WO2005037958A1 - Procede de craquage catalytique fluide active par tensioactif - Google Patents

Procede de craquage catalytique fluide active par tensioactif Download PDF

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Publication number
WO2005037958A1
WO2005037958A1 PCT/US2004/032223 US2004032223W WO2005037958A1 WO 2005037958 A1 WO2005037958 A1 WO 2005037958A1 US 2004032223 W US2004032223 W US 2004032223W WO 2005037958 A1 WO2005037958 A1 WO 2005037958A1
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WO
WIPO (PCT)
Prior art keywords
surfactant
process according
amount
mixture
fcc
Prior art date
Application number
PCT/US2004/032223
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English (en)
Inventor
Ramesh Varadaraj
George A. Swan, Iii
James D. Dearth
Stuart S. Goldstein
W. Russell Adamson
Original Assignee
Exxonmobil Research And Engineering Company
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Exxonmobil Research And Engineering Company filed Critical Exxonmobil Research And Engineering Company
Priority to JP2006534109A priority Critical patent/JP2007510007A/ja
Priority to EP04793928A priority patent/EP1678277A1/fr
Priority to AU2004282502A priority patent/AU2004282502B2/en
Priority to US10/574,764 priority patent/US20070267323A1/en
Priority to CA002542297A priority patent/CA2542297A1/fr
Publication of WO2005037958A1 publication Critical patent/WO2005037958A1/fr

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Classifications

    • 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
    • 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

Definitions

  • the present invention relates generally to the atomization of fluids. More particularly, the invention is concerned with enhancing the atomization of fluids, especially fluidized cat cracker (FCC) feeds, by using a surfactant to alter the interfacial tension between the fluid and atomizing media.
  • FCC fluidized cat cracker
  • Atomizing a fluid by passing it through an orifice into a lower pressure zone to produce a spray of droplets is a technique used in a wide variety of applications and processes.
  • FCC fluidized catalytic cracking
  • relatively viscous petroleum feeds are converted into more valuable products including gasoline, jet fuel, and heating oil.
  • a preheated oil feed is mixed with steam and the resulting two-phase fluid is passed into a lower pressure atomization zone in which the oil is atomized and brought into contact with a particulate, hot, cracking catalyst whereby the feed is converted into lower boiling products.
  • the present invention is directed a surfactant-enhanced atomization process.
  • the process comprises: a) mixing an effective amount of at least one surfactant with an atomization fluid to form a first mixture; b) injecting said first mixture into a fluidized catalytic cracking feedstream to form a second mixture; and c) conducting said second mixture through a feed nozzle.
  • the present invention comprises: a) mixing an effective amount of at least one surfactant with an atomization fluid to form a first mixture; b) injecting said first mixture into a fluidized catalytic cracking feedstream to form a second mixture; c) conducting said second mixture through a feed nozzle into a fluidized catalytic cracking reaction zone, thereby producing droplets of the second mixture and injecting them into the reaction zone; and d) contacting the droplets of the second mixture with a FCC catalyst under effective catalytic cracking conditions in the reaction zone thereby producing at least an FCC product stream comprising at least C 2 _ dry gas and spent catalyst comprising strippable hydrocarbons.
  • the effective amount of the at least one surfactant is that amount sufficient to reduce the amount of C 2- dry gas in the FCC product stream, relative to the amount of C 2- dry gas in the FCC product stream in the absence of the surfactant.
  • the instant invention further comprises: a) fractionating said FCC product stream to produce at least a naphtha boiling range product stream.
  • the effective amount of the at least one surfactant is that amount sufficient to reduce the amount of C 2- dry gas in the FCC product stream without causing foaming in the FCC unit.
  • the effective amount of the at least one surfactant is that amount sufficient to reduce the amount of C 2- dry gas in the FCC product stream without causing foaming, haze, or increasing the oxygenate content of the naphtha boiling range product.
  • Figure 1 is a plot showing the dynamic interfacial tension (denoted as dynamic IFT) of two different surfactants in water.
  • Figures 2 and 3 show plots of mean droplet diameter vs. steam weight % for oil and steam additized with a surfactant (squares) and oil and steam with no additive (diamonds).
  • the present invention is directed a surfactant-enhanced fluid catalytic cracking process.
  • an effective amount of at least one surfactant is mixed with an atomization fluid to form a first mixture.
  • the first mixture is subsequently injected into a fluidized catalytic cracking ("FCC") feedstream to form a second mixture, which is conducted through a feed nozzle.
  • FCC fluidized catalytic cracking
  • the invention further comprises conducting the second mixture through a feed nozzle into a fluidized catalytic cracking reaction zone, thereby producing droplets of the second mixture and injecting them into a reaction zone.
  • the droplets of the second mixture are contacted with a FCC catalyst under effective cracking conditions to produce at least an FCC product stream and spent catalyst comprising strippable hydrocarbons.
  • an effective amount of at least one surfactant is mixed with an atomization fluid to form a first mixture.
  • Any surfactant that can reduce the static and dynamic interfacial tension between an FCC feedstream and an atomizing fluid may be used.
  • Preferred surfactants suitable for use in the present invention are any of those surfactants known to be thermally stable under feed preheating but will decompose under the effective cracking conditions used herein.
  • the at least one surfactant does not contain components containing sulfur, nitrogen and metals.
  • suitable surfactants include non-ionic surfactants and mixtures thereof having hydrophilic lipophilic balance values (HLBs) in the range of about 3 to about 20.
  • Non-limiting examples of such surfactants include alkyl alkoxylates, preferably alkyl ethoxylates, mixtures of aldehydes and ketones, preferably alkyl aldehyde acids and ketones, more preferably alkyl aromatic aldehydes and ketones and acids.
  • the atomizing fluid may comprise subcooled water (water having a temperature above its normal atmospheric pressure boiling point at pressure sufficient to maintain it in a liquid state), steam, light hydrocarbon gas (C 4 -), inert gases and/or combinations thereof.
  • Light hydrocarbon gases include, but are not limited to methane, ethane, ethylene, acetylene, propane, propylene, propyne, butane and butenes and combinations thereof.
  • Inert gases as used herein include, but are not limited to, helium, hydrogen, nitrogen, argon, and other suitable inert gases and combinations thereof. It is preferred that the atomizing fluid be steam.
  • the first mixture i.e. the mixture of surfactants and atomizing fluid
  • the first mixture may be prepared either by any one or a combination of methods.
  • Non-limiting examples of preparing the first mixture include adding the surfactant to the atomizing fluid, vaporizing the surfactant and introducing the vaporized surfactant into the atomizing fluid, and adding the surfactant to water and heating the surfactant solution to provide a steam and surfactant mixture.
  • alkyl alkoxylate type surfactants are particularly suitable at treat rates in the range of about 25 ppm to 50,000 ppm based on the weight of steam, and preferably in the range of 50 to 10,000 ppm.
  • alkyl alkyloxylates represented by formulae I to III: RO(R 5 0) n H
  • R is a linear or branched alkyl group of about 3 to 24 carbon atoms; R 1 , R ⁇ ,
  • R3 and R ⁇ are independently alkoxylate groups, (R ⁇ O) m H where R ⁇ is an alkylene group of about 2 to 4 carbon atoms and m is from about 1 to 20, preferably from about 1 to 15, more preferably about 1 to 5, and more preferably about 1 to 3.
  • surfactants have a formula according to surfactant III above are used, it is preferred to use it in combination with an alkyl sorbitan of structure IV.
  • R is an alkyl group of 3 to 24 carbon atoms.
  • the ratio of surfactant III/IV is preferably between about 95/5 to 30/20 and more preferably about 80/20 to 30/70 and even more preferably 75/25 to 50/50.
  • any surfactants of the type I, II, III and IV discussed above may be used, alone or in mixtures.
  • an FCC feedstream containing a suitable surfactant can also be used.
  • the amount of surfactant generally is in the range of 50 to 20,000 ppm based on the weight of the FCC feedstream, preferably in the range of 50 to 5,000 ppm.
  • a petroleum oil containing alkyl substituted 1, 2 and 3 ring aromatic compounds may be oxidized to generate a suitable mixture of oxidized products suitable as additives for the invention.
  • the oxidization is conducted by heating the oil from about 150°C to about 200°C, in the presence of air for a time sufficient, typically about 4 hours, to produce the oxidized products suitable as additives for the invention. Typically such oxidation produces aldehydes, ketones and acids.
  • the first mixture is subsequently injected into a fluidized catalytic cracking feedstream to form a second mixture.
  • the method of injecting the first mixture into the FCC feedstream is not critical to the instant invention and can be accomplished by any means known for injecting an atomizing fluid into a hydrocarbonaceous material.
  • suitable injection methods include mixing tees, spargers, and injection devices.
  • Any conventional FCC feed can be used in the present invention.
  • Such feeds typically include heavy hydrocarbonaceous feeds boiling in the range of about 430°F to about 1050°F (220-565°C), such as gas oils, heavy hydrocarbon oils comprising materials boiling above 1050°F (565°C); heavy and reduced petroleum crude oil; petroleum atmospheric distillation bottoms; petroleum vacuum distillation bottoms; pitch, asphalt, bitumen, other heavy hydrocarbon residues; tar sand oils; shale oil; liquid products derived from coal liquefaction processes; and mixtures thereof
  • the FCC feed may also comprise recycled hydrocarbons, such as light or heavy cycle oils.
  • an effective amount of a surfactant is mixed with an atomizing fluid to form the first mixture that is injected into the FCC feedstream.
  • an effective amount of a surfactant is to be considered that amount of surfactant capable of reducing the static and dynamic interfacial tension between the FCC feedstream and atomizing fluid.
  • an effective amount of surfactant is about 25 to about 50,000 wppm, based on the atomization fluid, more preferably about 25 to about 10,000, most preferably about 25 to about 5,000. Reducing the interfacial tension results in a narrow distribution of small droplets of the second mixture when it is conducted through the feed nozzle.
  • an effective amount of surfactant be that amount effective at reducing the static and dynamic interfacial tension between the FCC feedstream and atomizing fluid by at least 50%.
  • an effective amount of surfactant or mixture of surfactants will be that amount sufficient to reduce the static and dynamic interfacial tension between the FCC feedstream and atomizing fluid such that the droplets formed by conducting the second mixture through a feed nozzle have a mean droplet diameter less than about 1000 ⁇ , preferably less than 500 ⁇ .
  • the above-described second mixture is conducted through a feed nozzle into a fluidized catalytic cracking reaction zone.
  • the droplets of the second mixture having the above-described droplet size, are contacted with a FCC catalyst under effective catalytic cracking conditions in the reaction zone.
  • any FCC cracking catalyst can be used.
  • Effective cracking conditions include: (i) temperatures from about 500°C to about 650°C, preferably from about 525°C to 600°C; (ii) hydrocarbon partial pressures from about 10 to 40 psia (70-280 kPa), preferably from about 20 to 35 psia (140-245 kPa); and, (iii) a catalyst to feed (wt/wt) ratio from about 1:1 to 12:1, preferably from about 4: 1 to 10: 1, where the catalyst weight is the total weight of the catalyst composite.
  • the contacting of the second mixture and the FCC catalyst produces at least an FCC product stream comprising at least C 2- dry gas and spent catalyst comprising strippable hydrocarbons.
  • C 2- dry gas as used herein is meant to refer to the gasses produced by the FCC cracking reaction that have a chemical makeup and boiling point range of C 2 and below, i.e. methane, ethane, H 2 , C ⁇ such as ethylene, etc.
  • Thermal cracking produces increased amounts of dry gas while effective catalytic cracking produces less C 2 . dry gas than thermal cracking.
  • An efficient FCC produces lower amounts of C 2 . dry gas by promoting increased catalytic cracking and decreased thermal cracking.
  • the efficiency of the present process is noted by a reduction in C 2- dry gas in the FCC product stream.
  • an effective amount of surfactant is further to be considered an amount of surfactant sufficient to reduce the amount of C 2 _ dry gas in the FCC product stream.
  • a naphtha boiling range product is meant to refer to hydrocarbon streams boiling in the range of about 50°F (10°C) to about 450°F (232°C).
  • the method by which the FCC product stream is fractionated is not critical to the instant invention, and any type of fractionation known can be used. For example, atmospheric or vacuum distillation may be employed in fractionating the FCC product stream.
  • an effective amount of surfactant is further defined as that amount of surfactant sufficient to reduce the amount of C 2- dry gas in the FCC product stream without causing foaming, haze, or increasing the oxygenate content of said naphtha boiling range product stream.
  • Controlling the haze, etc. of the naphtha boiling range product stream is important because it is typically used as a blending component for motor gasolines. It should be noted that haze is typically a result of water entrapment in the naphtha boiling range product.
  • an effective amount of surfactant is further defined as that amount of surfactant sufficient to reduce the amount of C 2- dry gas in the FCC product stream without causing foaming in the FCC process unit.
  • Neodol 91-2.5E a primary alcohol ethoxylate surfactant commercially available from Shell Chemicals was added to atomization steam in an amount of 1000 wppm, based on the atomization steam mass flow rate.
  • This surfactant- enhanced atomization steam was used to atomize an FCC feed whose properties are listed below: Gravity, API 19.1 Carbon, wt% 84.7 Hydrogen, wt% 11.57 Nitrogen, wppm 1504 Sulfur, wt% 2.964 5% / 50% / 95% BP (wt) 516 / 798 / 990°F
  • the injection of additized steam continued for a period of 2 to 3 hours.
  • the FCC unit was operated under constant conditions including an oil feed rate of 16.9 kbbl/day, 3.7 klb/hr atomization steam, riser outlet temperature of 1005°F, and a catalyst to oil weight ratio of 9.5 lbs. catalyst/lb. of oil.
  • Base line samples with no surfactant and samples obtained during surfactant addition showed no difference in foam height or foam stability.
  • the LCN was analyzed for haze by visual examination of the sample.
  • Base line samples with no surfactant and samples obtained during surfactant addition showed no difference in haze.
  • a sample of the FCC feed (containing the surfactant-enhanced atomization fluid) was also analyzed by for interfacial tension. About a 5% reduction in each hydrogen, ethane, and ethylene in dry gas samples was observed during the surfactant addition period.
  • Neodol 91-2.5E primary alcohol ethoxylate surfactant used in Example 1 was added to atomization steam in an amount of 2000 wppm, based on the steam mass flow rate.
  • This surfactant-enhanced atomization fluid was used to atomize a FCC feed with the following properties: Gravity, API 19.0 Carbon, wt% 86.41 Hydrogen, wt% 11.73 Nitrogen, wppm 1510 Sulfur, wt% 2.92 5% / 50% / 95% BP (wt) 513 / 796 / 991 °F
  • Neodol 91 -2.5E primary alcohol ethoxylate surfactant used in Example 1 was added to atomization steam in an amount of 5000 wppm, based on the steam mass flow rate.
  • This surfactant-enhanced atomization fluid was used to atomize an FCC feed with the following properties: Gravity, API 18.7 Carbon, wt% 85.1 Hydrogen, wt% 11.67 Nitrogen, wppm 1663 Sulfur, wt% 2.979 5% / 50% / 95% BP (wt) 511 / 804 / 1003 °F
  • Span 80, Tween-80, Brij-35, Brij-58 and Brij-700 surfactants were used to additize water.
  • Span, Tween and Brij are trademarks of ICI Americas, Inc.
  • the chemical structure of the Brij, Tween and Span surfactants is the same as formula II, III and IV respectively as previously given.
  • Neodol 91 -2.5E a surfactant which is a trademark of Shell Chemicals was used to additize water.
  • the chemical structures of the surfactant is shown below: R-0-(CH 2 -CH 2 -0) m -H
  • the FCC feed oil/water interfacial tension at 2000 ppm treat rate of Neodol in water was determined by the pendant drop method at 176°F (80°C)) (Table 2). At least 70% reduction in interfacial tension was observed for the Neodol additive.
  • the samples were heated to 212°F (100°C) with vigorous mixing to produce steam. Steam was collected and condensed in a receiving vessel. Surface tension was measured on the distilled water containing 1000 ppm surfactant and on the condensed water in the receiving vessel. Surface tension of water was 72 dynes/cm. Values of surface tension lower than 72 dynes/cm indicate the presence of surfactants in water. Identical surface tensions for the distilled water containing 2000 ppm surfactant and for the condensed water in the receiving vessel indicate that the surfactants vaporize with steam. The results are shown in Table 3.
  • the superheated steam and oil was mixed in a T-junction, and passed through a feed injector, 120 mm long and 1.4 mm in diameter.
  • the pressure and temperature of the oil and steam mixture were monitored at the T-junction using a thermocouple and a pressure gauge.
  • the oil and steam mixture was sprayed horizontally into an exhaust system, which separated the oil from the steam.
  • a Malvern particle diameter analyzer was positioned 3 inches from the exit of the feed injector. Drop sizes were obtained at each operating condition for three separate runs. Good repeatability between the runs was observed. The flow rate was maintained within +/- 2% during the duration of data collection. The temperature was also maintained within +/- 2°C during the same period. Figure 2 shows the results, namely a reduction in droplet size.
  • Neodal 91-2.5E was added to water at a treat rate to produce 2000 ppm of Neodol based on the weight of steam, the water heated to produce a mixture of steam and additive and the mixture was then mixed with the oil in a T-junction. Thereafter the procedure as with oil additization was followed.

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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)
  • Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)

Abstract

L'invention a trait à un procédé permettant d'améliorer l'atomisation d'un fluide injecté dans une zone d'atomisation, par l'ajout au fluide d'une quantité efficace d'un adjuvant permettant de réduire la contrainte interfaciale statique et dynamique des composants du fluide.
PCT/US2004/032223 2003-10-10 2004-10-01 Procede de craquage catalytique fluide active par tensioactif WO2005037958A1 (fr)

Priority Applications (5)

Application Number Priority Date Filing Date Title
JP2006534109A JP2007510007A (ja) 2003-10-10 2004-10-01 界面活性剤で強化された流動接触分解プロセス
EP04793928A EP1678277A1 (fr) 2003-10-10 2004-10-01 Procede de craquage catalytique fluide active par tensioactif
AU2004282502A AU2004282502B2 (en) 2003-10-10 2004-10-01 Surfactant enhanced fluid catalytic cracking process
US10/574,764 US20070267323A1 (en) 2003-10-10 2004-10-01 Surfactant Enhance Fluid Catalytic Cracking Process
CA002542297A CA2542297A1 (fr) 2003-10-10 2004-10-01 Procede de craquage catalytique fluide active par tensioactif

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US51020103P 2003-10-10 2003-10-10
US60/510,201 2003-10-10
US60466104P 2004-08-25 2004-08-25
US60/604,661 2004-08-25

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WO2005037958A1 true WO2005037958A1 (fr) 2005-04-28

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US (1) US20070267323A1 (fr)
EP (1) EP1678277A1 (fr)
JP (1) JP2007510007A (fr)
AU (1) AU2004282502B2 (fr)
CA (1) CA2542297A1 (fr)
WO (1) WO2005037958A1 (fr)

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9109177B2 (en) 2011-12-12 2015-08-18 Ensyn Renewables, Inc. Systems and methods for renewable fuel
WO2014210150A1 (fr) 2013-06-26 2014-12-31 Ensyn Renewables, Inc. Systèmes et procédés pour carburant renouvelable
MY193949A (en) 2016-12-29 2022-11-02 Ensyn Renewables Inc Demetallization Of Liquid Biomass

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4405445A (en) 1981-08-24 1983-09-20 Ashland Oil, Inc. Homogenization of water and reduced crude for catalytic cracking
US5173175A (en) 1990-04-27 1992-12-22 Exxon Research And Engineering Company Fcc feed injector
US5289976A (en) 1991-12-13 1994-03-01 Mobil Oil Corporation Heavy hydrocarbon feed atomization
GB2313131A (en) 1996-05-17 1997-11-19 Exxon Research Engineering Co Fluidized catalytic cracking of heavy hydrocarbons
EP0933123A2 (fr) 1998-01-30 1999-08-04 ExxonMobil Oil Corporation Buse d'alimentation à pulvérisation par pression et procédé d'utilisation correspondant
US6093310A (en) 1998-12-30 2000-07-25 Exxon Research And Engineering Co. FCC feed injection using subcooled water sparging for enhanced feed atomization
US6352639B2 (en) 1999-08-26 2002-03-05 Exxon Research And Engineering Company Superheating atomizing steam with hot FCC feed oil

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4483765A (en) * 1983-06-27 1984-11-20 Nalco Chemical Company Oil-dispersible antimony oxide sol dispersed as an oil in water emulsion into a cracking feed
DE69803864T3 (de) * 1997-09-12 2006-06-01 Exxonmobil Research And Engineering Co. Wässrige emulsionen von fischer-tropschprodukten
US7553878B2 (en) * 2003-04-29 2009-06-30 General Electric Company Spray atomization

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4405445A (en) 1981-08-24 1983-09-20 Ashland Oil, Inc. Homogenization of water and reduced crude for catalytic cracking
US5173175A (en) 1990-04-27 1992-12-22 Exxon Research And Engineering Company Fcc feed injector
US5289976A (en) 1991-12-13 1994-03-01 Mobil Oil Corporation Heavy hydrocarbon feed atomization
GB2313131A (en) 1996-05-17 1997-11-19 Exxon Research Engineering Co Fluidized catalytic cracking of heavy hydrocarbons
EP0933123A2 (fr) 1998-01-30 1999-08-04 ExxonMobil Oil Corporation Buse d'alimentation à pulvérisation par pression et procédé d'utilisation correspondant
US6093310A (en) 1998-12-30 2000-07-25 Exxon Research And Engineering Co. FCC feed injection using subcooled water sparging for enhanced feed atomization
US6352639B2 (en) 1999-08-26 2002-03-05 Exxon Research And Engineering Company Superheating atomizing steam with hot FCC feed oil

Also Published As

Publication number Publication date
AU2004282502A1 (en) 2005-04-28
CA2542297A1 (fr) 2005-04-28
US20070267323A1 (en) 2007-11-22
EP1678277A1 (fr) 2006-07-12
JP2007510007A (ja) 2007-04-19
AU2004282502B2 (en) 2010-01-21

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