US20150144527A1 - Method for enhanced upgrading of heavy oil by adding a hydrotreating step to an upgrading process - Google Patents

Method for enhanced upgrading of heavy oil by adding a hydrotreating step to an upgrading process Download PDF

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Publication number
US20150144527A1
US20150144527A1 US14/550,080 US201414550080A US2015144527A1 US 20150144527 A1 US20150144527 A1 US 20150144527A1 US 201414550080 A US201414550080 A US 201414550080A US 2015144527 A1 US2015144527 A1 US 2015144527A1
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Prior art keywords
mixture
bar
upgrading
transporting
catalyst
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Abandoned
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US14/550,080
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English (en)
Inventor
Mazin M. Fathi
Omer Refa Koseoglu
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Saudi Arabian Oil Co
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Saudi Arabian Oil Co
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Priority to US14/550,080 priority Critical patent/US20150144527A1/en
Assigned to SAUDI ARABIAN OIL COMPANY reassignment SAUDI ARABIAN OIL COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: FATHI, MAZIN M., KOSEOGLU, OMER REFA
Publication of US20150144527A1 publication Critical patent/US20150144527A1/en
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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
    • 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
    • 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
    • C10G65/12—Treatment of hydrocarbon oils by two or more hydrotreatment processes only plural serial stages only including cracking steps and other hydrotreatment 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
    • 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
    • C10G69/06—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 thermal cracking in the absence of hydrogen
    • 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
    • C10G2300/70—Catalyst aspects
    • 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
    • C10G2300/70—Catalyst aspects
    • C10G2300/703—Activation

Definitions

  • This invention relates to an improvement in methods for processing heavy oils to convert them into useful, lighter products. More particularly, it relates to a method for improving a catalytic hydrothermal aquathermolysis process, by adding a hydrotreating step to the process.
  • Residual and heavy hydrocarbon oils contain heteroatoms, heavy aromatic molecules, and asphaltenes, all of which adversely impact the potential of these starting materials to be upgraded to more valuable, lighter products.
  • Thermal cracking of heavy oil has been used, worldwide, (i) to crack these heavy oils to obtain lighter products, and to reject carbon in the form of coke, or (ii) to decrease the viscosity of the heavy oils for transportation.
  • thermal processes available; including delayed coking, fluid coking, and thermal coking.
  • Delayed coking which is a well-known technique, uses thermal decomposition of heavy liquid hydrocarbons to produce coke, gas, and liquid products at different boiling temperature ranges.
  • the resulting coke is generally treated as a low value by-product, and is recovered or not, depending on its quality.
  • Thermal cracking is a mild, thermal cracking process, used to lower the viscosity of heavy oils.
  • the degree of conversion of the starting material is compromised by low asphaltene stability limits.
  • RFCC Residue Fluid Catalytic Cracking
  • CCR Conradson Carbon Residue
  • asphaltenes asphaltenes
  • metal content in feedstocks.
  • Hydrocracking requires a high hydrogen supply, in order to maintain high hydrogen partial pressures.
  • the upgrading of heavy oil is dependent on three factors: (i) the type or origin of the heavy oil, (ii) its composition (e.g., asphaltene and polycyclic aromatic content), and the technology used. Of these, only technology is under the control of the investigator.
  • Processes for upgrading heavy oils via catalytic hydrothermal aquathermolysis is a known technology. It results in better conversion rates, and lower costs to implement, as compared to other processes.
  • the invention involves an improvement to this known process in that a hydrotreating step is added.
  • This step allows the artisan to increase upgrade process severity, improve product yields and quality, and provides a source of hydrogen for the entire process.
  • the invention relates to a method for processing heavy oils in a catalytic, aquathermolysis process, wherein the process further comprises hydrotreating the starting material.
  • the process requires the use of a catalyst, and the hydrotreating step is carried out at conditions which include temperatures ranging from about 300° C. to about 500° C., preferably from 380° C. to 450° C. and pressures ranging from about 50 kg/cm 2 to about 100 kg/cm 2 or from about 1 to about 200 Bar, preferably from about 50 Bar to about 180 Bar.
  • FIG. 1 shows an embodiment of the invention where hydrotreating takes place downstream of a feedstock preparation unit.
  • FIG. 2 shows an embodiment where the hydrotreating takes place upstream of the feedstock preparation unit.
  • FIG. 3 shows an embodiment of the invention where hydrotreating takes place downstream of the upgrading unit.
  • the feedstock/catalyst preparation unit consists of the vessels 102 , 107 and 109 as shown in FIG. 1 .
  • the heavy oil is mixed with an upgrading metallic catalyst precursor, water and hydrogen, and then heated in a furnace and sent to the decomposition reactor 108 to form the catalytic suspension.
  • a feedstock 101 having a boiling point greater than about 300° C. is added to a mixer 102 , which contains a catalyst together with aromatic rich hydrocarbons 103 , metal containing catalyst precursors 104 , and water 105 . This results in a catalytic slurry emulsion 106 , which is heated via heater 107 , and then moves to a decomposition reactor 108 operated at 300-500° C.
  • the catalyst is formed and the mixture is referred to as a catalytic suspension.
  • the catalytic suspension is routed to a low pressure separator 109 .
  • the bottom product from the low pressure separator is then preheated in the preheater 110 , before entering into a hydrotreater 111 , where the hydrogenation step occurs, using hydrogen 112 and the hydrotreating catalyst.
  • the resulting, hydrotreated effluent is separated in a fractionation zone 113 such that unreacted hydrogen is recycled to the hydrotreater, contaminant gases such as H 2 S and NH 3 are separated, while low weight materials, e.g., C 1 -C 4 hydrocarbons such as naphtha which boil at a temperature of 36-180° C., and hydrocarbons which boil at gas oil range (180-375° C.), are sent to a light products recovery unit, while heavier bottom products are mixed with water to form a slurry, optionally with hydrogen, and moved to a reactor 114 where catalytic hydrothermal aquathermolysis takes place, i.e., further upgrading of the heavy oil. This can be done via, e.g., thermal and/or catalytic cracking.
  • the upgraded oil is then dispatched to a fractionator 115 , where light weight fractions are removed, unconverted heavy oils are then recycled back to the mixer 102 , while the light gases, hydrocarbons which boil in naphtha at 36-180° C.), and gas oil range (180-375° C.), are sent to the light product recovery unit.
  • the fractionator may include multiple vessels to separate gas, liquid and aqueous phases.
  • FIG. 2 shows a feedstock 201 , also having a boiling point above 300° C., which is introduced, together with hydrogen 202 , into a hydrotreating reactor 203 , which contains a hydrotreating catalyst. Action of the catalyst on the mixture of feedstock and hydrogen results in a first effluent. This effluent moves to a fractionator 204 , where contaminant gases like H 2 S and NH 3 , light gases (C 1 -C 4 gases), hydrocarbons boiling in naphtha range (36-180° C.) and in gas oil range (180-375° C.), are separated, 205 .
  • contaminant gases like H 2 S and NH 3 , light gases (C 1 -C 4 gases), hydrocarbons boiling in naphtha range (36-180° C.) and in gas oil range (180-375° C.
  • the heavy bottoms, 206 are passed to a feedstock/catalyst preparation unit 207 .
  • the catalytic suspension from the feedstock/catalyst preparation unit 207 is then heated and sent to the upgrading reactor 208 (the catalytic hydrothermal aquathermolysis reactor).
  • the reactor effluent is sent to the fractionator 209 to separate the light fractions produced in the prior step (i.e., waste gases, light gases, naphtha and gas oil fractions).
  • the unreacted materials can be recycled to the hydrotreatment reactor, for further upgrading cycles.
  • the fractionation zone can include multiple vessels to separate gas, liquid and aqueous phases.
  • FIG. 3 one sees an embodiment of the invention where a hydrotreating unit is downstream of an upgrading unit.
  • hydrocarbons having a boiling point above 300° C., 301 are mixed with upgrading catalysts in a feedstock/catalyst preparation unit 302 , and then sent to a heater and decomposition reactor to produce the catalytic suspension, which is then heated in the charge heater.
  • the heated feedstock is then sent to the upgrading reactor 303 (the catalytic hydrothermal aquathermolysis zone for upgrading via further cracking.
  • the upgraded oil is then sent to a fractionator zone 304 , which separates light products described in embodiments 1 and 2, supra, while the heavy bottom is sent to a hydrotreater 306 , which contains a hydrotreating catalyst.
  • the resulting hydrotreated effluent is sent to a fractionator zone 305 , where light materials are separated, and the unconverted oil is recycled back to feedstock preparation unit 302 for further upgrading cycle.
  • the fractionation zones may include multiple vessels to separate gas, liquid and aqueous phases.
  • the hydrotreating reactor can be, e.g., a fixed bed, ebullated bed, moving bed, slurry, or CSTR.
  • Every reactor described herein may be single or multiple, depending upon the composition of the feedstock, the nature of contaminant, and/or the specification of the desired product. As an example, if the feedstock metal content is high, a separate reactor is used to remove the metals. When the metal content is low, one may only need a demetallization catalyst bed, in one reactor.
  • the catalysts used in the invention are those known to be used in the art for the stated purposes, especially those which contain one or more active metal components from Groups VI, VII, and/or VIII B of the Periodic Table plus alkali and alkaline metals and mixtures thereof. All catalysts are preferably incorporated, deposited, or in some way made part of a support, such as an alumina, alumina silica, silica, or zeolite support.
  • preferred conditions comprise a temperature of 300-500° C., a pressure of from 1-200 Bar, LHSV of from 0.1 1 -3.0 h ⁇ 1 , and a hydrogen/oil ratio of 500-2500 :L/L. More preferably, the temperature range is from 380-450° C., the pressure ranges from 1-100 Bar, the LHSV ranges from 0.5-1.0 h ⁇ 1 , and the hydrogen/oil ratio is preferably 1000-1500 L/L.
  • the preferred and especially preferred ranges are as above for hydrotreating.
  • Preferred pressures are from 30-200 Bar, preferably 30-100 Bar.
  • the LHSV is preferably 0.1-20.0 h ⁇ 1
  • the hydrogen/oil ratio is as above for hydrotreating.
  • the water/oil ratio may vary according to the skilled artisan.

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  • Chemical & Material Sciences (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)
  • Catalysts (AREA)
US14/550,080 2013-11-25 2014-11-21 Method for enhanced upgrading of heavy oil by adding a hydrotreating step to an upgrading process Abandoned US20150144527A1 (en)

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US201361908345P 2013-11-25 2013-11-25
US14/550,080 US20150144527A1 (en) 2013-11-25 2014-11-21 Method for enhanced upgrading of heavy oil by adding a hydrotreating step to an upgrading process

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US (1) US20150144527A1 (fr)
EP (1) EP3074487A1 (fr)
JP (1) JP2017500435A (fr)
KR (1) KR102339837B1 (fr)
CN (1) CN106029840A (fr)
SA (1) SA516371201B1 (fr)
WO (1) WO2015077558A1 (fr)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2021262639A1 (fr) * 2020-06-25 2021-12-30 Saudi Arabian Oil Company Procédé de valorisation d'huile lourde à l'aide d'hydrogène et d'eau
US20220372378A1 (en) * 2021-05-24 2022-11-24 Saudi Arabian Oil Company Catalyst and process to upgrade heavy oil
US20220372381A1 (en) * 2021-05-24 2022-11-24 Saudi Arabian Oil Company Integrated slurry hydroprocessing catalyst and process
US11680028B2 (en) 2019-01-29 2023-06-20 Sabic Global Technologies B.V. Methods and systems for upgrading crude oils, heavy oils, and residues
US11827857B2 (en) 2019-01-29 2023-11-28 Sabic Global Technologies B.V. Conversion of heavy ends of crude oil or whole crude oil to high value chemicals using a combination of thermal hydroprocessing, hydrotreating with steam crackers under high severity conditions to maximize ethylene, propylene, butenes and benzene

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10385282B2 (en) 2016-11-14 2019-08-20 Korea Institute Of Energy Research Method and system for upgrading and separating hydrocarbon oils

Citations (4)

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US3317419A (en) * 1964-06-01 1967-05-02 Universal Oil Prod Co Multiple-stage cascade hydrorefining of contaminated charge stocks
US4430442A (en) * 1982-07-20 1984-02-07 Exxon Research And Engineering Co. Catalysts from molybdenum polysulfide precursors and their preparation
US6043182A (en) * 1997-04-11 2000-03-28 Intevep, S.A. Production of oil soluble catalytic precursors
US20100065474A1 (en) * 2008-09-18 2010-03-18 Julie Chabot Systems and Methods for Producing a Crude Product

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US20020112987A1 (en) * 2000-12-15 2002-08-22 Zhiguo Hou Slurry hydroprocessing for heavy oil upgrading using supported slurry catalysts
US7431822B2 (en) * 2005-12-16 2008-10-07 Chevron U.S.A. Inc. Process for upgrading heavy oil using a reactor with a novel reactor separation system
US9669381B2 (en) * 2007-06-27 2017-06-06 Hrd Corporation System and process for hydrocracking
CN102197115B (zh) * 2008-09-18 2014-09-10 雪佛龙美国公司 用于生产粗产品的系统和方法
CA2737367C (fr) * 2008-09-18 2018-03-06 Chevron U.S.A. Inc. Systemes et procedes de production d'un produit brut
EP2782977B1 (fr) * 2011-11-21 2019-09-04 Saudi Arabian Oil Company Procedé et systeme d'hydrocracquage en suspension

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3317419A (en) * 1964-06-01 1967-05-02 Universal Oil Prod Co Multiple-stage cascade hydrorefining of contaminated charge stocks
US4430442A (en) * 1982-07-20 1984-02-07 Exxon Research And Engineering Co. Catalysts from molybdenum polysulfide precursors and their preparation
US6043182A (en) * 1997-04-11 2000-03-28 Intevep, S.A. Production of oil soluble catalytic precursors
US20100065474A1 (en) * 2008-09-18 2010-03-18 Julie Chabot Systems and Methods for Producing a Crude Product

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11680028B2 (en) 2019-01-29 2023-06-20 Sabic Global Technologies B.V. Methods and systems for upgrading crude oils, heavy oils, and residues
US11827857B2 (en) 2019-01-29 2023-11-28 Sabic Global Technologies B.V. Conversion of heavy ends of crude oil or whole crude oil to high value chemicals using a combination of thermal hydroprocessing, hydrotreating with steam crackers under high severity conditions to maximize ethylene, propylene, butenes and benzene
WO2021262639A1 (fr) * 2020-06-25 2021-12-30 Saudi Arabian Oil Company Procédé de valorisation d'huile lourde à l'aide d'hydrogène et d'eau
US11286429B2 (en) * 2020-06-25 2022-03-29 Saudi Arabian Oil Company Process for heavy oil upgrading utilizing hydrogen and water
US20220372378A1 (en) * 2021-05-24 2022-11-24 Saudi Arabian Oil Company Catalyst and process to upgrade heavy oil
US20220372381A1 (en) * 2021-05-24 2022-11-24 Saudi Arabian Oil Company Integrated slurry hydroprocessing catalyst and process

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Publication number Publication date
SA516371201B1 (ar) 2021-06-23
KR20160103991A (ko) 2016-09-02
JP2017500435A (ja) 2017-01-05
WO2015077558A1 (fr) 2015-05-28
CN106029840A (zh) 2016-10-12
KR102339837B1 (ko) 2021-12-15
EP3074487A1 (fr) 2016-10-05

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