US20140001089A1 - Method for hydrotreating heavy hydrocarbon feedstocks using permutable reactors, including at least one step of short-circuiting a catalyst bed - Google Patents

Method for hydrotreating heavy hydrocarbon feedstocks using permutable reactors, including at least one step of short-circuiting a catalyst bed Download PDF

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Publication number
US20140001089A1
US20140001089A1 US13/978,546 US201113978546A US2014001089A1 US 20140001089 A1 US20140001089 A1 US 20140001089A1 US 201113978546 A US201113978546 A US 201113978546A US 2014001089 A1 US2014001089 A1 US 2014001089A1
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Prior art keywords
catalyst
bed
reactor
feed
beds
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Frederic Bazer-Bachi
Christophe Boyer
Isabelle Guibard
Nicolas Marchal
Cecile Plain
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IFP Energies Nouvelles IFPEN
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IFP Energies Nouvelles IFPEN
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Assigned to IFP Energies Nouvelles reassignment IFP Energies Nouvelles ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MARCHAL, NICOLAS
Publication of US20140001089A1 publication Critical patent/US20140001089A1/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
    • B01J8/02—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds
    • B01J8/04—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds the fluid passing successively through two or more beds
    • 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
    • C10G65/00—Treatment of hydrocarbon oils by two or more hydrotreatment processes only
    • C10G65/02—Treatment of hydrocarbon oils by two or more hydrotreatment processes only plural serial stages only
    • C10G65/04—Treatment of hydrocarbon oils by two or more hydrotreatment processes only plural serial stages only including only refining steps
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
    • C10G2300/20—Characteristics of the feedstock or the products
    • C10G2300/201—Impurities
    • C10G2300/202—Heteroatoms content, i.e. S, N, O, P
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
    • C10G2300/20—Characteristics of the feedstock or the products
    • C10G2300/201—Impurities
    • C10G2300/205—Metal content
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
    • C10G2300/20—Characteristics of the feedstock or the products
    • C10G2300/201—Impurities
    • C10G2300/205—Metal content
    • C10G2300/206—Asphaltenes
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
    • C10G2300/20—Characteristics of the feedstock or the products
    • C10G2300/201—Impurities
    • C10G2300/208—Sediments, e.g. bottom sediment and water or BSW

Definitions

  • the present invention relates to a process for hydrotreating a heavy hydrocarbon fraction using a system of switchable fixed bed guard zones each containing at least two catalyst beds and in which whenever the catalyst bed that is brought initially into contact with the feed is deactivated and/or clogged during the steps in which the feed passes successively through all the guard zones, the point of introduction of the feed is shifted downstream.
  • the present invention also relates to an installation for implementing this process.
  • Hydrotreating of hydrocarbon feeds is becoming increasingly important in refining practice with the increasing need to reduce the quantity of sulphur in petroleum cuts and to convert heavy fractions to lighter fractions, which can be upgraded as fuels and/or chemical products. It is in fact necessary, in view of the standard specifications imposed by each country for commercial fuels, for imported crudes, which have higher and higher contents of heavy fractions, of heteroatoms and of metals, and lower and lower hydrogen contents, to be upgraded as far as possible.
  • Catalytic hydrotreating makes it possible, by bringing a hydrocarbon feed into contact with a catalyst in the presence of hydrogen, to reduce its content of asphaltenes, metals, sulphur and other impurities considerably, while improving the ratio of hydrogen to carbon (H/C) and while transforming it more or less partially into lighter cuts.
  • hydrotreating in particular means reactions of hydrodesulphurization (HDS) by which are meant the reactions for removing sulphur from the feed with production of H 2 S, reactions of hydrodenitrogenation (HDN) by which are meant the reactions for removing nitrogen from the feed with production of NH 3 , and reactions of hydrodemetallization by which are meant the reactions for removing metals from the feed by precipitation, but also hydrogenation, hydrodeoxygenation, hydrodearomatization, hydroisomerization, hydrodealkylation and hydro-deasphalting.
  • HDS hydrodesulphurization
  • HDN hydrodenitrogenation
  • hydrodemetallization by which are meant the reactions for removing metals from the feed by precipitation, but also hydrogenation, hydrodeoxygenation, hydrodearomatization, hydroisomerization, hydrodealkylation and hydro-deasphalting.
  • the technology of the fixed bed processes has found the widest industrial application owing to its technical maturity, lower cost and stable and reliable performance.
  • the feed circulates through several fixed bed reactors arranged in series, the first reactor(s) being used in particular for performing hydrodemetallization of the feed (so-called HDM step) as well as a proportion of hydrodesulphurization, the last reactor(s) being used for performing deep refining of the feed (hydrotreating step, HDT), and in particular hydrodesulphurization (so-called HDS step).
  • the effluents are withdrawn from the last HDT reactor.
  • the fixed bed processes lead to high performance in refining (production of 370° C. + cuts with less than 0.5 wt. % of sulphur and containing less than 20 ppm of metals) from feed containing up to 5 wt. % of sulphur and up to 300 ppm of metals, in particular nickel and vanadium).
  • the various effluents thus obtained can serve as a basis for the production of heavy fuel oils of good quality, of gas oil and gasoline, or feeds for other units such as catalytic cracking.
  • the first catalyst beds can quickly be deactivated because of the considerable deposit of metals that is produced.
  • the temperature of the reactor is then increased.
  • this increase in temperature promotes the deposition of coke, accelerating the processes of intragranular clogging (plugging of the catalyst pores) and extragranular clogging (plugging of the catalyst bed). Beyond these contents of metals in the feed, ebullating bed processes are thus generally preferred.
  • the main task of the guard beds is to protect the catalysts of the main HDM and HDT reactors downstream, by performing a proportion of the demetallization and by filtering the particles contained in the feed that can lead to clogging.
  • the guard beds are generally integrated in the HDM section in a process for hydrotreating heavy feeds generally including a first HDM section and then a second HDT section.
  • the guard beds are generally used for performing a first hydrodemetallization and a filtration, other hydrotreating reactions (HDS, HDN, etc.) will inevitably take place in these reactors owing to the presence of hydrogen and a catalyst.
  • the HDM step comprises one or more fixed bed HDM zones preceded by at least two guard HDM zones, also called “switchable reactors”, also of fixed bed design, arranged in series to be used cyclically consisting of successive repetition of steps b) and c) defined below:
  • This process can provide an overall desulphurization greater than 90% and an overall demetallization of the order of 95%.
  • the use of switchable reactors permits continuous cyclic operation.
  • the present invention thus improves the performance of switchable reactors as described by the applicant in patent FR2681871 by integrating into this process at least two catalyst beds in each switchable reactor and by integrating into certain steps of the process at least one step of by-passing deactivated and/or clogged catalyst beds, also called a by-pass step.
  • clogging occurs a priori in the upper portions of the catalyst beds, and in particular in the upper portions of the first catalyst bed brought into contact with the feed in the direction of flow.
  • deactivation of the catalyst deposition of metals.
  • this catalyst bed is by-passed and the point of introduction of the feed is shifted relative to this bed downstream onto the next catalyst bed, not yet deactivated and/or clogged, of the same switchable reactor.
  • the volume of each switchable reactor is fully utilized until it is exhausted (i.e.
  • This lengthening of the cycle leads to an increase in the operating factor of the unit as well as a saving of time, a reduction of operating costs and a reduction of the consumption of fresh catalyst.
  • the aim of the present application is thus to increase the cycle time of the switchable reactors.
  • the present invention provides an improvement of the hydrotreating process carried out using guard zones (switchable reactors) as described in patent FR2681871.
  • the operation of the guard zones according to FR2681871 is described in FIG. 1 , comprising two guard zones (or switchable reactors) R 1 a and R 1 b .
  • This hydrotreating process comprises a series of cycles each comprising four successive steps:
  • step a) of the process the feed is introduced via line 3 and line 21 , having an open valve V 1 , into line 21 ′ and the guard reactor R 1 a containing a fixed catalyst bed A.
  • valves V 3 , V 4 and V 5 are closed.
  • the effluent from reactor R 1 a is sent via pipe 23 , pipe 26 , having an open valve V 2 , and pipe 22 ′ into the guard reactor R 1 b containing a fixed catalyst bed B.
  • the effluent from reactor R 1 b is sent via pipes 24 and 24 ′, having an open valve V 6 , and pipe 13 to the main hydrotreating section 14 .
  • valves V 1 , V 2 , V 4 and V 5 are closed and the feed is introduced via line 3 and line 22 , having an open valve V 3 , into line 22 ′ and reactor R 1 b .
  • the effluent from reactor R 1 b is sent via pipes 24 and 24 ′, having an open valve V 6 , and pipe 13 to the main hydrotreating section 14 .
  • valves V 1 , V 2 and V 6 are closed and valves V 3 , V 4 and V 5 are open.
  • the feed is introduced via line 3 and lines 22 and 22 ′ into reactor R 1 b .
  • the effluent from reactor R 1 b is sent via pipe 24 , pipe 27 , having an open valve V 4 , and pipe 21 ′ to the guard reactor R 1 a .
  • the effluent from reactor R 1 a is sent via pipes 23 and 23 ′, having an open valve V 5 , and pipe 13 to the main hydrotreating section 14 .
  • valves V 2 , V 3 , V 4 and V 6 are closed and valves V 1 and V 5 are open.
  • the feed is introduced via line 3 and lines 21 and 21 ′ into reactor R 1 a .
  • the effluent from reactor R 1 a is sent via pipes 23 and 23 ′, having an open valve V 5 , and pipe 13 to the main hydrotreating section 14 .
  • steps a′ and c′ additional by-pass steps of deactivated and/or clogged catalyst beds in the steps of the cycle during which the feed passes successively through the two reactors (steps a) and c)), are added to the process steps as described above.
  • the present invention relates to a process for hydrotreating a heavy hydrocarbon fraction containing asphaltenes, sediments, sulphur-containing, nitrogen-containing and metallic impurities, in which the feed of hydrocarbons and hydrogen is passed, under conditions of hydrotreating, over a hydrotreating catalyst, in at least two fixed bed hydrotreating guard zones each containing at least two catalyst beds, the guard zones being arranged in series to be used cyclically, consisting of successive repetition of steps b), c) and c′) defined below:
  • the guard zones in particular the first guard zone brought into contact with the feed, gradually become laden with metals, coke, sediments and various other impurities.
  • the zones must be disconnected for carrying out replacement and/or regeneration of the catalyst(s).
  • the catalysts are replaced. This moment is called the deactivation time and/or clogging time.
  • the deactivation time and/or clogging time varies in relation to the feed, the operating conditions and the catalyst(s) used, it is generally manifested by a drop in catalyst performance (an increase in the concentration of metals and/or other impurities in the effluent), an increase in the temperature required for maintaining constant hydrotreating or, in the specific case of clogging, by a significant increase in head loss.
  • the head loss ⁇ p expressing a degree of clogging, is measured continuously throughout the cycle on each of the zones and can be defined by an increase in pressure resulting from partially blocked passage of the flow through the zone.
  • the temperature is also measured continuously throughout the cycle on each of the two zones.
  • a person skilled in the art first defines a maximum tolerable value of the head loss ⁇ p and/or of the temperature as a function of the feed to be treated, the operating conditions and catalysts selected, and starting from which it is necessary to proceed to by-passing of a catalyst bed or to disconnection of the guard zone.
  • the deactivation time and/or clogging time is thus defined as the time when the limit value of head loss and/or of temperature is reached.
  • the limit value of head loss and/or of temperature is confirmed during initial commissioning of the reactors.
  • the limit value of head loss is generally between 0.3 and 1 MPa (3 and 10 bar), preferably between 0.5 and 0.8 MPa (5 and 8 bar).
  • the limit value of temperature is generally between 400° C. and 430° C., the temperature corresponding, here and hereinafter, to the average measured temperature of the catalyst bed.
  • Another limit value for the temperatures, indicating that deactivation is reached (lower level of exothermic reactions), is that the temperature difference ( ⁇ T) on a catalyst bed becomes less than 5° C., regardless of the average temperature value.
  • FIG. 2 shows the hydrotreating process according to the present invention using a system of two switchable reactors each containing two catalyst beds and in which the catalyst beds can be by-passed.
  • the process comprises a series of cycles each having six successive steps, steps a), b), c) and d) being identical to the process described in FR2681871:
  • step a) the feed is introduced via line 3 and lines 21 and 21 ′, having an open valve V 1 , into the guard reactor R 1 a and passes through the fixed beds A 1 and A 2 .
  • valves V 1 ′, V 3 , V 3 ′, V 4 and V 5 are closed.
  • the effluent from reactor R 1 a is sent via pipe 23 , pipe 26 , having an open valve V 2 , and pipe 22 ′ to the guard reactor R 1 b and passes through the catalyst beds B 1 and B 2 .
  • the effluent is removed from reactor R 1 b via pipes 24 and 24 ′, having an open valve V 6 , and pipe 13 .
  • the catalyst beds, and in particular the first catalyst bed, on being brought into contact with the feed (A 1 of reactor R 1 a ), will become clogged and/or deactivated.
  • the moment when it is considered that the first catalyst bed brought into contact with the feed is deactivated and/or clogged is measured from the head loss ⁇ p and/or temperature of a guard zone.
  • a maximum tolerable value for the head loss and/or temperature from which it is necessary either to by-pass the deactivated and/or clogged catalyst bed, or to proceed with replacement of the catalyst in the reactor is defined beforehand.
  • the catalyst bed that is clogged and/or deactivated is by-passed by introducing the feed by a by-pass device outside the reactor onto the next catalyst bed not yet deactivated and/or clogged downstream of said reactor.
  • valve V 1 is closed and the feed is introduced via line 31 , having an open valve V 1 ′, onto the next catalyst bed A 2 in reactor R 1 a (step a′).
  • the deactivated and/or clogged catalyst bed A 1 is therefore by-passed.
  • Catalyst bed A 2 is much less clogged and/or deactivated than the first bed A 1 , permitting a considerable increase in the length of the first period, by using the lower bed A 2 for a longer time.
  • step b) is then carried out, during which the feed passes through all the catalyst beds of reactor R 1 b only, reactor R 1 a being by-passed for catalyst regeneration and/or replacement.
  • valves V 1 , V 1 ′, V 2 , V 3 ′, V 4 and V 5 are closed and the feed is introduced via line 3 and lines 22 and 22 ′, having an open valve V 3 , into reactor R 1 b .
  • the effluent from reactor R 1 b is removed via pipes 24 and 24 ′, having an open valve V 6 , and via pipe 13 .
  • step c) of the process is then carried out, during which the feed passes successively through reactor R 1 b , then reactor R 1 a .
  • valves V 1 , V 1 ′, V 2 , V 3 ′ and V 6 are closed and valves V 3 , V 4 and V 5 are open.
  • the feed is introduced via line 1 and lines 22 and 22 ′ into reactor R 1 b .
  • the effluent from reactor R 1 b is sent via pipe 24 , pipe 27 , having an open valve V 4 , and pipe 21 ′ to the guard reactor R 1 a .
  • the effluent from reactor R 1 a is removed via pipes 23 and 23 ′, having open valve V 5 , and via pipe 13 .
  • step c′ by-passing of the deactivated and/or clogged catalyst bed B 1 , called step c′), is carried out.
  • valve V 3 is closed and the feed is introduced into the reactor via line 32 , having an open valve V 3 ′, onto the next bed B 2 in reactor R 1 b .
  • the deactivated and/or clogged catalyst bed B 1 is therefore by-passed.
  • the catalyst bed B 2 is much less clogged and/or deactivated than the first catalyst bed B 1 , permitting a considerable increase in the length of the third period, by using the lower bed B 2 for a longer time.
  • step d) is then carried out, during which the feed passes through all the catalyst beds of reactor R 1 a only, reactor R 1 b being by-passed for catalyst regeneration and/or replacement.
  • valves V 1 ′, V 2 , V 3 , V 3 ′, V 4 and V 6 are closed and valves V 1 and V 5 are open.
  • the feed is introduced via line 3 and lines 21 and 21 ′ into reactor R 1 a .
  • the effluent from reactor R 1 a is removed via pipes 23 and 23 ′, having open valve V 5 , and via pipe 13 .
  • the system of switchable reactors with external by-pass can be extended to reactors having more than two catalyst beds, for example 3, 4 or 5 catalyst beds.
  • the external by-pass feeds, by additional lines and valves, respectively, the next catalyst bed downstream of the deactivated and/or clogged catalyst bed once the maximum value of head loss and/or of temperature is reached.
  • step a′) or c′) as defined above is repeated.
  • This by-passing of catalyst beds can continue until the last catalyst bed of the reactor in the direction of flow is deactivated and/or clogged. It is then necessary to replace the catalyst contained in the reactor.
  • steps a), a′), b), c) c′) and d) are identical to FIG. 2 , except that steps a′) and c′) are repeated. This repetition only will be described for this figure.
  • step a′ once catalyst bed A 1 , and then catalyst bed A 2 are deactivated and/or clogged, valve V 1 ′ is closed and the feed is introduced via line 33 , having an open valve V 1 ′′, onto the next catalyst bed A 3 in reactor R 1 a .
  • step b) replacement/regeneration of reactor R 1 a
  • step c′ once catalyst bed B 1 , and then catalyst bed B 2 are deactivated and/or clogged, valve V 3 ′ is closed and the feed is introduced via line 34 , having an open valve V 3 ′′, onto the next catalyst bed B 3 in reactor R 1 b .
  • step d) replacement/regeneration of reactor R 1 b
  • the catalyst beds contained in a guard zone can be of different or identical volumes but with the condition that the volume of the last bed is greater than each volume of the other beds.
  • the catalyst beds in one and the same guard zone have volumes that increase in the direction of flow. In fact, since clogging and/or deactivation occurs mainly on the first catalyst bed, it is advantageous to minimize the volume of this first bed.
  • the volume of each bed can be defined as follows:
  • Each guard zone has n beds, each bed i having a volume V i , the total catalyst volume of the reactor V tot being the sum of the volumes V i of the n beds:
  • V tot V 1 + . . . V i +V i+1 . . . +V n ⁇ 1 +V n
  • Each volume V i of a bed i included in the n ⁇ 1 first beds of the guard zone is defined between 5% of the total volume V tot and the percentage resulting from the total volume V tot divided by the number of beds n:
  • the volume of the first bed V i is less than or equal to the volume of the next bed V i+1 , except for the last two consecutive beds V n ⁇ 1 and where the volume of the penultimate bed V n ⁇ 1 is strictly less than the volume of the last bed V n .
  • the volume V 1 of the first bed is thus between 5 and 49%, the volume of the second bed is between 51 and 95%.
  • the volume V 1 of the first bed is thus between 5 and 33%
  • the volume V 2 of the second bed is between 5 and 33%
  • the volume V 3 of the third bed is between 34 and 90%.
  • the maximum volume of the by-passed catalyst bed(s) in a guard zone during steps a′) and c′), also called “by-passable fraction”, is the sum of the volumes V 1 + . . . V i +V i+1 . . . +V n ⁇ 1 of the n ⁇ 1 beds (or the total volume minus the volume of the last bed n).
  • This maximum volume of the by-passed catalyst bed(s) is defined as being less than the percentage expressed by the formula ((n ⁇ 1) V tot )/n, n being the bed number in a guard zone, V tot being the total catalyst volume of the guard zone.
  • a catalyst conditioning section is used, allowing these guard zones to be switched while in operation, i.e. without stopping the operation of the unit: first, a system that operates at moderate pressure (from 10 to 50 bar, but preferably from 15 to 25 bar) allows the following operations to be performed on the disconnected guard reactor: washing, stripping, cooling, before discharging the used catalyst; then heating and sulphurization after loading the fresh catalyst; then another system for pressurization/depressurization, with gate valves of appropriate design, permits efficient switching of these guard zones without stopping the unit, i.e.
  • moderate pressure from 10 to 50 bar, but preferably from 15 to 25 bar
  • a pre-activity catalyst can be used in the conditioning section so as to simplify the procedure for switching while in operation.
  • Each guard zone contains at least two catalyst beds (for example 2, 3, 4, or 5 catalyst beds).
  • Each catalyst bed contains at least one catalyst layer containing one or more catalysts, optionally supplemented with at least one inert layer.
  • the catalysts used in the catalyst bed(s) may be identical or different.
  • the hydrotreating process using switchable reactors with external by-pass can thus greatly increase the duration of a cycle.
  • the feed has a shorter residence time in the switchable reactors because of the by-pass.
  • the temperature in the guard zones is thus gradually increased.
  • the latter is also increased overall during the cycle to counteract the catalyst deactivation.
  • this temperature increase promotes the deposition of coke, accelerating the processes of clogging.
  • the by-passed fraction must be all the more restricted.
  • the reactor fraction that is by-passed is thus based on optimization between the gain in cycle time and limited temperature rise.
  • each guard zone passes through a filtering distributor plate composed of a single stage or of two successive stages, said plate is situated upstream of the catalyst beds, preferably upstream of each catalyst bed.
  • This filtering distributor plate described in patent US2009177023, makes it possible to trap the clogging particles contained in the feed by means of a special distributor plate comprising a filtering medium.
  • the filtering plate makes it possible to increase the gain of cycle time in the hydrotreating process using switchable guard zones.
  • This filtering plate simultaneously provides distribution of the gas phase (hydrogen and the gaseous portion of the feed) and the liquid phase (the liquid portion of the feed) feeding the reactor while providing a filtration function with respect to the impurities contained in the feed.
  • the filtering plate ensures a more uniform distribution of the mixture over the whole surface of the catalyst bed and limits the problems of poor distribution during the phase of clogging of the plate itself.
  • the filtering plate is a device for filtration and distribution, said device comprising a plate situated upstream of the catalyst bed, said plate consisting of a base that is approximately horizontal and integral with the walls of the reactor and to which approximately vertical chimneys are fixed, open at the top for admission of the gas, and at the bottom for removing the gas-liquid mixture intended to feed the catalyst bed situated downstream, said chimneys being pierced over a certain fraction of their height by a continuous lateral slit or by lateral orifices for admission of liquid, said plate supporting a filtering bed surrounding the chimneys, and said filtering bed consisting of at least one layer of particles of size less than or equal to the size of the particles of the catalyst bed.
  • the filtering bed consists of particles that are generally inert but can also comprise at least one layer of catalyst identical to or belonging to the same family as the catalyst of the catalyst bed. This last-mentioned variant makes it possible to reduce the volume of catalyst beds in the reactor.
  • the filtering distributor plate can also comprise two stages and be composed of two successive plates: the first plate supporting a guard bed composed of internal particles and of at least one layer of catalyst identical to or belonging to the same family as the catalyst of the catalyst bed.
  • This plate is described in patent US2009177023.
  • the bed is arranged on a grating, the liquid phase flows through the guard bed and the gas through the chimneys passing through the guard bed and the first plate.
  • the second plate provides the function of distribution of the gas and liquid: it can be composed of chimneys with lateral perforations for passage of the liquid or be composed of bubble-caps or vapour-lift.
  • the hydrotreating process according to the present invention can comprise more than two switchable reactors (for example 3, 4 or 5) functioning according to the same principle of switching and by-pass, each switchable reactor having at least two catalyst beds.
  • FIG. 4 shows the case of three guard zones each having two catalyst beds.
  • the process will comprise, in its preferred embodiment, a series of cycles each having nine successive steps:
  • valves V 1 , V 2 , V 7 and V 8 are open and valves V 1 ′, V 3 , V 3 ′, V 5 , V 6 , V 9 , V 10 and V 10 ′ are closed.
  • valves V 1 ′, V 2 , V 7 , V 8 are open and valves V 1 , V 3 , V 3 ′, V 5 , V 6 , V 9 , V 10 and V 10 ′ are closed.
  • valves V 3 , V 7 and V 8 are open and valves V 1 , V 1 ′, V 2 , V 3 ′, V 5 , V 6 , V 9 , V 10 and V 10 ′ are closed.
  • valves V 3 , V 7 , V 9 and V 5 are open and valves V 1 , V 1 ′, V 2 , V 3 ′, V 6 , V 8 , V 10 and V 10 ′ are closed.
  • valves V 3 ′, V 7 , V 9 and V 5 are open and valves V 1 , V 1 ′, V 2 , V 3 , V 6 , V 8 , V 10 and V 10 ′ are closed.
  • valves V 10 , V 9 and V 5 are open and valves V 1 , V 1 ′, V 2 , V 3 , V 3 ′, V 6 , V 7 , V 8 and V 10 ′ are closed.
  • valves V 10 , V 9 , V 2 and V 6 are open and valves V 1 , V 1 ′, V 3 , V 3 ′, V 5 , V 7 , V 8 and V 10 ′ are closed.
  • valves V 10 ′, V 9 , V 2 and V 6 are open and valves V 1 , V 1 ′, V 3 , V 3 ′, V 5 , V 7 , V 8 and V 10 are closed.
  • valves V 1 , V 2 and V 6 are open and valves V 1 ′, V 3 , V 3 ′, V 5 , V 7 , V 8 , V 9 , V 10 and V 10 ′ are closed.
  • the different variants of the process described above for a system of two switchable reactors having two catalyst beds also apply to a system having more than two switchable reactors.
  • These different variants are in particular: the conditioning system, the possibility of having more than two catalyst beds per reactor, the possibility of having beds with different volumes as defined above, the volume of the by-passed catalyst bed(s) in one guard zone being less than ((n ⁇ 1)Vtot)/n, maintaining the degree of hydrotreating by raising the temperature, integration of a filtering plate at the entrance of each reactor upstream of the first catalyst bed, preferably upstream of each catalyst bed.
  • the process according to the invention can advantageously be carried out at a temperature between 320° C. and 430° C., preferably 350° C. to 410° C., at a hydrogen partial pressure advantageously between 3 MPa and 30 MPa, preferably between 10 and 20 MPa, at a space velocity (HSV) advantageously between 0.05 and 5 volumes of feed per volume of catalyst and per hour, and with a ratio of hydrogen gas to liquid hydrocarbon feed advantageously between 200 and 5000 normal cubic metres per cubic metre, preferably 500 to 1500 normal cubic metres per cubic metre.
  • the value of HSV of each switchable reactor in operation is preferably from about 0.5 to 4 h ⁇ 1 and most often from about 1 to 2 h ⁇ 1 .
  • the overall value of HSV of the switchable reactors and that of each reactor is selected so as to achieve maximum HDM while controlling the reaction temperature (limiting the exothermic effect).
  • the hydrotreating catalysts used are preferably known catalysts and are generally granular catalysts comprising, on a support, at least one metal or metal compound having a hydro-dehydrogenating function. These catalysts are advantageously catalysts comprising at least one group VIII metal, generally selected from the group comprising nickel and/or cobalt, and/or at least one group VIB metal, preferably molybdenum and/or tungsten.
  • the support used is generally selected from the group comprising alumina, silica, silica-aluminas, magnesia, clays and mixtures of at least two of these minerals.
  • the catalysts used in the process according to the present invention are preferably subjected to a sulphurization treatment for transforming, at least partly, the metallic species to sulphide before they are brought into contact with the feed to be treated.
  • This treatment of activation by sulphurization is well known to a person skilled in the art and can be carried out by any method already described in the literature, either in situ, i.e. in the reactor, or ex situ.
  • the feeds treated in the process according to the invention are advantageously selected from atmospheric residues, vacuum residues from direct distillation, crude oils, topped crude oils, deasphalted oils, residues from conversion processes such as for example those originating from coking, from fixed-bed, ebullating-bed, or moving-bed hydroconversion, heavy oils of any origin and in particular those obtained from oil sands or oil shale, used alone or mixed.
  • feeds can advantageously be used as they are or diluted with a hydrocarbon fraction or a mixture of hydrocarbon fractions that can be selected from the products obtained from a fluid catalytic cracking (FCC) process, a light cut of oil (Light Cycle Oil, LCO), a heavy cut of oil (Heavy Cycle Oil, HCO), a decanted oil (DO), a residue from FCC, or that can be obtained from distillation, the gas oil fractions, in particular those obtained by vacuum distillation (Vacuum Gas Oil, VGO).
  • FCC fluid catalytic cracking
  • LCO Light Cycle Oil
  • HCO Heavy Cycle Oil
  • DO decanted oil
  • VGO vacuum distillation
  • the heavy feeds can also advantageously comprise cuts obtained from the coal liquefaction process, aromatic extracts, or any other hydrocarbon cuts or also non-petroleum feeds such as gaseous and/or liquid derivatives (containing little if any solids) from thermal conversion (with or without catalyst and with or without hydrogen) of coal, biomass or industrial waste, such as for example recycled polymers.
  • Said heavy feeds generally have more than 1 wt. % of molecules having a boiling point above 500° C., a content of metals Ni+V above 1 ppm by weight, preferably above 20 ppm by weight, a content of asphaltenes, precipitated in heptane, above 0.05 wt. %, preferably, above 1 wt. %.
  • the hydrotreating process according to the invention makes it possible to effect 50% or more of HDM of the feed at the outlet of the switchable reactors (and more precisely from 50 to 95% of HDM) owing to the HSV selected and the efficiency of the HDM catalyst.
  • the hydrotreating process according to the invention using the system of switchable guard zones including at least one by-pass step advantageously precedes a fixed bed or ebullating bed process for hydrotreating heavy hydrocarbon feeds.
  • the process according to the invention is preferably integrated upstream of the HDM section, the switchable reactors being used as guard beds.
  • the feed 1 enters the switchable guard reactor(s) via pipe 1 and leaves said reactor(s) via pipe 13 .
  • the feed leaving the guard reactor(s) enters, via pipe 13 , the hydrotreating section 14 and more precisely the HDM section 15 comprising one or more reactors.
  • the effluent from the HDM section 15 is withdrawn via pipe 16 , and then sent to the HDT section 17 comprising one or more reactors.
  • the final effluent is withdrawn via pipe 18 .
  • the present invention also relates to an installation ( FIG. 2 ) for implementing the process according to the invention comprising at least two fixed bed reactors (R 1 a , R 1 b ) arranged in series and each containing at least two catalyst beds (A 1 ,A 2 ; B 1 ,B 2 ), the first bed of each reactor having at least one inlet pipe for a gas (not shown) and an inlet pipe for a hydrocarbon feed ( 21 , 22 ), said inlet pipes for the feed each containing a valve (V 1 , V 3 ) and being connected by a common pipe ( 3 ), each reactor having at least one outlet pipe ( 23 , 24 ) each containing a valve (V 5 , V 6 ) for removal of the effluent, the outlet pipe of each reactor ( 23 , 24 ) being connected by an additional pipe ( 26 , 27 ) having a valve (V 2 , V 4 ) to the inlet pipe ( 22 , 21 ) of the feed of the reactor downstream, characterized in that the installation further
  • the installation comprises a filtering distributor plate composed of a single stage or of two successive stages at the entrance of each reactor, situated upstream of the catalyst beds, preferably upstream of each catalyst bed.
  • the feed consists of a mixture (70/30 wt. %) of atmospheric residue (AR) of Middle East origin (Arabian Medium) and of a vacuum residue (VR) of Middle East origin (Arabian Light).
  • This mixture is characterized by a high viscosity (0.91 cP) at ambient temperature, a density of 994 kg/m 3 , high contents of Conradson carbon (14 wt. %) and asphaltenes (6 wt. %) and a high level of nickel (22 ppm by weight), vanadium (99 ppm by weight) and sulphur (4.3 wt. %).
  • the hydrotreating process is carried out according to the process described in FR2681871 and comprises the use of two switchable reactors.
  • the two reactors are loaded with a CoMoNi/alumina hydrodemetallization catalyst.
  • a cycle is defined as integrating the steps from a) to d).
  • the deactivation time and/or clogging time is reached when the head loss reaches 0.7 MPa (7 bar) and/or the average temperature of a bed reaches 405° C. and/or when the temperature difference on a catalyst bed becomes less than 5° C.
  • Table 3 and FIG. 5 show the operating time (in days) for the process according to FR 2681871 (without by-pass).
  • the operating time of reactor R 1 a is therefore 210 days.
  • the head loss in reactor R 1 b reached about 3 bar.
  • the deactivation time and/or clogging time (or the operating time) of the first zone is therefore 210 days. Overall, a cycle time of 320 days for the first cycle and of 627 days for two cycles is observed.
  • the hydrotreating process is repeated with the same feed and under the same operating conditions and with the same catalyst according to example 1, except that the process comprises the use of two switchable reactors, each reactor containing two catalyst beds, the first catalyst bed representing a volume of 20%, and the second representing a volume of 80% (by-pass of 20%), and the process according to the invention is carried out.
  • a cycle is defined as integrating the steps from a) to d).
  • the deactivation time and/or clogging time is reached when the head loss reaches 0.7 MPa (7 bar) and/or the average temperature of a bed reaches 405° C. and/or when the temperature difference on a catalyst bed becomes less than 5° C.
  • the degree of HDM is maintained at 60%.
  • Table 3 and FIG. 5 show the gain in operating time (in days) for the process according to the invention with a by-passed fraction of 20% in each reactor.
  • the hydrotreating process integrating a by-passed fraction of 20% makes it possible to increase the duration of a first cycle by 60 days (i.e. by 18.75%) and by 114 days for two cycles (i.e. by 18.2%) while maintaining a degree of HDM of 75%, equivalent to the degree of HDM according to the process without external by-pass.
  • FIG. 5 shows the variation of head loss during the time measured in reactors R 1 a and R 1 b without external by-pass (according to FR2681871, curves for the Base Cases R 1 a and R 1 b ) and in reactors R 1 a and R 1 b with an external by-pass of 20% (according to the invention, curves PRS ByP R 1 a and R 1 b ).
  • the first bed is by-passed and the feed is introduced onto the second bed A 2 of reactor R 1 a .
  • the head loss in the reactor then drops suddenly (hook in curve PRS ByP R 1 a ), without returning to the initial head loss, to gradually increase again up to the point where the next (second) bed is clogged and the limit value of the head loss is reached again.
  • step a′ The gain in time obtained at the end of step a′) is then ⁇ t C1-R1a (32 days).
  • the head loss of reactor R 1 a then drops abruptly because the system passes to step b), during which the catalyst of reactor R 1 a is replaced.
  • the feed then only passes through reactor R 1 b , and then R 1 b and R 1 a after replacement.
  • Curve R 1 b (curve PRS ByP R 1 b ) shows the head loss of the second reactor R 1 b as a function of time. The same phenomenon of gain of time by external by-pass is observed at the end of step c′): ⁇ t C2-R1b (60 days).
  • FIG. 2 also shows a second cycle of switchable reactors.
  • the gain of time after 2 successive cycles is then ⁇ t C2-R1b (114 days). It can be seen that the more cycles there are, the larger the gain of time.

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EP3620499A1 (fr) * 2018-09-06 2020-03-11 INDIAN OIL CORPORATION Ltd. Procédé de production sélective d'oléfines légères et de composés aromatiques à partir de naphtha léger craqué
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US11136513B2 (en) 2017-02-12 2021-10-05 Magëmä Technology LLC Multi-stage device and process for production of a low sulfur heavy marine fuel oil from distressed heavy fuel oil materials
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