in the first reactor may contain a relatively low activity hydrodexygenation catalyst.
  • the low activity hydrodeoygenation catalysts may comprise, for example, a single metal such as Mo or W, or combinations of metals such as Ni/Mo or Ni/W supported on gamma alumina, preferably with relatively low metal loadings in the range of 0.1-15% wt.
  • the first reactor may preferably contain catalyst with the composition of Ni/Mo supported on gamma alumina and the second stage catalyst may preferably contain Ni/W supported on gamma alumina or amorphous silica alumina and/or a zeolite, such as zeolite Y impregnated with cobalt-molybdenum (CoMo), nickel-molybdenum (NiMo) or nickel-tungsten (NiW), to provide both a hydrogenation function and a cracking function for the catalyst.
  • CoMo cobalt-molybdenum
  • NiMo nickel-molybdenum
  • NiW nickel-tungsten
  • the second or later reactors 551 may comprise catalyst beds adapted to break up the hydrocarbons present in the feedstock 360 by hydrocracking.
  • the feedstock 360 and hydrogen 340 may be initially feed via heater 352 into the first reactor 550 and then subsequently fed into the second reactor 551 .
  • This series configuration may provide improved control of catalytic reactions and can spread the hydroprocessing reactions over more than one reactor.
  • the effluent mixture from the reactors may be processing through one or more separators such as a hot separator 574 , high pressure separator 374 and/or low pressure separator 674 .
  • a number of heat exchanges 596 may be used to recycle the heat produced in the exothermic reactions.
  • the separated hydrocarbon mixture from the separators 374 , 574 , 674 is fed to a distillation column 380 to separate the different hydrocarbon components according to the number of carbon atoms.
  • the lighter gas products 382 e.g. C 1 -C 2 , or C 1 -C 4 may optionally be piped back to a steam reformer of a methanol plant (not shown) or used as fuel for burners or collected for other uses.
  • Liquid hydrocarbon products such as naphtha 384 and diesel 388 may be collected for further refining into transportation fuels.
  • the heavy hydrocarbon products may be recycled back as an input to the hydroprocessing reactor 550 through recycle pipe 392 .
  • the heat produced in these exothermic reactions may be recycled using a number of heat exchanges 696 to assist in controlling the temperature of the reactions.
  • the effluent mixture produced from the second reactor 651 may be mixed with the effluent from the first reactor 650 and again cooled at condenser 656 and then separated in one or more separators such as high pressure separator 374 and low pressure separator 674 and fed to the distillation column 380 to remove the produced hydrocarbon products, such as naphtha 384 and diesel 388 .
  • the remaining heavy hydrocarbon products 390 may again be recycled to the second reactor 651 for further processing.
  • This two-stage configuration may provide a more complete conversion of the oil feedstock into the desired hydrocarbon products (e.g. naphtha) due to the repeated recycling of the heavy products back to the second reactor 651 .
  • the integration of the methanol plant with a hydroprocessing plant allows utilization of the excess hydrogen waste stream produced in the methanol plant, or hydrogen produced from a steam reformer from a methanol plant, to be used as a hydrogen source for the bio-oil and/or coal oil hydroprocessing plant providing significant cost savings in sourcing hydrogen, reducing the requirement of an additional catalytic reformer for the hydroprocessing plant to provide the required hydrogen. This may reduce the emission of GHG such as carbon dioxide (CO 2 ) that are released from catalytic reformers utilized to produce hydrogen in a traditional hydroprocessing plant.
  • GHG such as carbon dioxide (CO 2 )
  • the light gaseous hydrocarbon products, such as C 1-4 hydrocarbon products, produced in the hydroprocessing plant are piped back to the methanol plant and used as an additional feedstock.
  • the level of non-renewable natural gas feedstock used in the methanol plant may be reduced resulting in a decrease in the environmental impact of producing methanol.
  • methanol produced in an integrated processing plant may be produced in part from a renewable feedstock when the feedstock comprises bio-oil, resulting in a renewable methanol.
  • FIG. 4 shows an outline of an integrated plant 210 showing integration of a hydroprocessing plant with a methanol plant according to an exemplary embodiment of the invention.
  • the integrated plant 210 facilitates the use of the hydrogen co-product produced from the methanol plant 230 in a hydroprocessing plant 250 .
  • the integrated plant 210 comprises a hydrocarbon feedstock 212 which may be feed to a steam reformer 220 together with steam 214 to produce synthesis gas 228 .
  • the synthesis gas 228 may then be fed to the methanol plant 230 which includes a methanol reactor (not shown).
  • a bio-oil and/or coal oil containing feedstock 260 may be mixed with the hydrogen 240 from the methanol plant 230 in a hydroprocessing reactor in the presence of catalyst(s) as described above.
  • the hydroprocessing reaction can be performed under appropriate reaction conditions in the hydroprocessing reactor 250 as outlined above.
  • the hydrocarbon products 270 produced can then be separated into the different product groups for example using a distillation column 280 .
  • the light gaseous such as C 1-2 or C 1-4 hydrocarbon products 282 may be recycled back, via a pipe, as a supplementary feedstock to the steam reformer reactor 220 as indicated by arrow 284 .
  • the hydrocarbon products C 5-20 preferably C 5-16 such as naphtha 286 , can be collected as a feedstock for producing lower olefins, for example, by use as a feedstock for a steam cracker process as described in more detail below.
  • an oil of the invention e.g. bio-oil, coal-oil or blended oil
  • an oil of the invention may be subjected to catalytic cracking reactions to produce one or more desired hydrocarbon products without a performing a preceding hydroprocessing step.
  • FIG. 6 shows an exemplary side-by-side type catalytic cracker configuration used to produce gasoline and/or lower olefins from a catalytic cracker feedstock.
  • the catalytic cracker feedstock may be preheated to a temperature of between about 315° C. to about 430° C. and mixed with any recycled slurry oil from the bottom of the distillation column, used to separate the cracked hydrocarbon products following the catalytic cracking reactions, to form the total feed.
  • the total feed may be injected into the catalyst riser 7 for vaporization and cracking into smaller hydrocarbon vapours. In the catalyst riser 7 the total feed is mixed with a very hot powdered catalyst from the regenerator. All of the cracking reactions can occur within the catalyst riser 7 .
  • the hydrocarbon vapors “fluidize” the powdered catalyst and the mixture of hydrocarbon vapors and catalyst may flow upward to enter the reactor at a temperature of about 535° C. and a pressure of about 1.72 barg or 1720 KPa
  • the cracked hydrocarbon product vapors and the spent catalyst may be separated.
  • the separation may occur by passing the mixture of hydrocarbon vapors and catalyst through a set of two-stage cyclones 5 within the reactor.
  • the spent catalyst can be returned to the catalyst regenerator via a steam stripping section to remove any hydrocarbon vapors.
  • the catalyst may be regenerated by burning off any deposited coke with air blown into the regenerator.
  • the regenerator can operate at a temperature of about 715° C. and a pressure of about 2.41 barg or 2410 kPa.
  • the combustion of the coke may be exothermic and it produces a large amount of heat that is partially absorbed by the regenerated catalyst and provides the heat required for the vaporization of the feedstock and the endothermic cracking reactions that take place in the catalyst riser.
  • the hot catalyst (at about 715° C.) leaving the regenerator may flow into a catalyst withdrawal well 6 where any entrained combustion flue gases can be allowed to escape and flow back into the upper part to the regenerator.
  • the flow of regenerated catalyst to the feedstock injection point below the catalyst riser can be regulated by a slide valve in the regenerated catalyst line.
  • the hot flue gas exits the regenerator after passing through multiple sets of two-stage cyclones 5 that remove entrained catalyst from the flue gas.
  • the cracked hydrocarbon product vapors can be fed to a distillation column to separate the cracked hydrocarbon products.
  • the different hydrocarbon fractions can then be collected such as fuel oil and gasoline.
  • Some fractions may be further processed to produce various hydrocarbon products (e.g. lower olefins such as propylene and butylene).
  • certain embodiments of the invention enable biomass and/or coal, including brown coal, to be processed to produce a naphtha intermediate which can then be used as a feedstock to produce hydrocarbon products such as lower olefins.
  • the lower olefin hydrocarbon products such as ethylene, propylene and butylene may then be used to produce a wide variety of products such as plastics, polyethylene, polypropylene, synthetic rubber and adhesives by catalytic polymerization.
  • Lower olefins such as ethylene and propylene may also be processed to produce organic chemicals such as ethylene oxide and acrolein which form the basis for many chemical products.
  • Ethylene oxide and acrolein can be produced by oxidation of ethylene and propylene, respectively.
  • Ethylene oxide can be used as an ingredient in many surfactant and detergent compositions to produce ethylene glycol and other glycol esters.
  • Acrolein can be used in the preparation of polyester resin, polyurethane, propylene glycol, acrylic acid, acrylonitrile, and glycerol.

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