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
  • C10G1/00—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal
  • C10G1/002—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal in combination with oil conversion- or refining processes
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
  • 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
  • C10G1/00—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal
  • C10G1/10—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal from rubber or rubber waste
• • 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
  • C10G49/00—Treatment of hydrocarbon oils, in the presence of hydrogen or hydrogen-generating compounds, not provided for in a single one of groups C10G45/02, C10G45/32, C10G45/44, C10G45/58 or C10G47/00
  • C10G49/02—Treatment of hydrocarbon oils, in the presence of hydrogen or hydrogen-generating compounds, not provided for in a single one of groups C10G45/02, C10G45/32, C10G45/44, C10G45/58 or C10G47/00 characterised by the catalyst used
  • C10G49/04—Treatment of hydrocarbon oils, in the presence of hydrogen or hydrogen-generating compounds, not provided for in a single one of groups C10G45/02, C10G45/32, C10G45/44, C10G45/58 or C10G47/00 characterised by the catalyst used containing nickel, cobalt, chromium, molybdenum, or tungsten metals, or compounds thereof
• • 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
  • C10G49/00—Treatment of hydrocarbon oils, in the presence of hydrogen or hydrogen-generating compounds, not provided for in a single one of groups C10G45/02, C10G45/32, C10G45/44, C10G45/58 or C10G47/00
  • C10G49/10—Treatment of hydrocarbon oils, in the presence of hydrogen or hydrogen-generating compounds, not provided for in a single one of groups C10G45/02, C10G45/32, C10G45/44, C10G45/58 or C10G47/00 with moving solid particles
• • 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
• • 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
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10B—DESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS
  • C10B53/00—Destructive distillation, specially adapted for particular solid raw materials or solid raw materials in special form
  • C10B53/07—Destructive distillation, specially adapted for particular solid raw materials or solid raw materials in special form of solid raw materials consisting of synthetic polymeric materials, e.g. tyres
• • 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
  • C10G2300/10—Feedstock materials
  • C10G2300/1037—Hydrocarbon fractions
• • 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

Definitions

• the present invention relates to the field of hydroconversion of feeds comprising predominantly a heavy fraction of hydrocarbons, in particular a heavy fraction of hydrocarbons containing a portion of at least 50% by weight, preferably of at least 80% by weight, having a boiling temperature of at least 300°C, and a minor fraction of pyrolysis oil from plastics and/or solid recovered fuels (SRF), loaded with impurities.
• the heavy hydrocarbon fraction may be a crude oil or result from the distillation and/or refining of a crude oil, typically a topped crude oil, a residue from the atmospheric and/or vacuum distillation of a crude oil.
• the heavy hydrocarbon fraction is of the vacuum residue type composed of at least 50% by weight, preferably at least 80% by weight of hydrocarbons having a boiling temperature of at least 450°C. .
• the present invention relates to a process for hydroconversion of such a mixed feed, comprising at least one hydroconversion step using one or more reactors operating in a bubbling bed or in an entrained bubbling hybrid bed, and preferably two stages successive hydroconversions, with a view to producing higher quality materials, with a lower boiling point, for example for the production of fuels, or chemicals, while allowing the capture of impurities from the oil pyrolysis of plastics and/or CSR.
• plastics from collection and sorting sectors can undergo a pyrolysis step in order to obtain, among other things, pyrolysis oils.
• plastic pyrolysis oils are typically burned to generate electricity and/or used as fuel in industrial or district heating boilers.
• Solid recovered fuels also called “refuse derived fuel” (RDF), or “solid recovered fuels” (SRF) according to Anglo-Saxon terminology, are solid non-hazardous waste prepared for recovery. energy, whether they come from household and similar waste, waste from economic activities or construction-demolition waste.
• the CSRs are generally a mixture of any combustible waste such as used tires, food by-products (fats, animal meals, etc.), viscose and wood waste, light fractions from shredders (e.g. from vehicles used, electrical and electronic equipment (WEEE), household and commercial waste, residues from the recycling of various types of waste, including certain municipal waste, plastic waste, textiles, wood among others.
• CSR generally contain plastic waste.
• CSR are today mainly used as energy. They can be directly used as substitutes for fossil fuels in co-incineration installations (coal and lignite thermal power plants, cement plants, lime kilns) or in production units. incineration of household waste, or indirectly in pyrolysis units dedicated to energy recovery: CSR pyrolysis oils are thus generally burned to generate electricity, or even used as fuel in industrial or district heating boilers .
• Plastics and CSR pyrolysis oils can also be upgraded via refining processes to produce fuels, for example gasoline or diesel, and/or chemicals such as olefins for the production of various polymers of the 'chemical industry.
• plastic waste or CSR are generally mixtures of several polymers, for example mixtures of polyethylene, polypropylene, polyethylene terephthalate, polyvinyl chloride, polystyrene.
• plastics can contain, in addition to polymers, other compounds, such as plasticizers, pigments, dyes or even residues of polymerization catalysts, as well as other very varied impurities, organic and mineral, coming from the separation operations of sorting centers, an operation whose selectivity cannot be total.
• Oils resulting from the pyrolysis of plastics or CSR thus generally include a lot of diolefins and impurities, in particular metals, silicon, or even halogenated compounds, in particular compounds based on chlorine, heteroelements such as sulfur, oxygen and nitrogen, insolubles, at often high contents and which may be incompatible with certain refining units, such as fixed bed hydrotreatment units.
• Application WO2018/055555 proposes for example a global, very general and relatively complex recycling process for plastic waste, ranging from the very stage of pyrolysis of plastic waste to a steam cracking stage which makes it possible to produce highly recoverable products in the field of petrochemicals such as olefins and aromatic compounds.
• the process comprises, among other things, a step of hydrocracking the liquid phase resulting directly from pyrolysis, preferably in a fixed bed.
• Patent applications FR3107530, FR3113060 and FR31113061 describe processes for treating a plastic pyrolysis oil, comprising, among other things, a selective hydrogenation step of the plastic pyrolysis oil and a fixed bed hydrotreatment of the effluent hydrogen.
• the naphtha cut resulting from a water-specific separation of the hydrotreated effluent followed by fractionation of the separated hydrocarbon stream can be sent to a steam cracker or used as a fuel base.
• the process integrates one or two fixed bed hydrocracking stages after the hydrotreatment stage, to minimize the yield of the heavy cut and to maximize the yield of the naphtha cut by transforming the heavy cut at least partly in naphtha cut by hydrocracking, cut generally favored for a steam cracking unit.
• plastic pyrolysis oils Due to the impurity content of plastic pyrolysis oils, particularly when they are heavily loaded with impurities, we can observe a deactivation of the catalysts of the hydrotreatment unit which is operated in a fixed bed, which reduces the duration of cycle. Indeed, the main constraint of fixed bed units is the fact of having to shut down the unit to replace the catalysts.
• plastic pyrolysis oils particularly those heavily loaded with diolefins and impurities, can create blockage problems, particularly in preheating ovens, feed/effluent exchangers or on the headboards of fixed-bed catalytic reactors. .
• Unpublished patent application FR 20/09.750 describes a process for treating pyrolysis oil from plastics and/or CSR comprising, among other things, hydroconversion in a bubbling bed, in an entrained bed and/or in a moving bed of the charge , optionally previously hydrogenated.
• the feed contains at least 50% by weight of plastics pyrolysis oil and/or CSR, and preferably consists of plastics pyrolysis oil and/or CSR.
• Unpublished patent application FR 21/04.873 describes a process for treating a plastics and/or CSR pyrolysis oil close to application FR 20/09.750, in which there is in particular no step of separation between the hydroconversion stage and the hydrotreatment stage.
• Unpublished patent application FR 21/04.874 describes a process for the simultaneous treatment of a plastic pyrolysis oil and a filler from renewable sources, such as a vegetable oil, close to application 21/04.873, in in which the plastic pyrolysis oil, optionally previously hydrogenated, is sent to a hydrodemetallation step, then the demetalled effluent is sent to a hydrotreatment step.
• the hydrodemetallation and hydrotreatment steps can be carried out in an ebullated bed.
• the feedstock from renewable sources is introduced to the hydrogenation stage, and/or to the hydrodemetallation stage and/or to the hydrotreatment stage.
• the present invention relates to the field of the recovery of heavy loads that are difficult to recover such as petroleum residues, which generally contain high levels of impurities such as metals, sulfur, nitrogen, carbon Conradson and asphaltenes, to convert them into lighter products, usable as fuels, for example to produce gasoline or diesel, or raw materials for petrochemicals.
• heavy loads that are difficult to recover such as petroleum residues, which generally contain high levels of impurities such as metals, sulfur, nitrogen, carbon Conradson and asphaltenes, to convert them into lighter products, usable as fuels, for example to produce gasoline or diesel, or raw materials for petrochemicals.
• the inventors have demonstrated that, surprisingly, it was possible to incorporate a minor fraction of plastic and/or CSR pyrolysis oil, loaded with impurities, into a heavy hydrocarbon load of fossil origin, typically a residue vacuum, traditionally treated in a bubbling bed or bubbling hybrid entrained hydroconversion process, and thus improve the production of basic fuels and/or other recoverable hydrocarbons, while capturing in the supported catalyst of the hydroconversion stage the impurities initially present in the pyrolysis oil, such as silicon, which allows easier treatment of the products in downstream stages such as fixed bed hydrotreatment, and while maintaining good stability of the unconverted fraction.
• the present invention thus proposes a process for the hydroconversion of a heavy load of hydrocarbons of fossil origin, in particular of the vacuum residue type, in a bubbling or entrained bubbling hybrid bed, said load including a minor fraction of pyrolysis oil plastics and/or CSR, thus allowing the production of basic fuels and other recoverable hydrocarbons, and therefore the valorization of said fraction.
• the present invention proposes, according to a first aspect, a process for hydroconversion of a charge comprising a fraction of pyrolysis oil from plastics and/or solid recovered fuels and a heavy fraction of hydrocarbons of fossil origin containing a portion of at least 50% by weight having a boiling point of at least 300°C and containing sulfur and nitrogen, said fraction of pyrolysis oil constituting less than 50% by weight of said feed, said process comprising:
• step (c) optionally a step of separating part or all of said first effluent resulting from step (b), to form at least one heavy cut boiling mainly at a temperature greater than or equal to 350°C;
• step (d) optionally a second hydroconversion step in a second hydroconversion section comprising at least one second hydroconversion reactor with an ebullating bed or a bubbling-entrained hybrid bed of part or all of said first effluent resulting from the step (b) or optionally from said heavy cut from step (c), said second hydroconversion reactor comprising a second porous supported catalyst and operating in the presence of hydrogen, to produce a second hydroconverted effluent; step (b) and optional step (d) being carried out at an absolute pressure of between 2 MPa and 38 MPa, at a temperature of between 300°C and 550°C, at an hourly space speed of between 0.05 h 1 and 10 h 1 , and with a quantity of hydrogen between 50 Nm 3 /m 3 and 5000 Nm 3 /m 3 , (e) a step of fractionating all or part of said first hydroconverted effluent from step (b) or said second hydroconverted effluent from step (d), in a fractionation section,
• step (a) in step (a), the pyrolysis oil fraction and the heavy hydrocarbon fraction of the feed are mixed beforehand before their introduction into said at least one first reactor hydroconversion of the first hydroconversion section.
• step (a) the pyrolysis oil fraction of the feed is introduced separately from the heavy hydrocarbon fraction into said at least first hydroconversion reactor of the first hydroconversion section.
• step (a) comprises a step of preheating said heavy hydrocarbon fraction, preferably at a temperature between 280°C and 450°C, and optionally a step preheating the pyrolysis oil fraction, before introducing the feed into the first hydroconversion reactor of the first hydroconversion section.
• the fraction of pyrolysis oil constitutes between 1% and 45% by weight of the charge, preferably between 2% and 30% by weight of the charge, more preferably between 2% and 25% weight of the load, and even more preferably between 3% and 20% weight of the load.
• the feed consists of said pyrolysis oil fraction and said heavy hydrocarbon fraction, said pyrolysis oil fraction constituting between 1% and 45% by weight, of preferably between 2% and 30% by weight, of said charge and the heavy fraction of hydrocarbons constituting between 55% and 99% by weight, preferably between 70% and 98% by weight, of the charge.
• the pyrolysis oil fraction is a plastic pyrolysis oil.
• the heavy hydrocarbon fraction is chosen from the list consisting of a crude oil, a topped crude oil, an atmospheric residue or a vacuum residue resulting from atmospheric distillation and /or under vacuum of a crude oil or an effluent coming from a thermal conversion, hydrotreatment, hydrocracking or hydroconversion unit, an aromatic cut extracted from a lubricant production unit, an oil deasphalted from a deasphalting unit, an asphalt from a deasphalting unit, a residual fraction from the direct liquefaction of coal, a vacuum distillate from the direct liquefaction of coal, or their mixture.
• the heavy hydrocarbon fraction is a vacuum residue, preferably resulting from the primary fractionation of a crude oil.
• the process comprises the separation step (c) separating part, or all, of the first hydroconverted effluent from step (b) to produce at least the cut heavy boiling mainly at a temperature greater than or equal to 350°C, and comprising the second hydroconversion step (d) of said heavy cut.
• the hydroconversion reactor(s) of the first hydroconversion section in step (b), and optionally in the hydroconversion step (d), are hydroconversion reactors. bubbling-entrained hybrid bed, said method further comprising a step of introducing a catalyst precursor into the feed, preferably said catalyst precursor comprising molybdenum 2-ethylhexanoate, before injecting said feed into said at at least one first bubbling-entrained hybrid bed reactor of the first hydroconversion section, such that a colloidal or molecular catalyst, preferably comprising molybdenum disulfide, is formed when said feedstock reacts with sulfur.
• the first hydroconversion catalyst, and optionally the second hydroconversion catalyst contains at least one non-noble group VIII metal chosen from nickel and cobalt, preferably nickel, and at least one metal from group VIB chosen from molybdenum and tungsten, preferably molybdenum, and comprising an amorphous support, preferably alumina.
• step (b) and optional step (d) are carried out at a temperature between 405°C and 450°C.
• the optional intermediate separation step (c) is carried out in a separation section, and in which said separation section and/or the fractionation section in step (e ) comprise means for washing at least one cut separated by contact with an aqueous solution.
• the method further comprises a step (f) of subsequent treatment of the heavy liquid product and/or the other product(s) resulting from the fractionation step (e), said step (f) comprising at least one step chosen from the list consisting of hydrotreatment, steam cracking, catalytic cracking in a fluidized bed, hydrocracking, deasphalting, extraction of lubricating oils, and preferably a step of hydrotreatment (f 2) in a fixed bed in a hydrotreatment section, said hydrotreatment section comprising preferably at least one fixed bed reactor having n catalytic beds, n being an integer greater than or equal to 1, each comprising at least one hydrotreatment catalyst, said hydrotreatment section being supplied with at least part of a product liquid from step e) and a gas stream comprising hydrogen, to obtain a hydrotreated effluent.
• a step (f) of subsequent treatment of the heavy liquid product and/or the other product(s) resulting from the fractionation step (e) said step (f) comprising at least one step chosen from the list consisting of hydrotreatment
• the invention relates to a product obtained by the process according to the invention.
• the product is the hydroconverted effluent obtained at the end of the first hydroconversion step (b) or the second hydroconversion step (d), and comprises a liquid part comprising, for example relative to the total weight of said liquid part of the effluent, a silicon content less than or equal to 5 ppm by weight, and/or a chlorine element content less than or equal to 10 ppm by weight.
• FIG. 1 schematically illustrates an embodiment of the hydroconversion process according to the invention.
• FIG. 2 schematically illustrates another embodiment of the hydroconversion process according to the invention.
• the different ranges of values of given parameters can be used alone or in combination.
• a preferred range of pressure values may be combined with a more preferred range of temperature values, or a preferred range of values of one compound or chemical element may be combined with a more preferred range of values of another chemical compound or element.
• hydroconversion refers to a process whose primary purpose is to reduce the boiling point range of a feed comprising at least 50% of a heavy hydrocarbon fraction having a boiling point of at least 50%. least 300°C, or at least 450°C, and in which a substantial portion of the feedstock is converted to products with boiling point ranges lower than those of the original feedstock.
• Hydroconversion generally involves the fragmentation of larger hydrocarbon molecules into smaller molecular fragments possessing a smaller number of carbon atoms and a higher hydrogen to carbon ratio.
• the reactions carried out during hydroconversion make it possible to reduce the size of hydrocarbon molecules, mainly by cleavage of carbon-carbon bonds, in the presence of hydrogen in order to saturate the cut bonds and the aromatic rings.
• hydroconversion occurs typically involves the formation of hydrocarbon free radicals during fragmentation primarily by thermal cracking, followed by capping of the free radical termini or fragments with hydrogen in the presence of active catalyst sites .
• other reactions typically associated with hydrotreatment can occur, such as, among others, the elimination of sulfur or nitrogen from the feed, or the saturation of olefins, and as defined more broadly below.
• hydrotreating refers to a gentler operation whose main purpose is to remove impurities such as sulfur, nitrogen, oxygen, halides, and traces of metals from the charge, and to saturate olefins and/or stabilize hydrocarbon free radicals by reacting them with hydrogen rather than allowing them to react with themselves.
• the main purpose is not to change the boiling point range of the filler.
• hydrotreatment includes in particular hydrodesulfurization reactions (commonly called “HDS”), hydrodenitrogenation reactions (commonly called “HDN”) and hydrodemetallation reactions (commonly called “HDM”), accompanied by hydrodemetallation reactions (commonly called “HDM”).
• Hydrotreatment is most often carried out using a bed reactor. fixed, although other reactors can also be used for hydrotreatment, for example an ebullated bed hydrotreatment reactor.
• hydroconversion reactor refers to any vessel in which the hydroconversion of a feedstock is the primary purpose, e.g. cracking of the feedstock (i.e., reduction of the point range d boiling), in the presence of hydrogen and a hydroconversion catalyst.
• Hydroconversion reactors typically include at least one inlet port through which feed and hydrogen can be introduced and an outlet port from which upgraded material can be withdrawn.
• hydroconversion reactors are also characterized by possessing sufficient thermal energy to cause larger hydrocarbon molecules to break up into smaller molecules through thermal decomposition.
• hydroconversion reactors include, but are not limited to, entrained bed reactors, also called “slurry” reactors (three-phase reactors - liquid, gas, solid - in which the solid and liquid phases can behave as a homogeneous phase), bubbling bed reactors (three-phase fluidized reactors), moving bed reactors (three-phase reactors with downward movement of the solid catalyst and upward or downward flow of liquid and gas), and liquid and gas reactors.
• entrained bed reactors also called “slurry” reactors (three-phase reactors - liquid, gas, solid - in which the solid and liquid phases can behave as a homogeneous phase)
• bubbling bed reactors three-phase fluidized reactors
• moving bed reactors three-phase reactors with downward movement of the solid catalyst and upward or downward flow of liquid and gas
• liquid and gas reactors liquid and gas reactors.
• fixed bed three-phase reactors with downward trickling of liquid feed over a fixed bed of supported catalyst with hydrogen typically flowing simultaneously with the liquid, but possibly countercurrent in some cases).
• hybrid bed and “hybrid bubbling bed” and “ebullition-entrained hybrid bed” for a hydroconversion reactor refer to an ebullated bed hydroconversion reactor comprising an entrained catalyst in addition to the porous supported catalyst held in the bubbling bed reactor. Similarly, for a hydroconversion process, these terms thus refer to a process comprising hybrid operation of a bubbling bed and a bed entrained in at least the same hydroconversion reactor.
• the hybrid bed is a mixed bed of two types of catalysts of necessarily different particle size and/or density, one type of catalyst - the "porous supported catalyst” - being maintained in the reactor and the other type of catalyst - the "entrained catalyst", also commonly called “slurry catalyst” - being entrained out of the reactor with the effluents (recycled feed).
• the entrained catalyst is a colloidal catalyst or a molecular catalyst, as defined below.
• colloidal catalyst and “colloidally dispersed catalyst” refer to catalyst particles having a particle size that is colloidal, eg less than 1 ⁇ m in size (diameter), preferably less than 500 nm in size, more preferably less than 250 nm in size, or less than 100 nm in size, or less than 50 nm in size, or less than 25 nm in size, or less than 10 nm in size, or less than 5 nm in size.
• colloidal catalyst includes, but is not limited to, molecular or molecularly dispersed catalyst compounds.
• molecular catalyst and “molecularly dispersed catalyst” refer to catalyst compounds that are essentially “dissolved” or completely dissociated from other compounds or catalyst molecules in a feed, a non-volatile liquid fraction, a fraction background, residue, or another feed or product in which the catalyst may be found. They also refer to very small catalyst particles or sheets that contain only a few catalyst molecules joined together (e.g. 15 molecules or less).
• porous supported catalyst refers to catalysts that are typically used in conventional ebullated bed and fixed bed hydroconversion systems, including catalysts designed primarily for hydrocracking or hydrodemetallation and catalysts designed primarily for hydrotreating.
• Such catalysts typically include (i) a catalyst support having a large surface area and numerous interconnected channels or pores and (ii) fine particles of an active catalyst such as cobalt, nickel, tungsten, molybdenum sulfides , or mixed sulphides of these elements (e.g. NiMo, CoMo, etc.), dispersed in the pores.
• Supported catalysts are commonly produced as cylindrical extrudates (“pellets”) or spherical solids, although other shapes are possible.
• pyrolysis oil means an oil resulting from the pyrolysis of plastics and/or CSR, unless otherwise indicated.
• the “heavy hydrocarbon fraction” of the charge means a heavy fraction of hydrocarbons of fossil origin, unless otherwise indicated.
• the object of the invention is to propose a process for the hydroconversion of a feed comprising a fraction of plastic pyrolysis oil and/or CSR 102 and a heavy fraction of hydrocarbons of fossil origin 101 containing a portion of at least 50% by weight having a boiling point of at least 300°C and containing sulfur and nitrogen, said pyrolysis oil fraction constituting less than 50% by weight of said feed, the process including the following steps: (a) conditioning and introducing said feed into a first hydroconversion section 20 comprising at least one first bubbling bed or bubbling-entrained hybrid bed hydroconversion reactor comprising a first porous supported hydroconversion catalyst;
• step (c) optionally a step of separating part or all of said first effluent resulting from step (b), to form at least one heavy cut boiling mainly at a temperature greater than or equal to 350°C;
• step (d) optionally a second hydroconversion step in a second hydroconversion section comprising at least one second hydroconversion reactor with an ebullating bed or a bubbling-entrained hybrid bed of part or all of said first effluent resulting from the step (b) or optionally from said heavy cut from step (c), said second hydroconversion reactor comprising a second porous supported catalyst and operating in the presence of hydrogen, to produce a second hydroconverted effluent; step (b) and optional step (d) being carried out at an absolute pressure of between 2 MPa and 38 MPa, at a temperature of between 300°C and 550°C, at an hourly space speed of between 0.05 h 1 and 10 h 1 , and with a quantity of hydrogen between 50 Nm 3 /m 3 and 5000 Nm 3 /m 3 ,
• step (e) a step of fractionating all or part of said first hydroconverted effluent from step (b) or said second hydroconverted effluent from step (d), in a fractionation section 30, to produce at least one product heavy liquid which mainly boils at a temperature greater than or equal to 350°C, said heavy liquid product containing a residual fraction which boils at a temperature greater than or equal to 540°C.
• the feed mainly comprises a heavy fraction of hydrocarbons of fossil origin and a minor fraction of plastic pyrolysis oil and/or CSR.
• the feed consists of said minor fraction of plastic pyrolysis oil and/or CSR and a heavy fraction of hydrocarbons of fossil origin.
• the process according to the invention is thus specific to the hydroconversion of a mixture of low-content plastic pyrolysis oil and/or CSR and a heavy fraction of hydrocarbons of fossil origin.
• the fraction of plastics and/or CSR pyrolysis oil constitutes less than 50% by weight of the charge (total weight of the charge), preferably between 1% and 45% by weight of the charge, more preferably between 2% and 30% weight of the filler, even more preferably between 2% and 25% weight of the filler, even more preferably between 3% and 20% weight of the filler, and even more preferably between 5% and 20% % weight of the load, or even between 5% and 15% weight of the load.
• the charge can consist of these two fractions only: the pyrolysis oil fraction and the heavy hydrocarbon fraction, the sum of the pyrolysis oil fraction and the heavy hydrocarbon fraction forming 100% weight of the charge.
• the heavy hydrocarbon fraction may constitute, preferably when the charge consists of said heavy hydrocarbon fraction and the pyrolysis oil fraction, between 55% and 99% by weight of the charge, preferably between 70% and 98% weight of the load, more preferably between 75% and 98% weight of the load, even more preferably between 80% and 97% weight of the load, and even more preferably between 80% and 95% weight of the load , or even between 85% and 95% weight of the load.
• a “plastic pyrolysis oil or CSR pyrolysis oil” is an oil, advantageously in liquid form at room temperature, resulting from the pyrolysis of plastics, preferably plastic waste originating in particular from collection and sorting, or from the pyrolysis of CSR. It comprises in particular a mixture of hydrocarbon compounds, in particular paraffins, olefins, naphthenes and aromatics. At least 80% by weight of these hydrocarbon compounds preferably have a boiling point below 700°C, and preferably below 550°C.
• the pyrolysis oil can comprise up to 70% by weight of paraffins, up to 90% by weight of olefins and up to 90% by weight of aromatics, it being understood that the sum of paraffins, olefins and aromatics is equal to 100% weight of hydrocarbon compounds.
• the density of the pyrolysis oil measured at 15°C according to the ASTM D4052 method, is generally between 0.75 g/cm 3 and 0.99 g/cm 3 , preferably between 0.75 g/cm 3 and 0.95 g/cm 3 .
• the pyrolysis oil can include, and most often includes, impurities such as metals, in particular iron, silicon, halogenated compounds, in particular chlorinated compounds. These impurities can be present in the pyrolysis oil at high levels, for example up to 500 ppm by weight or even 1000 ppm by weight or even 5000 ppm by weight of halogen elements (eg chlorine) provided by halogenated compounds (eg chlorinated compounds ), and up to 2500 ppm weight, or even 10000 ppm weight of metallic or semi-metallic elements.
• halogen elements eg chlorine
• Alkali metals, alkaline earth metals, transition metals, poor metals and metalloids can be assimilated to contaminants of a metallic nature, called metals or metallic or semi-metallic elements.
• the pyrolysis oil can include up to 200 ppm by weight or even 1000 ppm by weight of silicon, and up to 15 ppm by weight or even 100 ppm by weight of iron.
• the pyrolysis oil may also include other impurities such as heteroelements provided in particular by sulfur compounds, oxygenated compounds and/or nitrogen compounds, at contents generally less than 20,000 ppm by weight of heteroelements, and preferably less than 10,000 ppm by weight of heteroelements.
• the process according to the invention is particularly well suited to treating a pyrolysis oil loaded with impurities, in combination with a heavy load of hydrocarbons as defined in more detail below.
• loaded with impurities we mean that the pyrolysis oil has the following properties:
• halogen content of between 2 ppm by weight and 5000 ppm by weight, often between 200 ppm by weight and 5000 ppm by weight, and which may be between 500 ppm by weight and 5000 ppm by weight;
• a silicon element content between 0 and 1000 ppm weight, often between 50 ppm weight and 1000 ppm weight, or even between 80 ppm weight or 100 ppm weight and 1000 ppm weight, and which can also be between 200 ppm weight and 1000 ppm weight ppm weight.
• the process according to the invention is particularly well suited to treating a pyrolysis oil heavily loaded with impurities, in combination with a heavy load of hydrocarbons as defined in more detail below.
• a pyrolysis oil heavily loaded with impurities, we mean that the pyrolysis oil has the following properties:
• halogen content of between 500 ppm by weight and 5000 ppm by weight
• the plastics and/or CSR pyrolysis oil can come from a thermal or catalytic pyrolysis treatment or even be prepared by hydropyrolysis (pyrolysis in the presence of a catalyst and hydrogen).
• the heavy fraction of hydrocarbons of fossil origin of the feed of the process according to the invention is a heavy fraction of hydrocarbons containing a portion of at least 50% by weight, preferably of at least 80% by weight, having a temperature boiling point of at least 300°C, preferably at least 350°C, and even more preferably at least 375°C.
• This heavy hydrocarbon fraction of the feed may be a crude oil, or come from the refining of a crude oil or the treatment of another fossil hydrocarbon source in a refinery.
• the heavy hydrocarbon fraction of the feed may be a crude oil, a headed crude oil or may comprise, or consist of, atmospheric residues and/or vacuum residues resulting from atmospheric and/or vacuum distillation of 'a crude oil.
• the heavy hydrocarbon fraction of the feed may also consist of atmospheric and/or vacuum residues resulting from the atmospheric and/or vacuum distillation of effluents from thermal conversion units, hydrotreatment, hydrocracking and/or hydroconversion.
• the heavy hydrocarbon fraction of the feed is a heavy hydrocarbon fraction containing a portion of at least 50% by weight, or even at least 80% by weight, having a boiling temperature of at least 450°C, preferably at least 500°C, and even more preferably at least 540°C, such as a vacuum residue.
• the heavy hydrocarbon fraction of the feed consists of one or more vacuum residues.
• Vacuum residues can come directly from crude oil, or from other refining units, such as, among others, residue hydrotreatment, residue hydrocracking, and residue visbreaking.
• the vacuum residues are vacuum residues from the vacuum distillation column of the primary fractionation of crude oil (known as "straight run", or "SR" for short, according to the English terminology). Saxon).
• the heavy hydrocarbon fraction of the feed can also consist of aromatic cuts extracted from a lubricant production unit, deasphalted oils from a deasphalting unit also called DAO (raffinates from the deasphalting unit), asphalts from a deasphalting unit (residues from the deasphalting unit).
• DAO deasphalted oils from a deasphalting unit also called DAO (raffinates from the deasphalting unit)
• asphalts from a deasphalting unit refs from the deasphalting unit
• the heavy hydrocarbon fraction of the feed may also consist of a settling oil or a recycle oil (which typically has a boiling range of 360°C to 550°C), for example a catalytic cracking effluent. in FCC fluidized bed such as a heavy recycling oil (HCO for Heavy cycle Oil in English) or an oil in the form of sludge called “slurry” (SLO for Slurry Oil in English).
• the heavy hydrocarbon fraction of the feed can also be a residual fraction resulting from the direct liquefaction of coal (an atmospheric residue and/or a vacuum residue resulting for example from the H-Coal® process), a vacuum distillate from the direct liquefaction of coal, such as the H-Coal® process.
• the heavy hydrocarbon fraction comprises, and may consist of, at least one of the following charges, alone or in mixture: a crude oil, a headed crude oil, an atmospheric residue or a vacuum residue from atmospheric or vacuum distillation of a crude oil (preferably from primary fractionation of crude oil), an atmospheric residue or a vacuum residue from atmospheric or vacuum distillation obtained during of a direct coal liquefaction process, and preferably is a vacuum residue from the vacuum distillation of a crude oil (preferably from the primary fractionation of crude oil).
• the heavy hydrocarbon fraction of the feedstock treated according to the invention contains impurities, such as sulfur and nitrogen. It may also contain impurities such as metals, Conradson carbon and asphaltenes, in particular C 7 asphaltenes which are insoluble in heptane.
• the metal contents may be greater than or equal to 20 ppm by weight, preferably greater than or equal to 100 ppm by weight.
• the sulfur content may be greater than or equal to 0.1% by weight, or even greater than or equal to 0.5% or 1% by weight, and may be greater than or equal to 2% by weight.
• the nitrogen content is usually between 1 ppm and 8000 ppm by weight, more generally between 200 ppm and 8000 ppm by weight, for example between 2000 ppm and 8000 ppm by weight.
• the level of asphaltenes C 7 (compounds insoluble in heptane according to standard ASTM D6560, also corresponding to standard NF T60-115) can amount to at least 1% by weight and is often greater than or equal to 3% by weight (with the exception of a heavy hydrocarbon fraction comprising essentially DAO).
• C 7 asphaltenes are compounds known to inhibit the conversion of residual cuts, both by their ability to form heavy hydrocarbon residues, commonly called coke, and by their tendency to produce sediments which strongly limit the operability of d units. hydrotreatment and hydroconversion.
• the Conradson carbon content can be greater than or equal to 3% by weight, or even at least 5% by weight.
• the Conradson carbon content is defined by the ASTM D482 standard and represents for skilled in the art a well-known evaluation of the quantity of carbon residue produced after pyrolysis under standard conditions of temperature and pressure.
• the filler of the process according to the invention may further comprise, at a low content, typically between 1% and 20% by weight of the filler, or even between 1% and 10% or 5% by weight, a fraction of vegetable and/or animal oil or fat, and/or a hydrocarbon fraction resulting from thermal and/or catalytic conversion processes of lignocellulosic biomass, such as an oil produced from lignocellulosic biomass, according to various methods of liquefaction such as hydrothermal liquefaction or pyrolysis, which is then co-treated with the pyrolysis oil of plastics and/or CSR and the heavy fraction of hydrocarbons of fossil origin.
• a low content typically between 1% and 20% by weight of the filler, or even between 1% and 10% or 5% by weight
• a fraction of vegetable and/or animal oil or fat and/or a hydrocarbon fraction resulting from thermal and/or catalytic conversion processes of lignocellulosic biomass, such as an oil produced from lignocellulosic biomass
• Oils/fats of plant and/or animal origin contain triglycerides and/or free fatty acids and/or esters.
• Vegetable oils can advantageously be crude or refined, totally or in part, and can be derived from the following plants: rapeseed, sunflower, soya, palm, palm kernel, olive, coconut, jatropha (jatropha), castor, cotton, peanuts, flax, crambe, this list is not exhaustive. Algae or fish oils are also relevant.
• Oils/fats of plant and/or animal origin can be used, for example used cooking oils.
• Animal fats can be chosen from bacon or fats composed of residues from the food industry or from the catering industries.
• lignocellulosic biomass designates compounds derived from plants or their by-products, and includes constituents chosen from the group formed by cellulose, hemicellulose (carbohydrate polymers) and/or lignin (aromatic polymer).
• the feed of the process according to the invention does not include any vegetable and/or animal oil or fat fraction, or any hydrocarbon fraction resulting from thermal and/or catalytic conversion processes of lignocellulosic biomass. such as biomass pyrolysis oil.
• the process according to the invention comprises a step (a) of conditioning and introducing the feed into a first hydroconversion section 20 comprising at least a first reactor in an ebullating bed or in a hybrid bed comprising a first porous supported catalyst of hydroconversion.
• conditioning the feed we mean putting it in a state suitable for the hydroconversion step b), in particular putting it at temperature and pressure conditions suitable for hydroconversion in the first hydroconversion reactor, a possible mixture plastics and/or CSR pyrolysis oil fractions and heavy hydrocarbon fraction before introducing the charge into the reactor, elimination of any solid particles from the plastics and/or CSR pyrolysis oil fraction (by filtration, centrifugation, electrostatic separation, washing with an aqueous solution, adsorption, etc.).
• the plastics and/or CSR pyrolysis oil fraction 102 can be mixed beforehand with the heavy hydrocarbon fraction 101 of the feed before entering the first hydroconversion reactor at the first stage of hydroconversion (b).
• the two fractions can be heated beforehand to ensure that they are in the liquid state before being mixed, by means of any heating device known to those skilled in the art.
• only the heavy hydrocarbon fraction 101 can be heated, particularly if the pyrolysis oil fraction is liquid and pumpable at room temperature.
• This mixture can be carried out in a dedicated capacity 10 as shown in Figure 1, the mixture being able to be active (e.g. a pump with a propeller or a turbine rotor) or not, or directly by the connection of the two conduits transporting the products.
• the homogeneity of the mixture can be ensured by installing an online static mixer, a technology well known to those skilled in the art.
• a more homogeneous charge 114 is introduced into the first hydroconversion reactor, which is for example favorable to good fluidization of the catalyst, and to good hydrodynamic operation of the reactor in general. It can also allow the use of common equipment, such as ovens, load distributors, hydrogen mixers with the load, for example of the T-shaped type ("T-mixer" in English), which can help reduce investment costs.
• FIG. 2 Another possibility, shown in Figure 2, is the separate injection of the plastic pyrolysis oil fraction and/or CSR102 and the heavy hydrocarbon fraction 101 into the first hydroconversion reactor at the first stage hydroconversion (b).
• This mode of injection may be preferred to avoid any problem linked to a chemical incompatibility between the two fractions (risk of demixing or precipitation of asphaltenes for example), or to avoid possible accelerated clogging of the preheating oven (the high contents of diolefins and olefins in the pyrolysis oil of plastics and/or CSR can lead to the formation of gum).
• the feed, and in particular the heavy hydrocarbon fraction 101 of the feed is heated to a temperature suitable for the hydroconversion in the first hydroconversion reactor, that is to say so as to advantageously reach a target temperature in the first hydroconversion reactor.
• a preheating step in this description. It is specified that said target temperature in the hydroconversion reactor, ie the temperature during the hydroconversion step, is generally not the preheating temperature, the latter being conventionally lower than the target temperature in the hydroconversion reactor .
• the preheating of the heavy hydrocarbon fraction is preferably carried out at a temperature between 280°C and 450°C, even more preferably between 300°C and 400°C, and even more preferably between 320°C and 365°C. vs.
• This preheating can also include heating the pyrolysis oil fraction 102, in particular if said fraction is injected separately from fraction 101 into the first hydroconversion reactor, however preferably at a lower temperature than for the heavy fraction d. hydrocarbons 101.
• the pyrolysis oil fraction 102 when injected into the first reactor separately from the heavy hydrocarbon fraction 101, can be heated to a temperature between ambient temperature, e.g. 15°C , and 350°C, preferably between 100° and 350°C, more preferably between 100°C and 250°C, even more preferably between 100°C and less than 230°C, or even between 150°C and less than 200 °C.
• preheating can be carried out after mixing, before or during.
• the fraction of plastic pyrolysis oil and/or CSR 102 is preheated to a temperature lower than the heavy fraction of hydrocarbons 101 so as to limit the formation of gums and/or coking of preheating equipment (for example ovens and/or heat exchangers) due to the presence of olefins and diolefins in the pyrolysis oil fraction 102.
• preheating equipment for example ovens and/or heat exchangers
• the preheating temperature of the plastics and/or CSR pyrolysis oil fraction 102 is preferably less than 230°C, preferably less than 200°C, more preferably less than or equal to 175°C, and very preferably less than or equal to 100°C.
• the heavy fraction 101 can be preheated, before mixing with the pyrolysis oil fraction 102, to a temperature between 280°C and 450°C, even more preferably between 300°C and 400°C. , and even more preferably between 320°C and 365°C.
• the pyrolysis oil fraction 102 is heated indirectly by the mixture with the heavy hydrocarbon fraction 101 (ie heat exchange between the two fractions by bringing said two fractions which have different temperatures into contact) which has been preheated preferably between 280°C and 450°C, even more preferably between 300°C and 400°C, and even more preferably between 320°C and 365°C, so that a target hydroconversion temperature can then be reached in the first hydroconversion reactor.
• it is the mixture of heavy hydrocarbon fractions 101 and pyrolysis oil 102 which is preheated, advantageously using heating means such as already described below (e.g. oven , heat exchangers etc.), preferably between 280°C and 450°C, even more preferably between 300°C and 400°C, and even more preferably between 320°C and 365°C, so that a target hydroconversion temperature can then be reached in the first hydroconversion reactor.
• heating means such as already described below (e.g. oven , heat exchangers etc.), preferably between 280°C and 450°C, even more preferably between 300°C and 400°C, and even more preferably between 320°C and 365°C, so that a target hydroconversion temperature can then be reached in the first hydroconversion reactor.
• the preheating can further comprise the exchange of calories between the load and a flow comprising preheated hydrogen (not shown in the figures), typically having a temperature between 350°C and 560°C , for example around 500°C or 540°C, so that a target hydroconversion temperature can then be reached in the first hydroconversion reactor.
• preheated hydrogen typically having a temperature between 350°C and 560°C , for example around 500°C or 540°C, so that a target hydroconversion temperature can then be reached in the first hydroconversion reactor.
• any means known to a person skilled in the art capable of preheating said load can be used. It can be used at least one oven, commonly called preheating oven, comprising for example at least one heating compartment, and/or tubes in which the load flows, a mixer of the load with H 2 , any type suitable heat exchangers, e.g. tubular or spiral heat exchangers through which the charge flows, etc.
• preheating oven comprising for example at least one heating compartment, and/or tubes in which the load flows, a mixer of the load with H 2 , any type suitable heat exchangers, e.g. tubular or spiral heat exchangers through which the charge flows, etc.
• a pressurization step is preferably carried out before the preheating step.
• the plastic pyrolysis oil fraction and/or CSR 102 may first undergo a filtration step and/or a centrifugation step and/or an electrostatic separation step and/or a step of washing using an aqueous solution and/or an adsorption step, to eliminate impurities which may be naturally present in plastic pyrolysis oils and/or CSR, in particular to eliminate solid particles .
• the feed Prior to its introduction into the first hydroconversion reactor, the feed can be mixed with an entrained catalyst precursor 104, for example the heavy hydrocarbon fraction 101 can be mixed with an entrained catalyst precursor 104, as shown in Figures 1 and 2, so that, when forming an entrained catalyst, in particular by reaction with sulfur, the entrained catalyst will comprise a colloidal or molecular catalyst dispersed in the feed.
• an entrained catalyst precursor 104 for example the heavy hydrocarbon fraction 101 can be mixed with an entrained catalyst precursor 104, as shown in Figures 1 and 2, so that, when forming an entrained catalyst, in particular by reaction with sulfur, the entrained catalyst will comprise a colloidal or molecular catalyst dispersed in the feed.
• the entrained catalyst precursor 104 can also be mixed with the pyrolysis oil fraction 102 before mixing the latter with the heavy hydrocarbon fraction 101 (not shown in Figure 1), or else be mixed with the charge 114 formed by the mixture of said fractions 101 and 102 (not shown in Figure 2), in the same manner as described below for a mixture between the heavy hydrocarbon fraction 101 and the entrained catalyst precursor 104, except is that the mixing temperature of the catalyst precursor and the pyrolysis oil fraction 102 is preferably lower than 230°C, or even lower than 200°C (and in all cases preferably at a temperature lower than a temperature at which a substantial portion of the catalyst precursor begins to decompose).
• the catalyst precursor is not part of the charge as defined above which comprises the fraction of plastics and/or CSR pyrolysis oil and the heavy fraction of hydrocarbons.
• the entrained catalyst precursor may be chosen from all metal catalyst precursors known to those skilled in the art, capable of forming a colloidally or molecularly dispersed catalyst (i.e. the entrained catalyst) in the presence of hydrogen and/or H 2 S and/or any other source of sulfur, and allowing the hydroconversion of the feed after its injection into the first hydroconversion reactor.
• the catalyst precursor is advantageously an oil-soluble catalyst precursor, containing at least one transition metal.
• the catalyst precursor preferably comprises an oil-soluble organometallic compound or complex.
• the catalyst precursor may comprise an oil-soluble organometallic or bimetallic compound or complex comprising one or two of the following metals: Mo, Ni, V, Fe, Co or W, or mixtures of such compounds/complexes.
• the oil-soluble catalyst precursor preferably has a decomposition temperature (temperature below which the catalyst precursor is substantially chemically stable) in a range of 100°C to 350°C, more preferably in a range of 150°C. C to 300°C, and most preferably in a range of 175°C to 250°C.
• the oil-soluble organometallic compound or complex is preferably chosen from the group consisting of molybdenum 2-ethylhexanoate, molybdenum naphthanate, vanadium naphthanate, vanadium octoate, molybdenum hexacarbonyl, vanadium hexacarbonyl, and pentacarbonyl iron. These compounds are non-limiting examples of oil-soluble catalyst precursors.
• the catalyst precursor comprises Mo and, for example, comprises a compound selected from the group consisting of molybdenum 2-ethylhexanoate, molybdenum naphthanate, and molybdenum hexacarbonyl.
• a currently preferred catalyst precursor includes, or consists of, molybdenum 2-ethylhexanoate (also commonly referred to as molybdenum octoate).
• molybdenum 2-ethylhexanoate contains 15% by weight molybdenum and has a sufficiently high decomposition temperature or decomposition temperature range to avoid substantial thermal decomposition when mixed with a heavy hydrocarbon fraction at a temperature below 250°C.
• One skilled in the art may choose a mixing temperature profile that results in mixing of the chosen precursor, without substantial thermal decomposition prior to formation of the colloidal or molecular catalyst.
• the catalyst precursor 104 preferably an oil-soluble catalyst precursor, may be pre-mixed with a hydrocarbon diluent stream to form a diluted precursor mixture, as described in US2005/0241991, US10822553 or US10941353 and recalled below.
• the catalyst precursor 104 may be premixed with a diluent to form a dilute precursor mixture, said premix preferably being carried out at a temperature below a temperature at which a substantial portion of the catalyst precursor begins to decompose, preferably between ambient temperature, e.g. 15°C, and 300°C, more preferably between 15°C and 200°C, even more preferably between 50°C and 200°C, even more preferably between 75°C and 150°C, and even more preferably between 75°C and 100°C, and advantageously for a period of time from 1 second to 30 minutes.
• the diluent of the catalyst precursor may be a hydrocarbon oil composed of hydrocarbons of which at least 50% by weight, relative to the total weight of the hydrocarbon oil, have a boiling temperature of between 180° C. and 540° C. vs.
• hydrocarbon diluents suitable for dilution of the precursor include, but are not limited to, a vacuum gas oil known as "VGO" (which typically has a boiling range of 360°C to 524°C), an oil decantation or a recycling oil (which typically has a boiling range of 360°C to 550°C), for example an effluent from catalytic cracking in a FCC fluidized bed such as a heavy recycling oil (HCO for Heavy cycle Oil in English) or a light recycling oil (LCO for Light Cycle Oil in English), a pyrolysis oil from a hydrocracker, a light gas oil (which typically has a boiling range of 200°C to 360°C), atmospheric residues, vacuum residues (which typically have a boiling range of greater than or equal to 524°C), deasphalted oils, and resins.
• the catalyst precursor diluent is preferably an atmospheric residue, a vacuum residue, a VGO.
• the diluted precursor can be mixed with the heavy hydrocarbon fraction 101, preferably at a temperature between room temperature, e.g. 15°C, and 300°C, and advantageously for a period of time from 1 second to 30 minutes, preferably from 1 second to 10 minutes, and even more preferably in a range of 2 seconds to 3 minutes.
• a mixing time (or residence time for mixing) of 1 second includes instant mixing.
• the mass ratio of catalyst precursor 104 to hydrocarbon oil diluent is preferably in a range of about 1:500 to about 1:1, more preferably in a range of about 1:150 to about 1:2, and again more preferably in a range from about 1:100 to about 1:5 (e.g. 1:100, 1:50, 1:30, or 1:10).
• Premixing the catalyst precursor 104 with a hydrocarbon diluent greatly facilitates the complete and intimate mixing of the precursor into the heavy hydrocarbon fraction, particularly in the relatively short period of time required for large-scale industrial operations to be economically viable. .
• the diluted precursor is preferably combined with the heavy hydrocarbon fraction and mixed for a sufficient time and so as to disperse the catalyst precursor throughout the heavy fraction so that the catalyst precursor is completely/thoroughly mixed with the heavy fraction. hydrocarbons.
• the diluted precursor and the heavy fraction are more preferably mixed for a period of time in the range of 1 second to 10 minutes, and even more preferably in a range of 2 seconds to 3 minutes. Increasing the vigor and/or shear energy of the mixing process generally reduces the time required to complete complete/intimate mixing.
• Examples of mixing apparatus that may be used to effect complete/intimate mixing of catalyst precursor 104 and heavy hydrocarbon feedstock 101 include, but are not limited to, high shear mixing such as created in a pump with a propeller or turbine rotor, multiple static in-line mixers, multiple static in-line mixers in combination with high shear in-line mixers, multiple static in-line mixers in combination with in-line mixers high shear, multiple static in-line mixers in combination with high shear in-line mixers followed by recirculation pumping into the surge tank, combinations of the above followed by one or more multi-stage centrifugal pumps.
• high shear mixing such as created in a pump with a propeller or turbine rotor
• multiple static in-line mixers such as created in a pump with a propeller or turbine rotor
• multiple static in-line mixers such as created in a pump with a propeller or turbine rotor
• multiple static in-line mixers such as created in a pump with a propeller or turbine rotor
• the heavy hydrocarbon fraction 101 and the diluted precursor are preferably mixed and conditioned at a temperature in a range of 50°C to 200°C, more preferably in a range of 75°C to 175°C.
• the gauge pressure is between 0 MPa and 25 MPa, more preferably between 0.01 MPa and 5 MPa.
• the catalyst precursor 104 is completely decomposed and the metal of the precursor has combined with sulfur (eg H 2 S dissolved present in the feed , or H 2 S contained in hydrogen recycled to the hydroconversion reactor, or sulfur coming from sulfur-containing organic molecules present in the feed or possibly previously introduced into the feed) to give the colloidal or molecular catalyst.
• sulfur eg H 2 S dissolved present in the feed , or H 2 S contained in hydrogen recycled to the hydroconversion reactor, or sulfur coming from sulfur-containing organic molecules present in the feed or possibly previously introduced into the feed
• the metal concentration of the catalyst, preferably Mo, in the feed is preferably between 5 ppm and 500 ppm by weight of the feed, more preferably between 10 ppm and 300 ppm by weight, more preferably between 10 ppm and 175 ppm by weight, even more preferably between 10 ppm and 75 ppm by weight, and even more preferably between 10 ppm and 50 ppm by weight.
• the colloidal or molecular catalyst comprises, or is constituted by, molybdenum disulfide.
• the pyrolysis oil fraction 102 is introduced, mixed or not with the heavy hydrocarbon fraction 101, into the first hydroconversion reactor of the first hydroconversion section 20.
• the first hydroconversion stage may comprise several hydroconversion reactors in series, and the pyrolysis oil fraction 102 may be introduced into a hydroconversion reactor downstream of the first hydroconversion reactor of the first hydroconversion section 20 without departing from the scope of the present invention.
• the feed is introduced, whether the fractions which compose it are separated (101 and 102) or mixed (114) according to step (a), into the first hydroconversion reactor of the first hydroconversion section 20, together with hydrogen (flow not shown).
• Said first reactor comprises a first porous supported hydroconversion catalyst.
• the first hydroconversion step (b) is carried out under conditions making it possible to obtain a first hydroconverted effluent 105.
• Said first hydroconverted effluent 105 contains the conversion products, in particular said first effluent has a reduced content (compared to the feed) in hydrocarbons having a boiling point of at least 300°C, or at least 350°C, 375°C, 450°C, 500°C, or even 540°C depending on the nature of the charge.
• Said first hydroconverted effluent 105 may also have a reduced content, relative to the feed, of sulfur, and/or of metals, and/or of silicon, and/or of halogenated compounds (e.g. chlorine), and/or of nitrogen.
• said first hydroconverted effluent 105 can advantageously have a reduced content, relative to the feed, of sulfur, of metals, of silicon, of halogenated compounds (e.g. chlorine), of nitrogen, of Conradson carbon, and of asphaltenes.
• the content of silicon and/or halogenated compounds (e.g. chlorine) of the first hydroconverted effluent 105 obtained at the end of step b) is advantageously reduced compared to that of the same impurities (i.e. silicon and/or halogenated compounds such as chlorine) included in the charge.
• the first hydroconverted effluent 105 comprises a liquid fraction (PI+ fraction) having:
• a chlorine element content less than or equal to 10 ppm weight, preferably less than or equal to 5 ppm weight, or even less than or equal to 2 ppm weight or even 1 ppm weight, relative to the total weight of said liquid part of the first effluent hydroconverted 105.
• Step (b) is preferably carried out under an absolute pressure of between 2 MPa and 38 MPa, more preferably between 5 MPa and 25 MPa, and even more preferably, between 6 MPa and 20 MPa, at a temperature of between 300°C and 550°C, more preferably between 350°C and 500°C, preferably between 370°C and 450°C, and even more preferably between 405°C and 450°C, or even between 410°C and 450°C.
• the hourly space velocity (WH) is preferably between 0.05 h 1 and 10 h 1 (WH relative to the volume of each reactor).
• the hourly space velocity also called hourly volume velocity (liquid hourly space velocity “LHSV” or hourly space velocity “HSV” according to Anglo-Saxon terminology), is defined here as the ratio between the hourly volume flow rate of the load liquid (sent to the hydroconversion stage) and the volume of each hydroconversion reactor.
• the WH is between 0.1 h 1 and 10 h 1 , more preferably between 0.1 h 1 and 5 h 1 , even more preferably between 0.15 h 1 and 2 h 1 , and even more preferably between 0.15 h 1 and 1 h 1 .
• the overall WH that is to say the flow rate of liquid feed sent to step b) relative to the volume of all the reactors if several hydroconversion reactors are implemented in step b), is between 0.05 h 1 and 0.09 h 1 .
• the quantity of hydrogen mixed with the charge is preferably between 50 and 5000 normal cubic meters (Nm 3 ) per cubic meter (m 3 ) of liquid charge, preferably between 100 Nm 3 /m 3 and 2000 Nm 3 / m 3 and very preferably between 200 Nm 3 /m 3 and 1000 Nm 3 /m 3 .
• the first hydroconversion section 20 comprises one or more ebullated or hybrid bed reactors, containing at least one first supported hydroconversion catalyst, the reactors being able to be arranged in series and/or in parallel. At this step, at least one first supported hydroconversion catalyst is therefore maintained in the reactor(s).
• the first hydroconversion section 20 comprises one or more hydroconversion reactors, which can be in series and/or in parallel, operating in a bubbling bed, as used for the process H -Oil® as described, for example, in patents US4521295 or US4495060 or US4457831 or US4354852, in the article Aiche, March 19-23, 1995, Houston, Texas, article number 46d, "Second generation ebullated bed technology", or in chapter 3.5 "Hydroprocessing and Hydroconversion of Residue Fractions" of the book “Catalysis by Transition Metal Sulphides", Éditions Technip, 2013.
• each reactor is operated in a fluidized bed called a bubbling bed.
• Each reactor advantageously comprises a recirculation pump which makes it possible to maintain the porous supported solid catalyst in a bubbling bed by continuous recycling of at least part of a liquid fraction drawn off at the upper part of the reactor and reinjected into the level of the lower part of the reactor.
• the bubbling bed reactor preferably comprises at least one inlet orifice located at or near the lower part of the reactor through which the charge is introduced together with the hydrogen, and in particular two inlet orifices in the case where the pyrolysis oil fraction 102 of the charge is introduced separately to the heavy hydrocarbon fraction 101, and an orifice of outlet at or near the upper part of the reactor through which the first hydroconverted effluent 105 is withdrawn.
• the reactor further preferably comprises an inlet and an outlet for the supported catalyst as already described previously in connection with the means for injecting and withdrawing the supported catalyst.
• the ebullated bed reactor further comprises an expanded catalyst zone comprising the porous supported catalyst.
• the ebullated bed reactor also includes a lower supported catalyst-free zone located below the expanded catalyst zone, and an upper supported catalyst-free zone located above the expanded catalyst zone.
• the feed in the ebullated bed reactor is continuously recirculated from the upper supported catalyst-free zone to the lower supported catalyst-free zone by means of a recycle conduit in communication with a boiling pump.
• a recycle conduit in communication with a boiling pump.
• At the upper part of the recycle conduit there is preferably a funnel-shaped recycle cup through which the charge is sucked from the upper supported catalyst-free zone.
• the internal recycled feed is mixed with “fresh” feed and additional hydrogen gas.
• the first supported hydroconversion catalyst used in the first hydroconversion step (b) may contain one or more elements from groups 4 to 12 of the periodic table of elements, which may or may not be deposited on a support. It is advantageous to use a catalyst comprising an amorphous support, such as silica, alumina, silica-alumina, titanium dioxide or combinations of these structures, and very preferably alumina.
• the first supported catalyst may contain at least one non-noble Group VIII metal chosen from nickel and cobalt, and preferably nickel, said Group VIII element preferably being used in association with at least one selected Group VIB metal. among molybdenum and tungsten, and preferably the metal of group VIB is molybdenum.
• group VIII according to the CAS classification corresponds to the metals of columns 8, 9 and 10 according to the new IUPAC classification.
• the first supported hydroconversion catalyst used in the first hydroconversion step (b) comprises an alumina support and at least one metal from group VIII chosen from nickel and cobalt, preferably nickel, and at least one metal from group VIB chosen from molybdenum and tungsten, preferably molybdenum.
• the first supported hydroconversion catalyst comprises nickel as a group VIII element and molybdenum as a group VIB element.
• the content of non-noble Group VIII metal, in particular nickel is advantageously between 0.5% to 10% expressed by weight of metal oxide (in particular NiO), and preferably between 1% to 6 % by weight, and the content of metal from group VIB, in particular molybdenum, is advantageously between 1% and 30% expressed by weight of metal oxide (in particular molybdenum trioxide MoO 3 ), and preferably between 4 % and 20% weight.
• the metal contents are expressed as a weight percentage of metal oxide relative to the weight of the catalyst.
• This first supported catalyst is advantageously used in the form of extrudates or beads.
• the balls have, for example, a diameter of between 0.4 mm and 4.0 mm.
• the extrudates have, for example, a cylindrical shape with a diameter of between 0.5 mm and 4.0 mm and a length of between 1 mm and 5 mm.
• Extrudates can also be objects of a different shape such as trilobes, regular or irregular tetralobes, or other multilobes.
• Porous supported catalysts of other shapes can also be used.
• the size of these different forms of porous supported catalysts can be characterized using the equivalent diameter.
• the equivalent diameter is defined as six times the ratio of the volume of the particle to the external surface area of the particle.
• the porous supported catalyst, used in the form of extrudates, beads or other shapes thus has an equivalent diameter of between 0.4 mm and 4.4 mm. These catalysts are well known to those skilled in the art.
• the first hydroconversion section 20 comprises one or more hybrid bed reactors (i.e. bubbling-entrained hybrid beds), simultaneously comprising at least one first supported hydroconversion catalyst which is maintained in the reactor and at least one entrained catalyst which enters the reactor with the feed and which is entrained outside the reactor with the effluents.
• a colloidal or molecular catalyst also called dispersed, entrained or slurry catalyst, could have formed upstream or formed in situ in the hybrid bed hydroconversion reactor.
• entrained catalysts are well known to those skilled in the art.
• the hybrid bed reactor comprises a solid phase which comprises a porous supported catalyst in the form of an expanded bed, a liquid hydrocarbon phase comprising the feed containing the colloidal or molecular catalyst dispersed therein, and a gas phase comprising 'hydrogen.
• the hybrid bed reactor is a bubbling bed hydroconversion reactor as described above, but comprising, in addition to the porous supported catalyst in the form of an expanded bed maintained in the reactor, the molecular or colloidal catalyst entrained out of the reactor with the hydroconverted liquid effluent 105.
• the operation of the hybrid bed hydroconversion reactor is based on that of the ebullated bed reactor already described, and further implies that the colloidal or molecular catalyst is dispersed throughout the feed in the reactor. hybrid bed, including both the expanded catalyst zone and the supported catalyst free zones, and therefore available to stimulate upgrading reactions in what constitute catalyst free zones in conventional ebullated bed reactors.
• the presence of colloidal or molecular catalyst in the hybrid bed reactor provides additional catalytic hydrogenation activity, both in the expanded catalyst zone, in the recycle conduit, and in the lower and upper supported catalyst-free zones. Capping free radicals outside the porous supported catalyst minimizes the formation of sediment and coke precursors, which are often responsible for deactivation of the supported catalyst. This may allow a reduction in the amount of porous supported catalyst that would otherwise be required to carry out a desired hydroconversion reaction. This can also reduce the rate at which the porous supported catalyst must be withdrawn and replenished.
• a colloidal or molecular catalyst in a hybrid bed reactor can also make it possible to operate the hydroconversion at higher temperatures than in the case of an ebullated bed reactor (supported catalyst(s) alone, without entrained catalyst), while remaining within the temperature ranges given above for step (b).
• a first different supported hydroconversion catalyst can be used in each reactor of the first hydroconversion section, the supported catalyst specific to each reactor being adapted to the load sent into this reactor.
• several types of first catalyst supported in each reactor are used.
• the first supported hydroconversion catalyst when used, can be partly replaced by fresh supported catalyst, and/or used but active supported catalyst.
• catalyst higher than the used supported catalyst to be replaced, and/or the regenerated supported catalyst, and/or the rejuvenated supported catalyst (catalyst from a rejuvenation zone in which the majority of the deposited metals are eliminated, before sending the catalyst spent and rejuvenated in a regeneration zone in which the carbon and sulfur which it contains are eliminated, thus increasing the activity of the catalyst), by withdrawing the used supported catalyst preferably at the bottom of the reactor, and by introducing the replacement supported catalyst either at the top or bottom of the reactor.
• This replacement of used supported catalyst is preferably carried out at regular time intervals, and preferably in puffs or almost continuously. This withdrawal and this replacement are carried out using a withdrawal and injection device advantageously allowing the continuous operation of this hydroconversion stage.
• One of the essential aspects of the invention lies in the capacity of the hydroconversion reactor operating in a bubbling bed or bubbling-entrained hybrid bed to continue the conversion of the pyrolysis oil into lighter products thanks to the combination of a high temperature and the presence of a catalyst which allows the hydrogenation of unsaturated molecules (olefins or aromatics).
• the co-treatment of pyrolysis oil thus makes it possible to improve the yield of certain cuts obtained in the hydroconverted effluent, in particular the gasoline cut.
• Another advantage of the invention linked to the use of a hydroconversion reactor operating in a bubbling bed or bubbling-entrained hybrid bed for the co-treatment of pyrolysis oil, is to capture impurities such as silicon or metals thanks to the supported catalyst. This makes it possible to obtain products low in impurities and which can thus be more easily treated in downstream processes such as fixed bed hydrotreatment processes for example.
• the advantage of the bubbling or bubbling-entrained hybrid bed is that the supported catalyst is continuously replaced and it is easy to compensate for more severe deactivation by increasing the catalytic replacement if necessary, particularly in the case of a pyrolysis oil. heavily loaded with impurities.
• step (b) when step (b) is carried out in one or more hybrid bed reactors, the feed or the entrained catalyst precursor can be pre-mixed with an organic additive, before the feed is introduced into the first hydroconversion reactor of the first hydroconversion section 20, in particular in order to minimize clogging of the installations before hydroconversion in the hybrid bed reactor(s).
• the organic additive mixed with the filler, allows better solubility of the catalyst precursor entrained in the filler, avoiding or reducing fouling in particularly due to metallic deposits in the installations upstream of the hydroconversion reactor, such as in the heating devices, and thus improving the dispersion of the entrained catalyst, thus generating an increased availability of metallic active sites, favoring the hydrogenation of free radicals which are precursors of coke and sediment, and generating a substantial reduction in the fouling of installations.
• Said organic additive which is neither a catalyst nor a catalyst precursor (eg it does not contain any metal), has at least one carboxylic acid function and/or at least one ester function and/or at least one anhydride function. 'acid.
• the organic additive may be 2-ethylhexanoic acid, naphthenic acid, caprylic acid, adipic acid, pimelic acid, suberic acid, azelaic acid, sebacic acid , ethyl octanoate, ethyl 2-ethylhexanoate, 2-ethylhexyl 2-ethylhexanoate, benzyl 2-ethylhexanoate, diethyl adipate, dimethyl adipate, bis( 2- ethylhexyl), dimethyl pimelate, dimethyl suberate, monomethyl suberate, hexanoic anhydride, caprylic anhydride, and mixtures thereof.
• the organic additive is preferably added during the mixing step so that the molar ratio of organic additive to the active metal(s) of the catalyst precursor composition (eg Mo) is between 0 1:1 and 20:1, more preferably between 0.75:1 and 7:1, and even more preferably between 1:1 and 5:1.
• the molar ratio of organic additive to the active metal(s) of the catalyst precursor composition eg Mo
• the process according to the invention further comprises a separation step (c), which separates part, or all, of the first hydroconverted effluent 105, to produce at least two cuts, one of which heavy cut boiling mainly at a temperature greater than or equal to 350°C.
• the other cut(s) are light and intermediate cut(s).
• the light cut thus separated mainly contains gases (H 2 , HCl, H 2 S, NH 3 , and Ci-C 4 ), naphtha (or gasoline, cut which boils at a temperature lower than 150°C), kerosene (or diesel, cut which boils between 150°C and 250°C), and at least part of the diesel (fraction which boils between 250°C and 375°C).
• the light cut can then be sent at least partially to a fractionation unit (not shown in the figures) where the light gases are extracted from said light cut, for example by passing through a flash tank.
• This fractionation unit can be that of the fractionation step (e), particularly in the case where a second hydroconversion step (d) is implemented.
• the hydrogen gas thus recovered which may have been sent to a purification and compression installation, can advantageously be recycled to the first hydroconversion stage (b), and/or to the second hydroconversion step (d) if it is implemented.
• the recovered hydrogen gas can also be used in other refinery facilities.
• the optional separation step (c) is implemented in a separation section (not shown in the figures), which comprises any separation means known to those skilled in the art.
• Said separation section may comprise one or more flash drums arranged in series, and/or one or more steam and/or hydrogen stripping columns, and/or an atmospheric distillation column, and/or a column of vacuum distillation, and is preferably made up of a single expansion flask, commonly called a “hot separator”.
• the separation section may also include means for washing the light cut containing mainly gases by contact with an aqueous solution.
• the optional separation step (c) comprises a hot separator operated at a temperature greater than or equal to 300°C, or even 350°C, so as to avoid the formation of ammonium chloride salts.
• the gas phase of the hot separator or at least one of the phases resulting from the subsequent separation of the gas phase of the hot separator is advantageously brought into contact with water or a basic aqueous solution (soda solution, amine(s) ) for example) in order to eliminate at least partly the hydrogen chloride (HCl) and/or to dissolve at least partly the ammonium chloride salts.
• the separation equipment or flasks may include at the bottom a zone allowing the separate decantation of a hydrocarbon fraction and an aqueous fraction comprising chloride salts, or even include a gas washing column by bringing it into contact with water or a basic solution.
• the process further comprises a second hydroconversion step, in at least a second ebullated bed or hybrid bed reactor comprising a second porous supported catalyst, in the presence of hydrogen, part or all of the first effluent 105 resulting from step (b), or optionally from the heavy cut resulting from step (c).
• This second hydroconversion step is carried out so as to produce a second hydroconverted effluent.
• Said second hydroconverted effluent advantageously contains a greater quantity of conversion products than the first hydroconverted effluent 105, and in particular an even lower content of hydrocarbons having a boiling point of at least 300°C, or at least 350 °C, 375°C, 450°C, 500°C, or even 540°C depending on the nature of the load.
• the second hydroconverted effluent may be provided with a further reduced Conradson carbon residue compared to the first hydroconverted effluent 105, and possibly with a still reduced quantity of sulfur, and/or nitrogen, and/or metals, and/ or silicon, and/or halogenated compounds (eg chlorine) and/or asphaltenes.
• said second hydroconverted effluent can advantageously have a reduced content, relative to the first hydroconverted effluent 105 and/or relative to the load, of sulfur, of metals, of silicon, of halogenated compounds (eg chlorine), of nitrogen, in Conradson carbon, and in asphaltenes.
• the content of silicon and/or halogenated compounds (eg chlorine) of the second hydroconverted effluent obtained at the end of step d) is advantageously reduced compared to that of the same impurities (ie silicon and/or halogenated compounds such as chlorine) included in the first hydroconverted effluent 105 and/or in the load.
• the second hydroconverted effluent comprises a liquid fraction (PI+ fraction) having:
• a chlorine element content less than or equal to 10 ppm weight, preferably less than or equal to 5 ppm weight, or even less than or equal to 2 ppm weight or even 1 ppm weight, relative to the total weight of said liquid part of the second effluent hydroconverted.
• the second hydroconversion step is carried out in a manner similar to what was described for the first hydroconversion step (b), and is not repeated here. This applies in particular to the operating conditions, the equipment used, and the supported porous hydroconversion catalysts used, with the exception of the details mentioned below.
• the second hydroconversion step is carried out in at least a second ebullated or hybrid bed reactor. It is preferably carried out in one or more bubbling bed reactors if the first hydroconversion step is also carried out in one or more bubbling bed reactors, and it is preferably carried out in one or more hybrid bed reactors if the first step hydroconversion is carried out in one or more hybrid bed reactors.
• the operating conditions may be similar or different from those in the hydroconversion step (d), the temperature remaining in the range between 405°C and 550°C, preferably between 405°C. °C and 500°C, more preferably between 405°C and 450°C, and the quantity of hydrogen introduced into the reactor remains in the range between 50 Nm 3 /m 3 and 5,000 Nm 3 /m 3 of charge liquid, preferably between 100 Nm 3 /m 3 and 3,000 Nm 3 /m 3 , and even more preferably between 200 Nm 3 /m 3 and 2,000 Nm 3 /m 3 .
• the other pressure and WH parameters are in the same ranges as those described for the hydroconversion step (d).
• the operating temperature in the second hydroconversion stage (d) may be higher than the operating temperature in the first hydroconversion stage (b). This can allow a more complete conversion of the charge not yet converted.
• the hydroconversion of liquid products from the first hydroconversion stage and the conversion of the feed are emphasized, as well as hydrotreatment reactions such as hydrodesulfurization and hydrodenitrogenation, among others.
• the operating conditions are chosen to minimize the formation of solids (eg coke).
• the second porous supported hydroconversion catalyst used in the second hydroconversion reactor may be the same as that used in the first hydroconversion reactor(s) of the first hydroconversion section 20, or may be another porous supported catalyst as well. suitable for the hydroconversion of the treated feedstock, as defined for the first supported catalyst used in the first hydroconversion step (b).
• step (a) the pyrolysis oil fraction 102 of the feed is introduced, mixed or not with the heavy hydrocarbon fraction 101, into the first hydroconversion reactor of the first section d hydroconversion 20.
• the pyrolysis oil fraction 102 can be introduced into a hydroconversion reactor of the second hydroconversion section 20 without departing from the scope of the present invention.
• This fractionation step (e) separates part or all of said hydroconverted effluent into several fractions including at least one heavy liquid product 106b boiling mainly at a temperature above 350°C, preferably above 500°C and preferably above at 540°C.
• the heavy liquid product 106b contains a part boiling at a temperature above 540°C, called the residual fraction (or vacuum residue), which is the unconverted part.
• the heavy liquid product 106b may contain a part of the gas oil fraction boiling between 250°C and 375°C and a part boiling between 375°C and 540°C (also called vacuum distillate).
• This fractionation step therefore produces at least two products including the heavy liquid product 106b as described above, the other product(s) 106a being light and intermediate cuts.
• the fractionation section 30 comprises any separation means known to those skilled in the art.
• the fractionation section 30 can thus comprise one or more of the following separation equipment: one or more flash flasks arranged in series, and preferably a sequence of at least two successive flash flasks, one or more steam stripping columns and/or hydrogen, an atmospheric distillation column, a vacuum distillation column. According to one or more embodiments, this fractionation step (e) is carried out by a sequence of at least two successive flash balloons.
• this fractionation step (e) is carried out by one or more steam and/or hydrogen stripping columns.
• this fractionation step (e) is carried out by an atmospheric distillation column, and more preferably by an atmospheric distillation column and a vacuum column receiving the atmospheric residue.
• this fractionation step (e) is carried out by one or more flash flasks, an atmospheric distillation column and a vacuum column receiving the atmospheric residue.
• the fractionation section 30 can also receive, in addition to part or all of the hydroconverted liquid effluent, one or more additional effluents such as one or more hydrocarbon feeds external to the process (e.g. distillates atmospheric and/or vacuum, atmospheric and/or vacuum residues), part of the heavy cut resulting from the separation step (c) if it is implemented, part of one or more of the cuts intermediates from the fractionation step (e), a part of a DAO or a light or heavy fraction of a DAO if a deasphalting step (fl) is carried out.
• the fractionation section 30 may also include means for washing one or more products separated by contact with an aqueous solution.
• the fractionation step (e) comprises a hot separator operated at a temperature greater than or equal to 300°C, or even 350°C, so as to avoid the formation of ammonium chloride salts in the liquid phase;
• the gas phase of the hot separator or at least one of the phases resulting from the subsequent separation of the gas phase of the hot separator, as well as at least part of the liquid phase of the hot separator or at least one of the phases resulting from the subsequent separation of the liquid phase of the hot separator are advantageously brought into contact with water or a basic aqueous solution (soda solution, amine(s) for example) in order to eliminate at least partly the chloride of hydrogen (HCl) and/or to dissolve at least part of the ammonium chloride salts.
• a basic aqueous solution sala solution, amine(s) for example
• the separation equipment or flasks may include at the bottom a zone allowing the separate decantation of a hydrocarbon fraction and an aqueous fraction comprising chloride salts, or even include a gas washing column by bringing it into contact with water or a basic aqueous solution.
• separation step c) when separation step c) is carried out, at least part of the separation equipment is common between steps c) and e).
• One or more subsequent treatment steps (f) of the heavy liquid product 106b and/or the other product(s) resulting from the fractionation step (e) can be carried out.
• Such a step (f) may comprise at least one step chosen from the list consisting of hydrotreatment, steam cracking, catalytic cracking in a fluidized bed, hydrocracking, deasphalting, extraction of lubricating oils. These examples of further processing are not exhaustive.
• the various hydrocarbon products which can result from the fractionation step (e) in the fractionation means 30 can in fact be sent to different processes in the refinery, illustrated in the figures under the general reference 40, and the details of all these post-processing are not described here as they are generally known to those skilled in the art.
• gaseous fractions, naphtha (gasoline), middle distillates, VGO, DAO can be sent to hydrotreating, steam cracking, fluidized bed catalytic cracking (FCC), hydrocracking, lubricating oil extraction, etc.
• Residues atmospheric or vacuum residues
• Heavy fractions, including residues can also be recycled into the hydroconversion process, for example in a hydroconversion reactor in step (b) or (d).
• the hydroconversion process comprises a deasphalting step (fl), in a deasphalter, of part or all of said heavy liquid product 106b obtained in the fractionation step (e), with at least one hydrocarbon solvent, to produce a DAO deasphalted oil and a residual asphalt (“SDA” step for Solvent DeAsphalting in English).
• a deasphalting step (fl) is carried out under conditions well known to those skilled in the art. We can thus refer to the article by Billon and others published in 1994 in volume 49, No.
• Deasphalting can be carried out in one or more mixer-settlers or in one or more extraction columns.
• the deasphalter thus comprises at least one mixer-settler or at least one extraction column.
• Deasphalting is a liquid-liquid extraction generally carried out at an average temperature between 60°C and 250°C with at least one solvent low boiling point hydrocarbon, preferably a paraffinic solvent, and preferably heavier than propane, preferably having 3 to 7 carbon atoms.
• Preferred solvents include propane, butane, isobutane, pentane, isopentane, neopentane, hexane, isohexanes, C 6 hydrocarbons, heptane, C 7 hydrocarbons, light gasolines more or less apolar, as well as the mixtures obtained from the aforementioned solvents.
• the solvent is butane, pentane or hexane, as well as mixtures thereof.
• the solvent/charge ratios (volume/volume) entering the deasphalter are generally between 3/1 and 16/1, and preferably between 4/1 and 8/1.
• the deasphalter comprises at least one extraction column, and preferably only one (eg as implemented in the SolvahlTM process) in which the solvent/charge ratios (volume/volume) entering the deasphalter are preferably low, typically between 4/1 and 8/1, or even between 4/1 and 6/1.
• the deasphalter produces a DAO practically free of C 7 asphaltenes, said C 7 asphaltenes content being preferably less than 2% by weight, more preferably less than 0.5% by weight, even more preferably less than 0.05% by weight, and a residual asphalt concentrating the majority of the impurities in the residue, said residual asphalt being withdrawn.
• the DAO yield is generally between 40% by weight and 95% by weight depending on the operating conditions and the solvent used, and depending on the load sent to the deasphalter and in particular the quality of the heavy liquid product 106b.
• the hydroconversion process comprises at least one hydrotreatment step (f2), preferably in a fixed bed, implemented in a hydrotreatment section, of one or more liquid products from the fractionation step (e).
• the hydrotreatment section may comprise at least one fixed bed reactor having n catalytic beds, n being an integer greater than or equal to 1, each comprising at least one hydrotreatment catalyst, said hydrotreatment reaction section being supplied by at least one hydrotreatment catalyst. minus a part of a liquid product from step e) and a gas stream comprising hydrogen, to obtain a hydrotreated effluent.
• Such a step implements hydrotreatment reactions well known to those skilled in the art, and more particularly hydrotreatment reactions such as the hydrogenation of aromatics, olefins, hydrodesulfurization and hydrodenitrogenation.
• Said hydrotreatment reaction section can be implemented at an average temperature (Weight Average Bed Temperature (WABT) according to Anglo-Saxon terminology) of between 250°C and 430°C, preferably between 300°C and 400°C. , at a partial pressure of hydrogen between 1.0 MPa abs. and 20.0 MPa abs., preferably between 3.0 MPa abs. and 15.0 MPa abs., and at an hourly volume velocity (WH) per volume of catalyst(s) between 0.1 -1 and 10.0 h 1 , preferably between 0.1 h 1 and 5.0 h 1 , preferably between 0.2 h -1 and 2.0 h 1 , preferred manner between 0.2 h 1 and 1.0 h 1 .
• WABT Weight Average Bed Temperature
• step f2) There hydrogen coverage in step f2) is advantageously between 50 Nm 3 and 2000 Nm 3 , preferably between 100 Nm 3 and 1000 Nm 3 , more preferably between 120 Nm 3 and 800 Nm 3 , of hydrogen per m 3 of load which supplies step f2).
• the hydrotreatment section may comprise several, preferably two reactors, which can operate in series and/or in parallel and/or in switchable mode (or PRS or “lead and lag” in English) and/or in “swing” mode. known to those skilled in the art.
• the hydrotreatment section may comprise a single fixed bed reactor with n catalytic beds, n preferably being between 1 and 10, or even between 2 and 5.
• Means for recovering catalyst fines and/or catalysts from hydroconversion can be implemented upstream or at the entrance to the hydrotreatment section, such as one or more filters or even reactor internals, for example.
• the fixed bed hydrotreatment catalyst used in step f2) can be chosen from known hydrotreatment and hydrodemetallation catalysts used in particular for the treatment of oil cuts.
• Known hydrotreatment catalysts are for example those described in patents EP0113297, EP0113284, US6589908, US4818743 or US6332976.
• Known hydrodemetallation catalysts are for example those described in patents EP0113297, EP0113284, US5221656, US5827421, US7119045, US5622616 and US5089463.
• the hydrotreatment catalyst comprises a support, preferably mineral, and at least one metallic element having a hydro-dehydrogenating function.
• Said metallic element with a hydro-dehydrogenating function advantageously comprises at least one element from group VIII, preferably chosen from the group consisting of nickel and cobalt, and/or at least one element from group VIB, preferably chosen from the group consisting by molybdenum and tungsten.
• the total oxide content of the metal elements of groups VIB and VIII is preferably between 0.1% and 40% by weight, more preferably between 5% to 35% by weight, relative to the total weight of the hydrotreatment catalyst. .
• the weight ratio between the metal (or metals) of group VIB relative to the metal (or metals) of group VIII, expressed as metal oxide, is preferably between 1 and 20, more preferably between 2 and 10.
• the hydrotreatment section of step f2) comprises a hydrotreatment catalyst comprising between 0.5% and 10% by weight of nickel, preferably between 1% and 8% by weight of nickel (expressed as nickel oxide NiO relative to the total weight of the hydrotreatment catalyst), and between 1.0% and 30% by total weight of molybdenum and/or tungsten, preferably between 3% and 29% by weight, (expressed as molybdenum oxide MoO 3 or tungsten oxide WO 3 relative to the total weight of the hydrotreatment catalyst), on a mineral support.
• the support of the hydrotreatment catalyst is advantageously chosen from alumina, silica, silica-aluminas, magnesia, clays and their mixtures.
• the support may also contain doping compounds (eg oxides chosen from boron oxide, in particular boron trioxide, zirconia, ceria, titanium oxide, phosphoric anhydride and a mixture of these oxides) .
• the hydrotreatment catalyst comprises an alumina support, preferably an alumina support doped with phosphorus and optionally boron.
• the alumina used can for example be a y (gamma) or q (eta) alumina.
• the hydrotreatment catalyst is advantageously used in the form of extrudates or beads, generally of millimeter size, for example having an equivalent diameter of between 0.4 mm and 4.4 mm.
• the hydrotreatment catalyst used in step f2) has a specific surface area (measured by the BET method of determination by nitrogen adsorption according to standard ASTM D3663) greater than or equal to 250 m 2 /g, or even 300 m 2 /g, and advantageously less than or equal to 800 m 2 /g, or even 600 m 2 /g, or even 400 m 2 /g.
• part of the heavy residue fraction e.g. part of the heavy liquid product 106b and/or part of the residual asphalt, or part of the DAO
• a purge on the recycled stream can be implemented, generally to prevent certain compounds from accumulating at excessive levels. It is specified that for the purposes of the present invention, such a recycle flow is not part of the load as defined above which comprises the pyrolysis oil fraction 102 and the heavy hydrocarbon fraction 101.
• Example 1 is a comparative example illustrating the performance of the hydroconversion process for a reference load (vacuum residue) without plastic pyrolysis oil.
• Example 2 illustrates the performance of an H-Oil® process with a load comprising a fraction of plastic pyrolysis oil and a fraction of the reference load (vacuum residue) used in Example 1.
• the mixture was implemented during a pre-step of homogenization of the medium (optional step).
• the heavy fraction (I) of the feed is a so-called straight-run vacuum residue (RSV-SR) coming directly from the distillation of a petroleum crude.
• the plastic pyrolysis oil fraction (II) of the feed is a pyrolysis oil derived from a mixture of plastics and containing a significant level of impurities.
• the batch reactor is loaded with a predefined mass of NiMo type catalyst on alumina and with 100% RSV-SR (fraction I of the load), previously heated to 100°C to make it less viscous.
• the reactor is closed, purged with nitrogen, purged with hydrogen, then pressurized with hydrogen to a pressure of approximately 3 MPa.
• the reactor is then heated up to 100°C.
• stirring is started at 500 rpm 1 .
• the temperature is raised from 100°C to the reaction temperature and, in parallel, the stirring is gradually increased from 500 to 1000 rpm 1 .
• the reaction temperature is reached, the pressure in the reactor is instantly adjusted to the targeted value by adding F. At this point, the reaction time is counted down.
• the reactor is rapidly cooled to stop the reaction, stirring is stopped when the reactor is at room temperature, and the liquid effluent and gases are collected for analysis.
• the batch reactor is first loaded with the same mass of NiMo type catalyst on alumina as for Example 1 and with the 90% of RSV-SR (fraction I of the load), previously heated to 100°C for the make it less viscous, then the 10% of plastic pyrolysis oil (fraction II of the load) is added.
• the reactor is closed, purged with nitrogen, purged with hydrogen, then pressurized with hydrogen up to a pressure of approximately 3 MPa.
• the reactor is then heated up to 100°C. At this temperature, stirring is started at 500 rpm 1 . Gradually, the temperature is increased from 100°C to 200°C and, in parallel, the stirring is gradually increased from 500 to 1000 rpm 1 . At 200°C, the pressure in the reactor is then 4 MPa.
• a one-hour level at this temperature is respected, although this step is optional, in order to ensure good dispersion of the pyrolysis oil (fraction II of the load) in the RSV-SR (load I) .
• the batch reactor is heated to the reaction temperature, temperature at which the pressure in the reactor is instantly adjusted to the targeted value by adding H 2 .
• the reaction time is counted down.
• the reactor is rapidly cooled to stop the reaction, stirring is stopped when the reactor is at room temperature, and the liquid effluent and gases are collected for analysis.
• the conversion of the 540°C+ cut is calculated by difference in masses between the load and the total liquid effluent, such as: Math 1 mass 540 + °C effluent - - — - - - - mass 540 + C load
• plastic pyrolysis oil does not affect the conversion at 540°C+ and allows a significant increase in the yield of the PI-180°C cut while reducing the yields of heavy cuts. It is also shown that despite the presence of silicon in the plastic pyrolysis oil, the products resulting from the hydroconversion no longer contain it, which indicates that the silicon was captured by the supported catalyst. Likewise, the chlorine has been fully converted. The products resulting from this step are therefore low in impurities and can in particular be sent to fixed bed hydrotreatment processes.

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• 2022
  • 2022-03-17 FR FR2202343A patent/FR3133618B1/fr active Active
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