WO2023280627A1

WO2023280627A1 - Entrained-bed hydroconversion of a heavy hydrocarbon feedstock, comprising mixing said feedstock with a catalyst precursor containing an organic additive

Info

Publication number: WO2023280627A1
Application number: PCT/EP2022/067626
Authority: WO
Inventors: Joao MARQUES; Thibaut CORRE; Jeremie Barbier; Brett Matthew SILVERMAN; David M. Mountainland; Sukesh Parasher
Original assignee: IFP Energies Nouvelles
Priority date: 2021-07-08
Filing date: 2022-06-27
Publication date: 2023-01-12
Also published as: FR3125060A1; CN117651754A

Abstract

The present invention relates to a process for the entrained-bed hydroconversion of a heavy hydrocarbon feedstock (101), comprising: (a) preparing a conditioned feedstock (103) by mixing said heavy hydrocarbon feedstock (101) with a catalyst precursor formulation (104) such that a colloidal or molecular catalyst forms when reacted with sulphur, said catalyst precursor formulation (104) comprising a catalyst precursor composition (105) including Mo and an organic additive (102) having a carboxylic acid function and/or an ester function and/or an acid anhydride function, and a molar ratio of organic additive (102) to Mo within the range from 0.1:1 to 20:1; (b) heating the conditioned feedstock; (c) introducing the heated conditioned feedstock (106) into at least one entrained bed reactor and operating said reactor in the presence of hydrogen and under hydroconversion conditions in order to produce an upgraded material (107), the colloidal or molecular catalyst being formed during step (b) and/or (c).

Description

HYDROCONVERSION IN A HEAVY HYDROCARBON LOAD ENDUCED BED COMPRISING THE MIXING OF SAID LOAD WITH A CATALYST PRECURSOR

CONTAINING AN ORGANIC ADDITIVE

Technical field The present invention relates to a process for the conversion of heavy hydrocarbon feedstocks in the presence of hydrogen, a colloidal or molecular catalyst, and an organic additive.

In particular, the present invention involves a process for the hydroconversion of heavy hydrocarbon feedstocks containing a fraction of at least 50% by weight having a boiling point of at least 300° C., and in particular heavy hydrocarbon feedstocks comprising a significant quantity of asphaltenes and/or fractions with a boiling point above 500°C, such as crude oils or heavy hydrocarbon fractions resulting from the atmospheric and/or vacuum distillation of a crude oil, for yield higher quality, lower boiling point materials.

The process specifically comprises mixing said heavy hydrocarbon feedstock with a catalyst precursor formulation comprising an organic additive, before being sent to one or more entrained bed reactors, in order to allow the upgrading of this low quality feedstock while minimizing plant fouling by inhibiting the formation of coke precursors and sediment prior to hydroconversion in the entrained bed reactor(s).

Prior Art The conversion of heavy hydrocarbon feedstocks into useful end products requires extensive processing, including reducing the boiling point of the heavy hydrocarbon feedstock, increasing the hydrogen-to-carbon ratio, and removing impurities such as as metals, sulphur, nitrogen and high carbon compounds.

Catalytic hydroconversion is commonly used for heavy hydrocarbon feedstocks and is generally implemented using three-phase reactors in which the feedstock is brought into contact with hydrogen and a catalyst. In the reactor, the catalyst can be used in the form of a fixed bed, a moving bed, an ebullating bed or an entrained bed, as described for example in chapter 18 “Catalytic Hydrotreatment and Hydroconversion: Fixed Bed, Moving Bed, Ebullated Bed and Entrained Bed” from the book “Heavy Crude Oils: From Geology to Upgrading, An OverView”, published by Éditions Technip in 2011. In the case of an ebullated bed or an entrained bed, the reactor comprises an upward flow of liquid and gas.

The choice of technology generally depends on the nature of the feed to be treated and in particular on its metal content, its tolerance to impurities and the intended conversion.

Entrained bed hydroconversion processes use entrained bed technologies also called slurry technologies.

In such processes, a dispersed catalyst or catalyst precursor is injected on a continuous basis into the heavy hydrocarbon feedstock in the entrained bed reactor, promoting the hydrogenation of radicals formed by thermal cracking reactions, and limiting the formation of coke. .

The catalyst provides the catalytic activity but also a surface for the deposition of metals and asphaltenes from the charge.

The very small catalyst, dispersed in the charge, is driven out of the reactor with the effluents, since the catalyst and the heavy hydrocarbon charge behave as a homogeneous phase.

Entrained bed hydroconversion processes are known to generally aim to completely convert the heavy hydrocarbon feedstock into lighter fractions, using very severe operating conditions (temperature, partial pressure of hydrogen, residence time).

The theoretical advantages of entrained bed processes lie in much better hydrogenation, especially of heavier products, through better accessibility of active sites, resulting in higher conversion, improved product quality and higher product stability. .

Additionally, due to the lower catalyst residence time, catalyst deactivation is greatly reduced.

Regarding product stability, it is known that during operation of an entrained bed reactor for the upgrading of a heavy hydrocarbon feedstock, the heavy feedstock is heated to a temperature at which the high boiling point fractions heavy hydrocarbon feedstock typically having a high molecular weight and/or low hydrogen to carbon ratio, an example of which is a family of complex compounds collectively referred to as "asphaltenes", tend to undergo thermal cracking to form radicals free with reduced chain length. These free radicals can react with other free radicals, or with other molecules, to produce coke precursors and sediments. An entrained catalyst passing through the reactor reacts with free radicals in these areas, forming stable molecules of reduced molecular weight and boiling point, and thus helps to control and reduce the formation of sediments and coke precursors. Since the formation of coke and sediment is the main cause of the fouling of hydroconversion installations, such an entrained bed process makes it possible to prevent the fouling of installations downstream, such as separation tanks, distillation columns, heat exchangers etc.

Entrained catalysts for the hydroconversion of heavy hydrocarbon feedstock, and in particular colloidal or molecular catalysts formed by the use of soluble catalyst precursors, are well known in the art. It is known in particular that certain metal compounds, such as organosoluble compounds (eg molybdenum naphthenate or molybdenum octoate as cited in US4244839, US2005/0241991, US2014/0027344) or water-soluble compounds (eg phosphomolybdic acid cited in patents US3231488, US4637870 and US4637871; ammonium heptamolybdate cited in patent US6043182, salts of a heteropolyanion as cited in FR3074699), can be used as dispersed catalyst precursors and form catalysts. In the case of water-soluble compounds, the dispersed catalyst precursor is generally mixed with the filler to form an emulsion. The dissolution of the dispersed catalyst precursor (generally molybdenum), optionally activated by cobalt or nickel in an acid medium (in the presence of H ₃ PO ₄ ) or in a basic medium (in the presence of NH ₄ OH), has been the subject of numerous studies and patents.

Patent document US8431016 describes a hydroconversion process for heavy hydrocarbon feeds using a colloidal or molecular catalyst in an entrained bed hydrocracking reactor. The addition of a dispersed organosoluble catalyst precursor, which is pre-diluted in vacuum gas oil (VGO), is carried out in a step of intimate mixing with the charge for the preparation of a conditioned charge before its introduction in the entrained bed reactor. The catalyst precursor, typically molybdenum 2-ethylhexanoate, forms a colloidal or molecular catalyst (e.g. dispersed molybdenum sulfide) when heated, by reaction with hhS from the hydrodesulfurization of the feed.

Such a process inhibits the formation of coke precursors and sediments that might otherwise foul the ebullated bed reactor and downstream facilities, while providing conversion of the asphaltene fraction at essentially the same rate as the tailings conversion rate. overall, even at a very high overall residue conversion, unlike hydroconversion processes using conventional supported catalysts. In addition to the fouling due to coke precursors and sediments which may appear in the entrained bed reactor and in the installations downstream, the inventors have observed that fouling can also appear in the installations upstream, as soon as the heavy hydrocarbon charge containing the catalyst precursor is heated before it is introduced into the hydroconversion reactor.

Such fouling in installations upstream of the hydroconversion reactor, in particular in the installation for heating the heavy hydrocarbon feedstock mixed with the catalyst precursor of the particulate molecular or colloidal catalyst, seems to be mainly linked to the accumulation of metals and of carbon in the wall, and can limit the usability of the facilities.

Thus, although the entrained catalyst in known entrained bed processes, as disclosed in US8431016, is known to reduce coke precursor and sediment fouling in the hydroconversion reactor and in downstream facilities , the fouling observed in upstream installations containing the heavy hydrocarbon feed mixed with the catalyst precursor, such as in a preheater, constitutes another operational problem which has not yet been solved. Furthermore, it was observed that fouling due to coke precursors and sediments can still occur in downstream facilities in some cases, showing that the performance of entrained catalyst addition can still be improved.

Objects and summary of the invention

In the context described above, an object of the present invention is to provide an entrained bed hydroconversion process using a colloidal or molecular catalyst formed by the use of a soluble catalytic precursor, solving the problem of fouling, in particular in installations upstream of the hydroconversion reactor, in particular in a device for preheating the charge before its conversion in the entrained bed hydroconversion reactor(s).

More generally, the present invention aims to provide an entrained bed hydroconversion process for the recovery of heavy hydrocarbon feedstocks allowing one or more of the following effects: reduced fouling of equipment, more efficient treatment of asphaltene molecules, reduction of formation of coke precursors and sediments, increased conversion rate, ability for the reactor to process a wider range of lower grade hydrocarbon feedstocks, elimination of catalyst-free zones in downstream processing facilities, longer operation between maintenance shutdowns, and increased throughput of heavy hydrocarbon feedstock, and increased production rate of converted products. A reduction in the frequency of stopping and starting process equipment implies a reduction in the cycles of pressure and temperature of process installations, and this significantly increases process safety and extends the useful life of expensive installations.

Thus, in order to achieve at least one of the objectives referred to above, among others, the present invention provides, according to a first aspect, a process for the hydroconversion of a heavy hydrocarbon feedstock containing a fraction of at least 50% by weight having a boiling point of at least 300°C, and containing metals and asphaltenes, comprising the following steps:

(a) preparing a conditioned heavy hydrocarbon feedstock by mixing said heavy hydrocarbon feedstock with a catalyst precursor formulation such that a colloidal or molecular catalyst is formed when reacted with sulfur, said precursor formulation catalyst comprising:

- a catalyst precursor composition comprising molybdenum, and

- an organic chemical compound comprising at least one carboxylic acid function and/or at least one ester function and/or one acid anhydride function, and

- a molar ratio between said organic chemical compound and molybdenum in said catalyst precursor formulation being between 0.1:1 and 20:1;

(b) heating said conditioned heavy hydrocarbon feedstock from step (a) in at least one preheater;

(c) introducing said heated conditioned heavy hydrocarbon feedstock of step (b) into at least one entrained bed reactor and operating said entrained bed reactor in the presence of hydrogen and under hydroconversion conditions to produce a material valued; and wherein the colloidal or molecular catalyst is formed in situ in the heavy hydrocarbon feedstock conditioned in step (b) and/or in step (c).

According to one or more embodiments, step (a) comprises simultaneously mixing said organic chemical compound with said catalyst precursor composition, preferably previously diluted with a hydrocarbon oil diluent, and with said heavy hydrocarbon feedstock, preferably at a temperature below a temperature at which a substantial portion of the catalyst precursor composition begins to thermally decompose, such as at a temperature between room temperature and 300°C, and for a time period of 1 second to 30 minutes.

According to one or more embodiments, step (a) comprises (a1) premixing said organic chemical compound with said catalyst precursor composition to produce said catalyst precursor formulation and (a2) mixing said catalyst precursor formulation with said heavy hydrocarbon feedstock.

According to one or more embodiments, in step (al) said catalyst precursor composition is mixed at a temperature below a temperature at which a substantial part of the catalyst precursor composition begins to thermally decompose, preferably at a temperature between room temperature and 300°C.

According to one or more embodiments, a hydrocarbon oil diluent is used to form the catalyst precursor formulation, said hydrocarbon oil diluent being preferably selected from the group consisting of a vacuum gas oil, a decantation oil or a recycling oil, light diesel, vacuum residues, deasphalted oils and resins.

According to one or more embodiments, the organic chemical compound is chosen from the group consisting of ethylhexanoic acid, naphthenic acid, caprylic acid, adipic acid, pimelic acid, suberic acid, azelaic acid, and sebacic acid, ethyl octanoate, ethyl 2-ethylhexanoate, 2-ethylhexyl 2-ethylhexanoate, benzyl 2-ethylhexanoate, diethyl adipate, adipate dimethyl, bis(2-ethylhexyl) adipate, dimethyl pimelate, dimethyl suberate, monomethyl suberate, hexanoic anhydride, caprylic anhydride, and mixtures thereof.

According to one or more embodiments, the organic chemical compound comprises 2-ethylhexanoic acid, and is preferably 2-ethylhexanoic acid.

According to one or more embodiments, the organic chemical compound comprises ethyl octanoate or 2-ethylhexyl 2-ethylhexanoate, and is preferably ethyl octanoate or 2-ethylhexyl 2-ethylhexanoate.

According to one or more embodiments, the catalyst precursor composition comprises an oil-soluble organometallic compound or complex selected from the group consisting of molybdenum 2-ethylhexanoate, molybdenum naphthanate, molybdenum hexacarbonyl, and is preferably molybdenum 2-ethylhexanoate.

According to one or more embodiments, the molar ratio between said organic chemical compound and molybdenum of said catalyst precursor formulation is between 0.75: 1 and 7: 1, and preferably between 1: 1 and 5: 1. According to one or more embodiments, the colloidal or molecular catalyst comprises molybdenum disulfide.

According to one or more embodiments, step (b) comprises heating to a temperature between 280°C and 450°C, more preferably between 300°C and 400°C, and even more preferably in a range of 320 °C to 365°C.

According to one or more embodiments, the heavy hydrocarbon feedstock comprises at least one of the following feedstocks: a crude oil, bitumen from bituminous sands, bottoms of atmospheric distillation columns, bottoms of vacuum distillation columns, residues , visbreaker bottoms, coal tar, heavy oil from oil shale, liquefied coal, heavy bio-oils, and heavy oils including plastic waste and/or plastic pyrolysis oil.

According to one or more embodiments, the heavy hydrocarbon feedstock has sulfur at a content greater than 0.5% by weight, a Conradson carbon residue of at least 0.5% by weight, C ₇ asphaltenes at a content greater than 1% by weight, of transition and/or post-transition metals and/or metalloids at a content greater than 2 ppm by weight, and of alkali metals and/or alkaline-earth metals at a content greater than 2 ppm in weight.

According to one or more embodiments, step (c) is implemented under an absolute pressure of between 2 MPa and 38 MPa, at a temperature of between 300° C. and 550° C., at an hourly volumetric speed WH per relative to the volume of each entrained bed reactor between 0.05 h ¹ and 10 h ¹ and under a quantity of hydrogen mixed with the feed entering the entrained bed reactor between 50 and 5000 Nm ³ /m ³ of feed .

According to one or more embodiments, the molybdenum concentration in the conditioned heavy hydrocarbon feedstock is preferably in a range from 10 ppm to 10,000 ppm by weight of the heavy hydrocarbon feedstock.

Other subjects and advantages of the invention will become apparent on reading the following description of specific exemplary embodiments of the invention, given by way of non-limiting examples, the description being made with reference to the appended figures described below.

List of Figures

FIG. 1 is a block diagram illustrating the principle of the entrained bed hydroconversion process according to the invention. Figure 2 is a block diagram illustrating an entrained bed hydroconversion process according to one embodiment of the invention, in which the catalyst precursor formulation is obtained by premixing the organic additive with the precursor composition of catalyst.

Figure 3 is a block diagram illustrating an example of an entrained bed hydroconversion as shown in Figure 2, wherein the catalyst precursor formulation is obtained by mixing the catalyst precursor composition with a diluent containing an additive organic.

Figure 4 is a block diagram illustrating another example of an entrained bed hydroconversion as shown in Figure 2, wherein the catalyst precursor formulation is obtained by blending an additive-containing catalyst precursor composition with a hydrocarbon oil diluent.

Figure 5 is a block diagram illustrating another example of an entrained bed hydroconversion as shown in Figure 2, wherein the catalyst precursor formulation is obtained by mixing a diluted catalyst precursor composition with an organic additive .

FIG. 6 is a block diagram illustrating an example of an entrained bed hydroconversion process and system according to the invention.

FIG. 7 is a graph showing the fouling tendency of examples of conditioned hydrocarbon feedstocks as prepared in the entrained bed hydroconversion process according to the invention and according to the prior art.

Description of embodiments

The object of the invention is to provide entrained bed hydroconversion methods and systems for improving the quality of a heavy hydrocarbon feedstock.

Such processes and systems for the hydroconversion of heavy hydrocarbon feedstocks employ an entrained catalyst which is a molecular or colloidal catalyst dispersed in the heavy hydrocarbon feedstock. They also employ an organic additive added to a catalyst precursor formulation which is mixed with the heavy hydrocarbon feedstock, before using the entrained catalyst in one or more entrained bed reactors, each of which includes a liquid phase comprising the heavy hydrocarbon feedstock , the colloidal or molecular catalyst dispersed therein and the organic additive, and a gas phase comprising hydrogen gas.

The entrained bed hydroconversion methods and systems of the invention reduce the fouling of the installations, and in particular the fouling in the installations upstream of the reactor(s) hydroconversion reactors, in particular in plants for preheating the feedstock before its conversion in the entrained bed hydroconversion reactor(s), and can effectively treat asphaltenes, reduce or eliminate the formation of coke precursors and sediments, increase the conversion rate in particular by making it possible to carry out the hydroconversion at high temperature, and eliminate zones free of catalyst which would otherwise exist in downstream treatment installations.

Terminology

Some definitions are given below, although more details on the objects defined below are given later in the description.

The term "hydroconversion" refers to a process the primary purpose of which is to reduce the boiling point range of a heavy hydrocarbon feedstock and in which a substantial portion of the feedstock is converted to products with lower boiling point ranges. boiling points lower than those of the original charge. Hydroconversion generally involves the fragmentation of larger hydrocarbon molecules into smaller molecular fragments having a lower number of carbon atoms and a higher hydrogen to carbon ratio. The reactions implemented 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. The mechanism by which hydroconversion occurs typically involves the formation of hydrocarbon free radicals during fragmentation primarily by thermal cracking, followed by capping of the free radical ends or fragments with hydrogen in the presence of active catalyst sites. . Of course, during a hydroconversion process, other reactions typically associated with "hydrotreating" may occur such as the removal of sulfur and nitrogen from the feed as well as the saturation of olefins.

The term "hydrocracking" is often used as a synonym for "hydroconversion" in English terminology, although "hydrocracking" rather refers to a process similar to a hydroconversion but in which the cracking of hydrocarbon molecules is primarily a catalytic cracking, that is to say cracking occurring in the presence of a hydrocracking catalyst possessing a phase responsible for the cracking activity, for example acid sites such as contained in a clay or zeolites. According to the French terminology for example, hydrocracking, which can be translated as "hydrocracking", generally refers to this last definition (catalytic cracking), and its use is for example rather reserved for the case of vacuum distillates as feedstocks. oil to be converted, while the French term " hydroconversion” is generally reserved for the conversion of heavy hydrocarbon feedstocks such as atmospheric and vacuum residues (but not only).

The term "hydrotreating" refers to a milder operation whose primary purpose is to remove impurities such as sulfur, nitrogen, oxygen, halides, and trace metals from the feed 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 feed. Hydrotreating is most often carried out using a fixed bed reactor, although other hydroprocessing reactors can also be used for hydrotreating, for example an ebullated bed hydrotreating reactor .

The term "hydroprocessing" generally refers to both "hydroconversion"/"hydrocracking" and "hydrotreating" processes.

The term "hydroconversion reactor" refers to any vessel in which the hydroconversion of a feedstock is the primary purpose, e.g. cracking the feedstock (i.e. reducing the d point range boiling), in the presence of hydrogen and a hydroconversion catalyst. Hydroconversion reactors typically include an inlet through which heavy hydrocarbon feedstock and hydrogen can be introduced and an outlet from which upgraded material can be withdrawn. Specifically, hydroconversion reactors are also characterized by possessing sufficient thermal energy to cause larger hydrocarbon molecules to break down into smaller molecules by thermal decomposition. Examples of hydroconversion reactors, and in particular hydrocracking 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 fixed-bed reactors (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 countercurrently in some case).

The terms "hybrid bed" and "hybrid bubbling bed" and "entrained-bubbling hybrid bed" for a hydroconversion reactor refer to a bubbling bed hydroconversion reactor comprising an entrained catalyst in addition to a porous supported catalyst maintained in the bubbling bed reactor. Similarly, for a hydroconversion process, these terms thus make reference to a process comprising hybrid operation of an ebullated bed and an entrained bed in at least one and 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 (upgraded feed). In the present invention, the entrained catalyst is a colloidal catalyst or a molecular catalyst, as defined below.

The terms "entrained bed reactor", "entrained phase reactor" and "slurry reactor" generally refer to two-phase, i.e. liquid and gas, or three-phase entrained-bed reactors, c ie liquid, gas, and solid, for the hydroconversion, in particular the hydrocracking, of heavy hydrocarbon feedstock.

In the present invention, this refers to an entrained bed reactor which at least comprises a colloidal or molecular catalyst as defined below.

In the present invention, the entrained bed reactor contains an entrained catalyst, at least one colloidal catalyst or molecular catalyst as defined below, which is the only hydroconversion catalyst in the entrained bed reactor (no porous supported catalyst maintained in the reactor during operation as in an ebullated or hybrid bed reactor).

An example of an entrained bed reactor is disclosed in US6960325 B.

The liquid phase typically comprises a hydrocarbon feed that contains a colloidal catalyst or a molecular size catalyst (solid particles).

The solid catalyst particles, colloidal or molecular in size, together with the liquid hydrocarbon feed, can behave as a continuous liquid phase due to the catalyst particle size (colloidal or molecular).

A solid catalyst in the form of a solid particle of micron size or larger can also be used as well as liquid and gas.

The terms "colloidal catalyst" and "colloidally dispersed catalyst" refer to catalyst particles having a particle size that is colloidal, eg less than 1 µm 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. The term "colloidal catalyst" includes, but is not limited to, molecular or molecularly dispersed catalyst compounds. The terms "molecular catalysts" and "molecularly dispersed catalysts" refer to catalyst compounds that are substantially "dissolved" or completely dissociated from other catalyst compounds or molecules in a heavy hydrocarbon feedstock, non-volatile liquid fraction, a bottoms fraction, residues, or other 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 molecules of catalyst joined together (eg 15 molecules or less).

The terms "porous supported catalyst", "solid supported catalyst", and "supported catalyst" refer to catalysts that are typically used in conventional bubbling bed and fixed bed hydroconversion systems, including catalysts designed primarily for hydrocracking or hydrodemetallization and catalysts designed primarily for hydrotreating. Such catalysts typically comprise (i) a catalyst support having a large surface area and many interconnected channels or pores and (ii) fine particles of an active catalyst such as sulphides of cobalt, nickel, tungsten, and/or or molybdenum dispersed in the pores. Supported catalysts are commonly produced as cylindrical extrudates ("pellets") or spherical solids, although other shapes are possible.

The terms "upgraded", "upgraded" and "upgraded", when used to describe a feedstock which is or has been subjected to hydroconversion, or a resulting material or product, refer to the one of the following characteristics: a reduction in the molecular weight of the filler, a reduction in the boiling point range of the filler, a reduction in the concentration of asphaltenes, a reduction in the concentration of hydrocarbon free radicals, a reduction in the Conradson carbon residue, an increase in the H/C atomic ratio of the charge, and a reduction in the amount of impurities, such as sulfur, nitrogen, oxygen, and halides.

The terms "conditioned feedstock" and "conditioned heavy hydrocarbon feedstock" refer to the heavy hydrocarbon feedstock to be processed in at least one hydroconversion entrained bed reactor, wherein a catalyst precursor formulation comprising a catalyst precursor composition catalyst and an organic additive have been combined and mixed sufficiently so that during the formation of the catalyst, in particular by reaction with sulfur, the catalyst will comprise a colloidal or molecular catalyst dispersed in the load.

The term "active mixing device" refers to a mixing device comprising a moving part, eg a stirring rod or impeller or a turbine rotor, for actively mixing the components. In the following, the term "includes" is synonymous with (means the same as) "includes" and "contains", and is inclusive or open ended and does not exclude other unspecified items. It will be understood that the term "includes" includes the exclusive and exclusive term "constituted".

The terms "between ... and ..." and "in the range of ... to ..." and "in a range of ... to ..." mean that the values at the limits of the interval are included in the range of values described, unless otherwise stated.

In the detailed description below, many specific details are set forth to convey a deeper understanding of the method of the system according to the invention. However, it will be apparent to those skilled in the art that the method and system can be employed without all of these specific details. In other cases, features which are well known have not been described in detail, so as not to complicate the description unnecessarily.

FIG. 1 is a functional diagram schematically illustrating the principle of the entrained bed hydroconversion process 100 according to the invention. It differs from a conventional entrained bed process, as described for example in document US8431016 in particular, in that the catalyst precursor formulation comprises an organic additive when it is mixed with the hydrocarbon charge, said precursor formulation catalyst also comprising a catalyst precursor composition comprising molybdenum and having a specific molar ratio of organic additive to molybdenum.

The terms “organic chemical compound” and “organic additive” are used interchangeably in the present description to designate the organic chemical compound comprising at least one carboxylic acid function and/or at least one ester function and/or one added acid anhydride function. in the catalyst precursor formulation mixed with the heavy hydrocarbon feed in step (a), and described in detail below. The organic additive is a compound in addition to any possible organic compound initially present in the catalyst precursor composition.

According to the invention, a heavy hydrocarbon feedstock 101 containing a fraction of at least 50% by weight having a boiling point of at least 300° C., and containing metals and asphaltenes, is treated in a process of hydroconversion 100 comprising the following steps:

(a) preparing a conditioned heavy hydrocarbon feedstock 103 by mixing said heavy hydrocarbon feedstock 101 with a catalyst precursor formulation 104 such that a colloidal or molecular catalyst is formed when reacted with sulfur, said precursor formulation catalyst 104 comprising: - a catalyst precursor composition 105 comprising molybdenum, and

- an organic chemical compound 102 comprising at least one carboxylic acid function and/or at least one ester function and/or at least one acid anhydride function, and

- a molar ratio between said organic chemical compound 102 and molybdenum of between 0.1:1 to 20:1;

(b) heating the conditioned heavy hydrocarbon feedstock 103 from step (a) in at least one preheater;

(c) introducing the heated conditioned heavy hydrocarbon feedstock 106 of step (b) into at least one entrained bed reactor and operating said entrained bed reactor in the presence of hydrogen and under hydroconversion conditions to produce a material valued 107.

In the hydroconversion process according to the invention, the colloidal or molecular catalyst is formed in situ in the heavy hydrocarbon feedstock conditioned in stage (b) and/or in stage (c).

The recovered material 107 may be further processed in an optional step (d).

Each step, flow and material involved are now detailed below.

Some of the reference numerals mentioned below refer to FIG. 6, which schematically illustrates an example of an entrained bed hydroconversion system 600 according to the invention, said system being described in detail later in the description, after the description of the general process.

Heavy hydrocarbon feedstock

The term "heavy hydrocarbon feedstock" refers to crude oils, oil sands bitumen, bottoms and residuals from refinery processes (e.g. visbreaker bottoms), and any other lower quality feed that contains a substantial amount of high boiling hydrocarbon fraction and/or which includes a significant amount of asphaltenes which can deactivate a solid supported catalyst and/or cause or result in the formation of coke precursors and sediments.

The heavy hydrocarbon feedstock 101 can thus comprise at least one of the following feedstocks: a crude oil, a bitumen from bituminous sands, bottoms of atmospheric distillation columns, bottoms of vacuum distillation columns, residues, bottoms of visbreaker, coal tar, heavy oil from oil shale, liquefied coal, heavy bio-oils, and heavy oils including plastic waste and/or plastic pyrolysis oil. Plastic pyrolysis oils are oils obtained by the pyrolysis of plastics, preferably waste plastics, and can be obtained by treatment by catalytic, thermal pyrolysis or can be prepared by hydropyrolysis (pyrolysis in the presence of a catalyst and hydrogen).

In particular, the heavy hydrocarbon charge treated contains hydrocarbon fractions among which at least 50% by weight, preferably at least 80% by weight have a boiling point of at least 300° C., preferably of at least 350° C. or at least 375°C.

These are crude oils or heavy hydrocarbon fractions resulting from the atmospheric and/or vacuum distillation of a crude oil. They can also be atmospheric and/or vacuum residues, and in particular atmospheric and/or vacuum residues resulting from hydrotreatment, hydrocracking and/or hydroconversion. They can also be vacuum distillates, fractions originating from a catalytic cracking unit such as fluidized bed catalytic cracking (FCC), a coking or visbreaking unit.

Preferably, these are vacuum residues. Generally, these residues are fractions in which at least 80% by weight have a boiling point of at least 450°C or more, and most often of at least 500°C or 540°C.

Aromatic fractions extracted from a lubricant production unit, deasphalted oils (raffinates from a deasphalting unit), and asphalt (residues from a deasphalting unit) are also suitable as feed.

The feedstock can also be a residual fraction originating from a direct coal liquefaction (vacuum distillate and/or atmospheric and/or vacuum residue originating e.g. from an H-Coal process, registered trademark), from a pyrolysis of coal or residues of bituminous shale, or of a residual fraction originating from the direct liquefaction of lignocellulosic biomass alone or mixed with coal and/or a petroleum fraction (referred to herein as “heavy bio-oils”).

Examples of heavy hydrocarbon feedstocks include, but are not limited to, Lloydminster Crude Oil, Cold Lake Bitumen, Athabasca Bitumen, Urals Crude Oil, Arabian Heavy Crude Oil, Arabian Crude Oil Light, atmospheric distillation column bottoms, vacuum distillation column bottoms, bottoms (or "tails"), bottoms pitch, vacuum bottoms, solvent deasphalting pitch, and liquid fractions not volatiles that remain after subjecting a crude oil, bitumen from oil sands, liquefied coal, oil shales, or coal tar feeds to distillation, hot separation, and the like which contain high boiling point fractions and/or asphaltenes.

All these fillers can be used alone or in a mixture.

The heavy hydrocarbon feedstocks treated above in the process and the system according to the invention contain metals and asphaltenes, in particular C ₇ asphaltenes, and other impurities such as sulfur and nitrogen.

The term "asphaltene" refers to the fraction of a heavy hydrocarbon feedstock which is typically insoluble in paraffinic solvents such as propane, butane, pentane, hexane, and heptane and which comprises sheets of compounds fused rings held together by heteroatoms such as sulfur, nitrogen, oxygen and metals. Asphaltenes broadly include a wide range of complex compounds having 80 to 160,000 carbon atoms. Asphaltenes are operationally defined as "C ₇ asphaltenes", i.e. compounds insoluble in heptane according to the ASTM D 6560 standard (also corresponding to the NF T60-115 standard), and any content of asphaltenes refers to C ₇ asphaltenes in the present description. C ₇ asphaltenes are compounds known to inhibit the conversion of residual fractions, both by their ability to form heavy hydrocarbon residues, commonly called coke, and by their tendency to produce sediments which greatly limit the exploitability of hydrotreating and hydroconversion units.

The heavy hydrocarbon charge 101 can typically have sulfur at a content greater than 0.5% by weight, a Conradson carbon residue of at least 3% by weight, C ₇ asphaltenes at a content greater than 1% by weight , transition and/or post-transition metals and/or metalloids at a content greater than 2 ppm by weight, and alkali metals and/or alkaline-earth metals at a content greater than 2 ppm by weight.

These types of fillers are in fact generally rich in impurities such as metals, in particular transition metals (e.g. Ni, V) and/or post-transition metals, and/or metalloids, for which a content may be higher than 2 ppm by weight, or greater than 20 ppm by weight, and even greater than 100 ppm by weight, and also in alkali metals (e.g. Na) and/or in alkaline-earth metals, the content of which may be greater than 2 ppm in weight, even greater than 5 ppm by weight, and even greater than 7 ppm or 10 ppm by weight.

The sulfur content is in fact generally greater than 0.5% by weight, and even greater than 1% by weight, or even greater than 2% by weight. The content of C ₇ asphaltenes can in fact be at least 1% by weight, and even greater than 3% by weight.

The Conradson carbon residue is in fact generally greater than 3% by weight, and even at least 5% by weight. Conradson carbon residue is defined by ASTM D 482 and represents the amount of carbon residue produced after pyrolysis under standard conditions of temperature and pressure.

These contents are expressed in % by weight of the total weight of the filler.

Step (a): Preparation of Conditioned Heavy Hydrocarbon Feedstock

Step (a) comprises mixing said heavy hydrocarbon feedstock 101 with a catalyst precursor formulation 104 in such a manner that a colloidal or molecular catalyst is formed when reacted with sulfur. This mixture forms what is referred to herein as conditioned heavy hydrocarbon feedstock 103.

The catalyst precursor formulation 104 comprises a catalyst precursor composition 105 comprising molybdenum, and an organic chemical compound 102 comprising at least one carboxylic acid function and/or at least one ester function and/or at least one anhydride function. acid.

The molar ratio between said organic chemical compound 102 and molybdenum is between 0.1:1 and 20:1.

This step includes complete/intimate mixing with the catalyst precursor formulation which will lead to the formation of a colloidal or molecular catalyst dispersed in the heavy hydrocarbon feedstock.

According to one or more embodiments, a hydrocarbon oil diluent is used to form catalyst precursor formulation 104. Preferably, said hydrocarbon oil diluent is selected from the group consisting of vacuum gas oil, settling oil or recycle oil, light gas oil, vacuum resid, deasphalted oils, and resins, as further detailed below.

The inventors have shown that this mixing step (a) improves the bubbling-entrained entrained bed hydroconversion process, in particular by reducing the fouling of the installations, in particular upstream of the entrained bed hydroconversion reactor in the installation heating load in step (b). Without being bound by any theory, the presence of the organic additive during the mixing of the heavy hydrocarbon feedstock with the catalyst precursor composition, allows better solubility of the colloidal or molecular catalyst precursor in the feedstock, avoiding or reducing the clogging in particular due to deposits in the installations upstream of the entrained bed hydroconversion reactor such as in the heating installation, and thus improving the dispersion of the colloidal or molecular catalyst formed in step (b) and/or at a later stage, thus generating an increased availability of the metallic active sites, promoting the hydrogenation of free radicals which are precursors of coke and sediments, and generating a substantial reduction in the fouling of the installations.

The organic additive

The organic additive 102 having at least one carboxylic acid function and/or at least one ester function and/or at least one acid anhydride function preferably comprises at least 6 carbon atoms, and more preferably at least 8 carbon atoms.

Typically, the organic additive 102 is neither a catalyst precursor nor a catalyst.

In particular, the organic additive 102 does not contain any metal.

Examples of organic additive include, but are not limited to, 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) adipate, dimethyl pimelate, dimethyl suberate, monomethyl suberate, hexanoic anhydride, caprylic anhydride. Advantageously, the organic additive is an organic chemical compound chosen from the group consisting of the list of specific compounds described above, and mixtures thereof.

Preferably, the organic additive is an organic chemical compound comprising at least one carboxylic acid function, and more preferably chosen from the group consisting of 2-ethylhexanoic acid, naphthenic acid, caprylic acid, adipic acid, pimelic acid, suberic acid, azelaic acid, and sebacic acid.

More preferably, the organic additive comprises, or consists of, 2-ethylhexanoic acid.

The organic additive can be an organic chemical compound comprising at least one ester function and/or one acid anhydride function, and for example chosen from the group consisting of ethyl octanoate, ethyl 2-ethylhexanoate, 2-ethylhexyl 2-ethylhexanoate, benzyl 2-ethylhexanoate, diethyl adipate, dimethyl adipate, bis(2-ethylhexyl) adipate, dimethyl pimelate, dimethyl suberate, monomethyl suberate, and/or in the group consisting of hexanoic anhydride and caprylic anhydride.

More preferably, the organic additive comprising at least one ester function and/or one acid anhydride function comprises, or consists of, ethyl octanoate or 2-ethylhexyl 2-ethylhexanoate or mixtures thereof, and preferably is ethyl octanoate or 2-ethylhexyl 2-ethylhexanoate.

The organic additive is added such that the molar ratio of organic additive to molybdenum (provided by the catalyst precursor compound, e.g. molybdenum 2-ethylhexanoate) in the catalyst precursor formulation 104 is within a range of about 0.1:1 to about 20:1, preferably in a range of about 0.75:1 to about 7:1, and more preferably in a range of about 1:1 to about 5:1. approximately” refers to an approximation of ±5%, preferably ±1%.

Catalyst precursor formulation

The catalyst precursor formulation comprises a catalyst precursor composition selected from all metal catalyst precursors containing molybdenum 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 S and / or any other source of sulfur, and allowing the hydroconversion of a heavy hydrocarbon feedstock after injection into said heavy hydrocarbon feedstock.

The molybdenum-containing catalyst precursor composition is advantageously an oil-soluble catalyst precursor composition containing at least one transition metal.

The catalyst precursor composition preferably comprises an oil-soluble organometallic compound or complex.

The oil-soluble catalyst precursor composition preferably has a decomposition temperature (temperature below which the catalyst precursor composition is substantially chemically stable) in a range of 100°C to 350°C, more preferably in a range of 150°C to 300°C, and even more preferably in a range of 175°C to 250°C. The oil-soluble organometallic compound or complex is preferably selected from the group consisting of molybdenum 2-ethylhexanoate, molybdenum naphthanate, and molybdenum hexacarbonyl.

These compounds are non-limiting examples of oil-soluble catalyst precursor compositions.

A presently preferred catalyst precursor composition is molybdenum 2-ethylhexanoate (also commonly referred to as molybdenum octoate). Typically, 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 feedstock at a temperature below 250°C.

One skilled in the art can, by following the present invention, select a mixing temperature profile which results in the mixing of a selected precursor composition, without substantial thermal decomposition prior to the formation of the colloidal or molecular catalyst. Incorporation of the organic additive

The mixing step (a) can be implemented in different ways detailed below, mainly depending on whether the organic additive is mixed simultaneously with the heavy hydrocarbon feedstock and the catalyst precursor composition, or is introduced sequentially. , in particular by premixing the catalyst precursor composition with the organic additive to form the catalyst precursor formulation before mixing it with the heavy hydrocarbon feedstock.

Mixing step (a) advantageously includes the use of at least one conditioning mixer 610 configured to provide thorough/intimate mixing between the feedstock and the catalyst precursor formulation 104 to form the conditioned heavy hydrocarbon feedstock. First Embodiment: Simultaneous Mixing of the Hydrocarbon Feedstock, the Organic Additive and the Catalyst Precursor Composition

According to a first embodiment, step (a) comprises the simultaneous mixing of the organic additive 102 with the catalyst precursor composition 105, preferably previously diluted with a hydrocarbon oil diluent, and with the heavy hydrocarbon feedstock 101 . According to this embodiment, the catalyst precursor formulation 104, comprising the catalyst precursor composition 105, preferably previously diluted, and the organic additive 102 is thus formed during the mixing with the heavy hydrocarbon feedstock 101.

The organic additive is added such that the molar ratio of organic additive to molybdenum (provided by the catalyst precursor compound, e.g. molybdenum 2-ethylhexanoate) is within a range of about 0.1:1 to about 20 : 1, preferably in a range of about 0.75:1 to about 7:1, and more preferably in a range of about 1:1 to about 5:1, as mentioned above.

Such simultaneous mixing is preferably carried out at a temperature below a temperature at which a substantial part of the catalyst precursor composition begins to thermally decompose, such as at a temperature between room temperature, e.g. 15°C and 300°C, more preferably between 50°C and 200°C, and even more preferably between 75°C and 175°C.

Such simultaneous mixing is carried out for a sufficient time and in such a manner as to disperse the catalyst precursor formulation throughout the feedstock to provide a conditioned heavy hydrocarbon feedstock 103 in which the catalyst precursor composition is thoroughly/intimately mixed into the feedstock. heavy hydrocarbon.

Preferably, the gauge pressure is between 0 MPa and 25 MPa, more preferably between 0.01 MPa and 5 MPa.

In order to obtain sufficient mixing of the catalyst precursor composition in the heavy hydrocarbon feedstock before the formation of the colloidal or molecular catalyst, the simultaneous mixing of the heavy hydrocarbon feedstock 101, the organic additive 102 and the precursor composition catalyst 105, preferably diluted with a hydrocarbon diluent, is preferably operated for a period of time in the range of 1 second to 30 minutes, more preferably 1 second to 10 minutes, and even more preferably in a range of 2 seconds 3 minutes away. In the present description, a mixing time (or dwell time for mixing) of 1 second includes instant mixing.

Although it is within the scope of the invention to directly mix catalyst precursor composition 105 with heavy hydrocarbon feedstock 101 and organic additive 102, care should be taken in such cases to mix the components for a time. sufficient to completely/intimately mix the catalyst precursor composition into the feed prior to catalyst formation. However, a long mixing time, for example a mixing of 24 hours, can generate for certain industrial operations a prohibitive cost.

Consequently, according to the first embodiment, step (a) preferably comprises a dilution of the catalyst precursor composition 105 before the simultaneous mixing with the heavy hydrocarbon feedstock 101 and the organic additive 102: a pre-dilution of the catalyst precursor composition 105 with a hydrocarbon diluent prior to the simultaneous mixing of said diluted catalyst precursor composition with the heavy hydrocarbon feedstock and the organic additive 102 greatly facilitates thorough and intimate mixing of the catalyst precursor composition in charging, particularly in the relatively short period of time required for large-scale industrial operations to be economically viable.

Such a mixture of a catalyst precursor composition, preferably of the oil-soluble catalyst precursor composition, with a hydrocarbon stream of diluent is for example described in the document US2005/0241991 and recalled below.

Using a dilute catalyst precursor composition shortens the overall mixing time by (1) reducing or eliminating solubility differences between the more polar catalyst precursor composition and the heavy hydrocarbon feedstock, (2) reducing or by eliminating rheology differences between the catalyst precursor composition and the heavy hydrocarbon feedstock, and/or (3) by breaking up the catalyst precursor molecules to form a solute in a hydrocarbon oil diluent which is much more easily dispersed in the heavy hydrocarbon charge. It is particularly advantageous to first form a dilute catalyst precursor composition in the case where the heavy hydrocarbon feed contains water (e.g. condensed water).

Otherwise, the greater affinity of water for the polar catalyst precursor composition can cause localized agglomeration of the catalyst precursor composition, resulting in poor dispersion and the formation of catalyst particles of micron or larger size. The hydrocarbon oil diluent is preferably substantially water-free (i.e., contains less than 0.5% by weight water, preferably less than 0.1% by weight water, and more preferably less than 750 ppmw water) to prevent the formation of substantial amounts of catalyst particles of micron or larger size.

Examples of suitable hydrocarbon diluents 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), slop oil or recycling (which typically has a boiling range of 360°C to 550°C), light gas oil (which typically has a boiling range of 200°C to 360°C), residue vacuum (which typically have a boiling range of 524°C+), deasphalted oils, and resins.

The weight ratio of catalyst precursor composition 105 to hydrocarbon oil diluent is preferably in a range of 1:500 to 1:1, more preferably in a range of 1:150 to 1:2, and even more preferably in a range of 1:100 to 1:5 (e.g. 1:100, 1:50, 1:30, or 1:10).

Said dilution before simultaneous mixing is advantageously carried out for a time period of 1 second to 30 minutes, preferably in a range of 1 second to 10 minutes, and even more preferably in a range of 2 seconds to 3 minutes. The actual time for this dilution depends, at least in part, on the temperature (i.e. which affects the viscosity of the fluids) and the mixing intensity used for the dilution.

Said dilution is also advantageously carried out at a temperature below a temperature at which a substantial part of the catalyst precursor composition begins to thermally decompose, preferably at a temperature between room temperature, e.g. 15°C, and 300 °C, more preferably between room temperature 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.

It will be appreciated that the actual temperature at which the dilute catalyst precursor composition 105 is formed typically depends largely on the decomposition temperature of the specific precursor composition being used.

Conditioner mixer 610 may include an active mixing device, any line injection system, or any in-line mixer as detailed below.

The simultaneous mixing of step (a) according to the first embodiment can be implemented in a dedicated tank of an active mixing device forming the conditioner mixer 610.

Such a configuration makes it possible in particular to increase the dispersion of the colloidal or molecular catalyst formed at a later stage. The use of a dedicated tank also allows a long residence time.

Such simultaneous mixing may alternatively comprise the injection of said organic additive 102 and the catalyst precursor composition 105, preferably previously diluted with a hydrocarbon oil diluent, into a line conveying the heavy hydrocarbon feed 101 to the entrained bed reactor (heating plant between the two). The conditioner mixer 610 thus comprises, in such a configuration, the part(s) of the pipe in which the mixing is carried out, and possibly additional systems to facilitate the mixing, such as for example static in-line mixers or mixers. high shear line as described later. Such a configuration makes it possible in particular to reduce the investments in installations and the space required by comparison with a mixture in a dedicated tank.

The conditioner mixer 610 used for simultaneous mixing may also include a combination of such a dedicated vessel, an active mixing device and in-line injection systems possibly including static and/or high shear in-line mixers.

Examples of mixing apparatus that can be used to effect complete simultaneous mixing of catalyst precursor composition 105, preferably diluted, with heavy hydrocarbon feedstock 101 and organic additive 102 include, but are not limited to, a high shear mix such as a mix 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 high shear in-line mixers; multiple static in-line mixers in combination with high shear in-line mixers followed by recirculation pumping in the buffer tank; combinations of the above devices followed by one or more multi-stage centrifugal pumps. According to one embodiment, continuous rather than discontinuous mixing in successive batches can be implemented using high-energy pumps having several compartments in which the catalyst precursor composition 105, preferably diluted, the heavy hydrocarbon feedstock 101 and organic additive 102 are stirred and mixed as part of the pumping process itself. The mixing apparatus previously described can also be used for the dilution stage discussed above in which the catalyst precursor composition 105 is mixed with the hydrocarbon oil diluent.

Increasing the shear force and/or energy of the simultaneous mixing process generally reduces the time required to achieve thorough mixing.

Second Embodiment: Premixing the Catalyst Precursor Composition with the Organic Additive

According to a second embodiment, as illustrated schematically in Figure 2, mixing step (a) comprises (a1) premixing the organic additive compound 102 with the catalyst precursor composition 105 to produce the formulation catalyst precursor 104, and (a2) mixing said catalyst precursor formulation 104 with said heavy hydrocarbon feedstock 101.

Step (a1) of premixing the organic additive compound 102 with the catalyst precursor composition 105 to produce the catalyst precursor formulation 104 can be carried out ex-situ (i.e. outside the hydroconversion system).

In such a second embodiment, the conditioner mixer 610 comprises at least one first mixing device for step (al) and at least one second mixing device for step (a2).

In step (al), the organic additive is added such that the molar ratio of organic additive 102 to molybdenum (provided by the catalyst precursor composition, e.g. molybdenum 2-ethylhexanoate) in the precursor formulation catalyst 104 is in a range of about 0.1:1 to about 20:1, preferably in a range of about 0.75:1 to about 7:1, and more preferably in a range of about 1: 1 to about 5:1.

In step (al) the catalyst precursor composition 105 is mixed at a temperature below a temperature at which a substantial portion of the catalyst precursor composition begins to thermally decompose, preferably at a temperature between room temperature , e.g. 15°C and 300°C, more preferably between room temperature and 200°C, even more preferably between 50°C and 200°C, and even more preferably between 75°C and 150°C, and even more preferably between 75°C and 100°C.

Stage (al)

Step (al) can itself be implemented in different ways detailed below.

Although it is within the scope of the invention to directly mix a catalyst precursor formulation consisting of the catalyst precursor composition 105 and the organic additive 102 with the heavy hydrocarbon feedstock 101 in step (a2) , the method according to said second embodiment of the invention preferably comprises in step (a1) the use of a hydrocarbon oil diluent to produce the catalyst precursor formulation 104, in particular to facilitate mixing in a complete and intimate of the catalyst precursor composition in the feed to step (a2) in the relatively short period of time required for large-scale industrial operations to be economically viable. The use of a hydrocarbon oil diluent to produce the catalyst precursor formulation 104 shortens the mixing time in step (a2) for the reasons already mentioned above in connection with the description of the precursor composition. of diluted catalyst for the first embodiment (reduction or elimination of differences in solubility, rheology etc.).

Examples of suitable hydrocarbon diluents 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), slop oil or recycle (which typically has a boiling range of 360°C to 550°C), and light gas oil (which typically has a boiling range of 200°C to 360°C).

The weight ratio of catalyst precursor 105 composition to hydrocarbon oil diluent in catalyst precursor 104 formulation is preferably in a range of 1:500 to 1:1, more preferably in a range of 1:150 to 1: 2, and even more preferably in a range of 1:100 to 1:5 (e.g. 1:100, 1:50, 1:30, or 1:10).

According to one or more sub-embodiments, as illustrated schematically in FIG. 3, step (al) of the method 300 according to the second embodiment comprises:

- (al) premixing said organic additive 102 with a hydrocarbon oil diluent to form an additive-containing diluent 108'; and

- (a2) mixing additive-containing diluent 108' with said catalyst precursor composition 105 to produce said catalyst precursor formulation 104.

Step (al) is preferably carried out at a temperature between room temperature, e.g. 15°C and 300°C, preferably between room temperature and 200°C, even more preferably between 50°C and 200°C. °C, even more preferably between 75°C and 150°C, and even more preferably between 75°C and 100°C.

The pressure for the pre-mix (al) stage is preferably the actual pressure of the diluent stream 108. Preferably, the gauge pressure for the pre-mix (al) stage is between 0 MPa and 25 MPa, more preferably between between 0.01 MPa and 5 MPa.

The residence time can be between 1 second and several days, preferably in a range of 1 second to 30 minutes, more preferably in a range of 1 second to 10 minutes, and even more preferably in a range of 1 second to 30 seconds .

Step (a2) is preferably carried out at a temperature below a temperature at which a substantial part of the catalyst precursor composition 105 begins to thermally decompose, preferably at a temperature between room temperature, eg 15° C and 300°C, preferably between room temperature 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.

The pressure of the mixing step (a2) is advantageously the actual pressure of the flow of diluent 108'.

Preferably, the gauge pressure for the pre-mixing stage (a2) is between 0 MPa and 25 MPa, more preferably between 0.01 MPa and 5 MPa.

The residence time can be between 1 second and several days, preferably in a range of 1 second to 30 minutes, more preferably in a range of 1 second to 10 minutes, and most preferably in a range of 1 second to 30 seconds .

It is understood that the actual temperature used in step (a2) typically depends on the decomposition temperature of the particular precursor composition being used.

According to one or more sub-embodiments, as schematically illustrated in FIG. 4, step (al) of the method 400 according to said second embodiment comprises:

- (bΐ) premixing said organic additive 102 with said catalyst precursor composition 105 to form a catalyst precursor composition containing the additive 105'; and

- (b2) mixing said additive-containing catalyst precursor composition 105' with a hydrocarbon oil diluent 108 to produce said catalyst precursor formulation 104.

Step (bΐ) is preferably carried out at a temperature below a temperature at which a substantial part of the catalyst precursor composition 105 begins to thermally decompose, preferably at a temperature between room temperature, e.g. 15° C and 300°C, preferably between room temperature and 200°C, even more preferably between 50°C and 200°C, even more preferably between 75°C and 150°C, and even even more preferably between 75 °C and 100°C.

Preferably, the gauge pressure for the mixing stage (bΐ) is between 0 MPa and 25 MPa, more preferably between 0.01 MPa and 5 MPa.

Step (b2) is preferably carried out at a temperature below a temperature at which a substantial portion of the catalyst precursor composition 105 begins to thermally decompose, preferably at a temperature between room temperature, eg 15° C and 300°C, preferably between room temperature and 200°C, even more preferably between 50°C and 200°C, even more preferably between 75°C and 150°C, and even even more preferably between 75°C and 100°C.

Preferably, the gauge pressure for the mixing stage (b2) is between 0 MPa and 25 MPa, more preferably between 0.01 MPa and 5 MPa.

It is understood that the actual temperature used in steps (bΐ) and (b2) typically depends largely on the decomposition temperature of the particular precursor composition that is used.

According to one or more sub-embodiments, as schematically illustrated in Figure 5, step (al) of the method 500 according to said second embodiment comprises:

- (yl) premixing said catalyst precursor composition 105 with a hydrocarbon oil diluent 108 to form a dilute catalyst precursor composition 109; and

- (y2) mixing said diluted catalyst precursor composition 109 with the organic additive 102 to produce said catalyst precursor formulation 104.

Step (yl) is preferably carried out at a temperature below a temperature at which a substantial portion of the catalyst precursor composition 105 begins to thermally decompose, preferably at a temperature between room temperature, e.g. 15° C and 300°C, preferably between room temperature and 200°C, even more preferably between 50°C and 200°C, even more preferably between 75°C and 150°C, and even even more preferably between 75 °C and 100°C.

Preferably, the gauge pressure for the mixing stage (yl) is between 0 MPa and 25 MPa, more preferably between 0.01 MPa and 5 MPa.

Step (y2) is preferably carried out at a temperature below a temperature at which a substantial part of the catalyst precursor composition 105 begins to thermally decompose, preferably at a temperature between room temperature, eg 15° C and 300°C, preferably between room temperature 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.

Preferably, the gauge pressure for the mixing stage (g2) is between 0 MPa and 25 MPa, more preferably between 0.01 MPa and 5 MPa.

It is understood that the actual temperature used in steps (y1) and (g2) typically depends largely on the decomposition temperature of the particular precursor composition being used.

The various mixing sub-steps of step (a1) can be carried out using different mixing apparatus, examples of which include, but are not limited to, high shear mixing such as mixing created in a tank with a turbine propeller or 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 high shear in-line mixers; multiple static in-line mixers in combination with high shear in-line mixers followed by recirculation pumping in the buffer tank; combinations of the above devices followed by one or more multi-stage centrifugal pumps. According to one embodiment, continuous rather than discontinuous mixing in successive batches can be implemented using high energy pumps having several compartments in which the components to be mixed are stirred and mixed as part of the mixing process. pumping itself.

For example, each of the different mixing sub-steps of step (al) can be implemented in a dedicated tank of an active mixing device forming part of the first mixing device of the conditioner mixer 610.

Such a configuration makes it possible in particular to increase the dispersion of the colloidal or molecular catalyst formed at a later stage. The use of a dedicated tank also makes it possible to achieve a high residence time.

According to another example, each of the different mixing sub-steps of step (a1) may alternatively comprise injecting the component to be mixed into a line conveying the other component, referred to herein as an in-line injection system. The second mixing device of the mixer-conditioner 610 thus comprises in such a configuration the part(s) of the pipe in which the mixing is carried out, and optionally systems to facilitate mixing, such as static in-line mixers or high shear in-line mixers as described above. Such a configuration makes it possible in particular to reduce the investments in installations and the space required by comparison with a mixture in a dedicated tank.

According to another example, the first mixing device of the conditioner mixer 610 can comprise a combination of such a dedicated tank of an active mixing device and in-line injection systems possibly comprising static in-line mixers and/or high shear.

Step (a2)

The step (a2) of mixing the catalyst precursor formulation 104 already containing the organic additive with said heavy hydrocarbon feedstock 101 is preferably carried out at a temperature below a temperature at which a substantial part of the precursor composition catalyst begins to thermally decompose, such as at a temperature from room temperature, e.g. 15°C, to 300°C, preferably in a range of 50°C to 200°C, and even more preferably in a range of 75° C to 175°C, to give the conditioned heavy hydrocarbon feedstock 103.

Step (a2) is performed for a sufficient time and in a manner to disperse the catalyst precursor formulation throughout the feedstock to provide a conditioned heavy hydrocarbon feedstock 103 in which the catalyst precursor composition is completely/intimately mixed with the heavy hydrocarbon feedstock.

In order to obtain sufficient mixing of the catalyst precursor formulation 104 into the heavy hydrocarbon feedstock forming the colloidal or molecular catalyst, step (a2) is preferably carried out for a period of time in the range of 1 second to 30 minutes, more preferably 5 seconds to 10 minutes, and even more preferably in a range of 20 seconds to 3 minutes.

Step (a2) according to the second embodiment can be implemented in a dedicated tank of an active mixing device forming the second mixing device of the conditioner mixer

610. Such a configuration makes it possible in particular to increase the dispersion of the colloidal or molecular catalyst formed in a later stage. The use of a dedicated tank also makes it possible to achieve a high residence time.

Step (a2) may alternatively comprise injecting said catalyst precursor formulation 104 into a line conveying the heavy hydrocarbon feedstock 101 to the entrained bed reactor. The second mixing device of the conditioner mixer 610 thus comprises in such a configuration the part(s) of the pipe in which the mixing is carried out, and possibly additional systems to facilitate the mixing, such as, for example, mixers in static in-line or high shear in-line mixers as described above. Such a configuration makes it possible in particular to reduce the investments in installations and the space required by comparison with a mixture in a dedicated tank.

The second mixing apparatus of the mixer-conditioner 610 may also comprise a combination of such a dedicated vessel of an active mixing device and in-line injection systems possibly comprising static and/or high shear in-line mixers.

Alternatively, in step (a2), the catalyst precursor formulation 104 may be initially blended with 20% of the heavy hydrocarbon feedstock 101, the resulting blended heavy hydrocarbon feedstock may be blended with another 40% of the heavy hydrocarbon feedstock , and the resulting 60% of the mixed heavy hydrocarbon feedstock can be mixed with the remaining 40% heavy hydrocarbon feedstock in accordance with good gradual dilution engineering practices to fully disperse the catalyst precursor formulation 104 into the heavy hydrocarbon feedstock . Mixing time in the appropriate mixing devices or methods described herein should also be used for the stepwise dilution approach.

The process according to the present invention is preferably carried out according to the second embodiment in which step (a) comprises (al) premixing the organic additive compound 102 with the catalyst precursor composition 105 to produce the formulation of catalyst precursor 104, and (a2) mixing said catalyst precursor formulation 104 with said heavy hydrocarbon feedstock 101.

In step (a), mixing of the heavy hydrocarbon feedstock 101 with the catalyst precursor formulation 104 can be done for the heavy hydrocarbon feedstock 101, in part or in whole.

According to one or more preferred embodiments, the mixing step (a) is carried out between the catalyst precursor formulation 104 and the entire stream of the heavy hydrocarbon feedstock 101 sent to the hydroconversion system. In one or more alternate embodiments, the mixing step (a) is implemented between the catalyst precursor formulation 104 and part of the heavy hydrocarbon feed stream 101 sent to the hydroconversion. Thus, the preparation of the conditioned heavy hydrocarbon feedstock 103 can be implemented by mixing at least part of the stream of said heavy hydrocarbon feedstock 101, for example at least 50% by weight of the stream of said heavy hydrocarbon feedstock 101, with the catalyst precursor formulation 104. The complementary part of the flow of said heavy hydrocarbon feedstock 101 can be reincorporated once the catalyst precursor formulation 104 has been added, that is to say mixed with the heavy hydrocarbon feedstock conditioned 103 before its preheating in step (b).

Stage (b): heating of the conditioned heavy hydrocarbon feedstock

The conditioned heavy hydrocarbon charge 103 formed in step (a) is then heated in at least one preheater 630, before being introduced into the entrained bed reactor for hydroconversion.

The conditioned hydrocarbon charge 103 is sent to the at least one preheating device 630, optionally pressurized by a pump.

The preheating device comprises any heating means capable of heating a heavy hydrocarbon charge known to a person skilled in the art. The preheating device can comprise a furnace comprising at least one preheating compartment, and/or tubes in which the hydrocarbon feedstock flows, a mixer of the conditioned hydrocarbon feedstock with H2, any type of suitable heat exchangers, for example tubular or spiral heat exchangers in which the hydrocarbon feedstock flows, etc.

This pre-heating of the conditioned heavy hydrocarbon feed makes it possible to reach a target temperature in the entrained bed hydroconversion reactor in the subsequent step (d).

Conditioned hydrocarbon feedstock 103 is more preferably heated in preheater 630 to a temperature within a range of 280°C to 450°C, even more preferably within a range of 300°C to 400°C, and even more preferably within a range of 300°C to 400°C. a range of 320°C to 365°C, in particular in order to later reach a target temperature in the hydroconversion reactor in step (c).

The skin temperature of the preheating device, eg the skin temperature of the steel shell of a compartment or tubes of a furnace or heat exchanger(s), can reach from 400°C to 650°C . Mixing catalyst precursor formulation 104 comprising catalyst precursor composition 105 and organic additive 102 with heavy hydrocarbon feedstock 101 to step (a) avoids or reduces fouling which can occur in the preheater at these high temperatures.

According to one or more embodiments, the conditioned feed is heated to a temperature which is 100°C lower than the hydroconversion temperature in the entrained bed hydroconversion reactor, preferably 50°C lower than the hydroconversion temperature. For example, for a hydroconversion temperature in the range of 410°C to 440°C, the conditioned hydrocarbon feed may be heated in step (b) to a temperature in the range of 310°C to 340°C.

The absolute pressure is between atmospheric pressure (e.g. 0.101325 MPa) and 38 MPa, preferably between 5 MPa and 25 MPa and preferably between 6 MPa and 20 MPa.

The heating in step (b) advantageously causes the conditioned hydrocarbon feedstock to release sulfur which can combine with the metal of the catalyst precursor composition.

According to one or more embodiments, the colloidal or molecular catalyst is formed, or at least begins to form, in situ in the heavy hydrocarbon charge conditioned in this step (b) of heating in the preheating device 630.

In order to form the colloidal or molecular catalyst, sulfur must be available (e.g. as H2S) to combine with the metal of the catalyst precursor composition.

Formation of the colloidal or molecular catalyst in situ in the conditioned heavy hydrocarbon charge

The general formation of the colloidal or molecular catalyst in situ in the conditioned heavy hydrocarbon feed is described in detail below, as well as the conditions required for such formation in step (b) and/or (c).

In the event that the heavy hydrocarbon feedstock includes sufficient or excess sulfur, the final activated catalyst may be formed in situ by heating the conditioned heavy hydrocarbon feedstock 103 to a temperature sufficient to liberate the sulfur therefrom.

A source of sulfur can thus be hhS dissolved in the heavy hydrocarbon feedstock, or hhS contained in hydrogen recycled to the entrained bed hydroconversion reactor for the hydroconversion or hhS originating from molecules organic sulfur present in the charge or possibly introduced beforehand into the heavy hydrocarbon charge (injection of dimethyl disulphide, of thioacetamide, of any hydrocarbon charge containing sulfur of the mercaptan type, of sulphides, of oil containing sulphur, of diesel containing sulfur, vacuum distillate containing sulfur, residue containing sulfur), such injection being rare and reserved for very atypical heavy hydrocarbon feedstocks.

Thus, a sulfur source can be sulfur compounds in the feed or a sulfur compound added to the feed.

According to one or more embodiments, the formation of the colloidal or molecular dispersed catalyst is carried out at an absolute pressure between atmospheric pressure and 38 MPa, preferably between 5 MPa and 25 MPa, and more preferably between 6 MPa and 20 MPa. .

Due to the thorough/intimate mixing in step (a), a molecularly dispersed catalyst may form upon reaction with sulfur to form the metal sulfide compound. Under certain circumstances, weak agglomeration may occur resulting in colloidal sized catalyst particles. However, it is believed that taking care to thoroughly mix the precursor formulation into all of the heavy hydrocarbon feedstock in step (a) will yield individual catalyst molecules rather than colloidal particles. Simple assembly, failing to sufficiently mix, typically results in the formation of large agglomerated metal sulfide-like compounds that are micron in size or larger.

In order to form the metal sulfide catalyst, the conditioned charge 103 is preferably heated to a temperature in the range of room temperature, e.g. 15°C, to 500°C, more preferably in the range of 200°C to 500°C. °C, even more preferably in a range of 250°C to 450°C, and even more preferably in a range of 300°C to 435°C.

The temperature used in step (b) and/or (c) allows the formation of the catalyst of metal sulphide type.

The colloidal or molecular catalyst can thus be formed, at least in part, during this heating step (b), before the heated conditioned charge 106 is introduced into the entrained bed hydroconversion reactor in step (c). .

The colloidal or molecular catalyst can also be formed in situ in the entrained bed hydroconversion reactor itself in step (c), in particular either totally or in part in the case where it has started to form at the step (b).

The molybdenum concentration in the conditioned hydrocarbon feed is preferably in a range of 10 ppm to 10000 ppm by weight of the heavy hydrocarbon feed 101, more preferably in a range of 50 ppm to 6000 ppm by weight, more preferably in a range from 100 ppm to 1000 ppm by weight, even more preferably in a range of 100 ppm to 800 ppm by weight, and even more preferably in a range of 150 ppm to 400 ppm by weight.

The Mo can become more concentrated as volatile fractions are removed from a non-volatile residue fraction.

Since the colloidal or molecular catalyst tends to be very hydrophilic, the individual particles or molecules will tend to migrate towards the more hydrophilic fragments or molecules in the heavy hydrocarbon feed, in particular the asphaltenes. While the highly polar nature of the catalyst compound causes or allows the colloidal or molecular catalyst to associate with asphaltene molecules, it is the general incompatibility between the highly polar catalyst compound and the hydrophobic heavy hydrocarbon feedstock that requires the aforementioned intimate or complete mixing of the oil-soluble catalyst precursor formulation into the heavy hydrocarbon feedstock prior to formation of the colloidal or molecular catalyst.

Preferably, the colloidal or molecular catalyst comprises molybdenum disulfide.

Theoretically, a nanoscale crystal of molybdenum disulfide has 7 molybdenum atoms sandwiched between 14 sulfur atoms, and the total number of molybdenum atoms exposed at the edge, thus available for catalytic activity, is greater than in a micron-sized crystal of molybdenum disulfide. In practical terms, the formation of small catalyst particles as in the present invention, i.e. a colloidal or molecular catalyst, with improved dispersion, results in more catalyst particles and catalyst sites. distributed more evenly throughout the hydrocarbon charge. In addition, molybdenum disulfide particles of nanometer size or smaller are believed to associate intimately with asphaltene molecules.

Step (c): hydroconversion of the heated conditioned feedstock

The heated conditioned charge 106 is then introduced, optionally pressurized by a pump, in particular if it has not already been pressurized before step (b), into at least one entrained bed reactor 640 together with hydrogen 601, and is operated under hydroconversion conditions to produce Upgraded Material 107.

As mentioned earlier, the colloidal or molecular catalyst may form in situ in the entrained bed hydroconversion reactor itself in step (c), if not fully formed or not formed at all at the time. step (b). When the colloidal or molecular catalyst is formed in situ in the conditioned heavy hydrocarbon feedstock in step (b), the heated conditioned feedstock 106 already contains the colloidal or molecular catalyst, in part or in whole, when it is introduced into the at least one entrained bed reactor 640.

The entrained bed reactor 640 comprises a liquid phase which comprises said heated conditioned feed 106 containing the colloidal or molecular catalyst dispersed therein, and a gas phase comprising hydrogen.

This type of entrained bed reactor is well known to those skilled in the art.

The entrained bed reactor preferably comprises an upward flow of liquid and gas.

The entrained bed reactor for the hydroconversion of heavy hydrocarbon oils can, like most entrained bed reactors, be a plug-flow type vacuum reactor, since the conditioned heavy hydrocarbon feedstock 106 containing the colloidal or molecular catalyst dispersed therein behaves as a homogeneous phase.

When operating with an upward flow of liquid and gas, the entrained bed reactor preferably includes an inlet located at or near the bottom of the entrained bed reactor through which the heated conditioned feed 106 is introduced together with the hydrogen 201, and an outlet port at or near the top of the reactor through which the upgraded material 107 is withdrawn.

The colloidal or molecular catalyst is dispersed throughout the feed in the entrained bed reactor and is carried out of the reactor with the effluents comprising the upgraded material 107.

The entrained bed reactor may include at its lower portion an agitator to more evenly disperse the hydrogen in the charge.

The entrained bed reactor may comprise a former ebullated bed reactor converted to an entrained phase reactor by removing porous supported catalyst from the former ebullated bed reactor.

In some cases, the entrained bed reactor may comprise at its lower part an agitator, and alternatively or in addition to such an agitator, the entrained bed reactor may comprise a recycle conduit, a recycle pump, and a distributor grate plate as in conventional ebullated bed reactors, allowing the continuous recycling of at least part of a liquid fraction drawn in at the upper part of the reactor and reinjected at the level of the lower part of the reactor and promote a more uniform dispersion of reactants, catalyst, and heat, and, as for example in document US6960325B, also comprising a riser.

If internal recycle feed is used, such internal recycle feed may be mixed with a second cool heated conditioned feed 106 and additional hydrogen gas 201.

The presence of colloidal or molecular catalyst in the entrained bed reactor provides the catalytic hydrogenation activity. Free radical capping minimizes the formation of sediment and coke precursors, as already explained.

In the hydroconversion step (c), said heated conditioned feedstock 106 is generally converted under conventional conditions for the hydroconversion of a heavy hydrocarbon feedstock.

According to one or more embodiments, the hydroconversion step (c) is carried out under an absolute pressure of between 2 and 38 MPa, preferably between 5 and 25 MPa and preferably between 6 and 20 MPa, and at a temperature between 300°C and 550°C, preferably between 350°C and 500°C, preferably between 370°C and 450°C, and more preferably between 400°C and 440°C, and even more preferably between 410°C and 435°C.

According to one or more embodiments, the hourly volume velocity (WH), or liquid hourly space velocity (LHSV) in English, of the load relative to the volume of each entrained bed reactor is between 0.05 h ¹ and 10 h ¹ , preferably between 0.10 h ¹ and 2 h ¹ and preferably between 0.10 h ¹ and 1 h ¹ . According to another embodiment, the WH is between 0.05 h ¹ and 0.09 h ¹ . The WH is defined as the volumetric flow rate of liquid feed at ambient temperature and atmospheric pressure (typically 15° C. and 0.101325 MPa) per reactor volume.

According to one or more embodiments, the quantity of hydrogen mixed with the heavy hydrocarbon feedstock 106 is preferably between 50 and 5000 normal cubic meters (Nm ³ ) per cubic meter (m ³ ) of liquid heavy hydrocarbon feedstock, such as between 100 and 2000 Nm ³ /m ³ and preferably between 500 and 1500 Nm ³ /m ³ .

According to one or more embodiments, the hydroconversion step (c) is carried out in one or more entrained bed hydroconversion reactors, which can be in series and/or in parallel.

Stage (d): further processing of the recovered material from the hydroconversion stage (c)

The recovered material 107 can be processed further. Examples of such further processing include, without limitation, at least one of the following: separation of hydrocarbon fractions from the upgraded material, further hydroconversion in one or more entrained bed reactors or bubbling-entrained hybrid reactors or additional ebullated bed reactors, which may be in series and/or in parallel, to produce further upgraded material, fractionation of the further upgraded material into hydrocarbon fractions, deasphalting of at least a portion of the upgraded material 107 or a heavy liquid fraction resulting from fractionation of the upgraded or further upgraded material, purification in a guard bed of the upgraded or further upgraded material to remove at least a portion of the colloidal or molecular catalyst and metallic impurities .

The various hydrocarbon fractions that can be produced from the upgraded material 107 can be sent to different processes in the refinery, and details of these post-treatments are not described here since they are generally known to those skilled in the art. art and will complicate the description unnecessarily. For example, gaseous fractions, naphtha, middle distillates, VGO, DAO can be sent to hydrotreating, steam cracking, fluidized bed catalytic cracking (FCC), hydrocracking, extraction lubricating oil, etc., residues (atmospheric or vacuum residues) can also be post-treated, or used for other applications such as gasification, bitumen production, etc. Heavy ends, including residues, can also be recycled in the hydroconversion process, for example in the entrained bed reactor.

According to one or more embodiments, as illustrated in Figure 6, the method further comprises:

- a second stage of hydroconversion in a second entrained bed reactor 660 in the presence of hydrogen 604 of at least part of, or all, the upgraded material resulting from the hydroconversion stage (c) or optionally of a liquid heavy fraction 603 which predominantly boils at a temperature greater than or equal to 350°C resulting from an optional separation step separating part of, or all, the upgraded material resulting from the hydroconversion step ( c), said second entrained bed reactor 660 being operated under hydroconversion conditions to produce a hydroconverted liquid effluent 605 having a reduced heavy residue fraction, a reduced Conradson carbon residue, and optionally an amount reduced in sulfur and/or nitrogen;

- a step of fractionating part of, or all, said hydroconverted liquid effluent 605 in a fractionation section 670 to produce at least one heavy fraction 607 which boils from predominantly at a temperature greater than or equal to 350°C, said heavy fraction containing a residual fraction which boils at a temperature greater than or equal to 540°C;

- an optional step of deasphalting a part of, or all, said heavy fraction 607 in a deasphalter 680 with at least one hydrocarbon solvent to produce a deasphalted oil DAO 608 and a residual asphalt 609.

Said second hydroconversion step is carried out in a manner similar to that which has been described for the hydroconversion step (c), and its description is therefore not repeated here. This applies in particular to the operating conditions, to the equipment used, with the exception of the specifications mentioned below.

As with the hydroconversion step (c), the second hydroconversion step is carried out in a second entrained bed reactor 660 similar to the entrained bed reactor 640.

In this additional hydroconversion step, the operating conditions may be similar or different from those in the hydroconversion step (c), the temperature remaining in the range between 300°C and 550°C, preferably between 350 ° C and 500 ° C, more preferably between 370 ° C and 450 ° C, more preferably between 400 ° C and 440 ° C, and even more preferably between 410 ° C and 435 ° C, and the amount of hydrogen introduced into the reactor remaining in the range between 50 and 5000 Nm ³ /m ³ of liquid feed, preferably between 100 and 2000 Nm ³ /m ³ , and even more preferably between 500 and 1500 Nm ³ /m ³ . The other pressure and WH parameters are in ranges identical to those described for the hydroconversion step (c).

The optional separation step, separating some or all of the upgraded material 107 to produce at least two fractions comprising the heavy liquid fraction 603 which boils predominantly at a temperature greater than or equal to 350°C, is carried out. works in a separation section 650.

The other moiety(s) 602 are light and intermediate moiety(s). The light fraction thus separated mainly contains gases (H ₂ , H ₂ S, NH ₃ , and C1-C4), naphtha (fraction which boils at a temperature below 150°C), kerosene (fraction 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 fraction can then be sent at least partially to a fractionation unit (not represented in FIG. 6) where the light gases are extracted from said light fraction, for example by passing through a flash drum. The gaseous hydrogen thus recovered, which may have been sent to a purification and compression installation, can advantageously be recycled in the hydroconversion stage (c). The recovered hydrogen gas can also be used in other refinery facilities. Separation section 650 includes any separation means known to those skilled in the art. It may comprise one or more flash drums arranged in series, and/or one or more vapor and/or hydrogen stripping columns, and/or an atmospheric distillation column, and/or a vacuum distillation column , and preferably consists of a single expansion tank, commonly referred to as a “hot separator”.

The fractionation step separating a portion of, or all, the hydroconverted liquid effluent from the second hydroconversion step to produce at least two fractions comprising the at least one heavy liquid fraction 607 which predominantly boils at a higher temperature at 350°C, preferably greater than 500°C and preferably greater than 540°C, is implemented in the fractionation section 670 comprising any separation means known to those skilled in the art. The other moiety(s) 606 are light and intermediate moiety(s).

The heavy liquid fraction 607 contains a fraction which boils at a temperature above 540°C, called the vacuum residue (which is the unconverted fraction). It may contain a part of the diesel fraction which boils between 250°C and 375°C and a fraction which boils between 375°C and 540°C, called vacuum distillate.

Fractionation section 670 may include one or more flash drums arranged in series, and/or one or more vapor and/or hydrogen stripping columns, and/or an atmospheric distillation column, and/or a vacuum distillation, and preferably consists of a set of several flash drums in series and atmospheric and vacuum distillation columns.

When it is desired to recycle part of the heavy residue fraction (e.g. part of the heavy liquid fraction 107, and/or part of the residual asphalt 609, or part of the DAO 608) in the hydroconversion (e.g. in the 640 entrained bed reactor or upstream) it may be advantageous to leave the colloidal or molecular catalyst in the residues, and/or the residual asphalt fraction. A purge on the recycled stream can be implemented, generally to prevent certain compounds from accumulating at excessive levels.

The present invention also relates to an entrained bed system 600 configured to hydroconvert the heavy hydrocarbon feedstock 101 as detailed above. The reference numerals mentioned below relate to FIG. 6, which schematically illustrates an example of an entrained bed hydroconversion system according to the invention. Said system 600 includes:

- the conditioning mixture 610 configured to prepare the conditioned charge 103 by mixing said heavy hydrocarbon charge 101 with the catalyst precursor formulation 104 which comprises the catalyst precursor composition 105 comprising molybdenum and the additive organic in the proportion of a molar ratio between said organic chemical compound 102 and molybdenum of between 0.1:1 and 20:1;

- the at least one preheating device 630 configured to heat the conditioned load 103;

- the at least one entrained bed reactor 640 configured to include:

-- a liquid hydrocarbon phase comprising the heated conditioned charge 106 containing the colloidal or molecular catalyst dispersed therein;

-- and a gaseous phase comprising hydrogen.

Said at least one entrained bed reactor 640 is configured to operate in the presence of hydrogen and under hydroconversion conditions to cause thermal cracking of hydrocarbons in said heated conditioned feed to provide upgraded material 107.

Said at least one preheater 630 and/or said at least one entrained bed reactor 640 are also configured to form the colloidal or molecular catalyst in said conditioned heavy hydrocarbon charge.

Details of each apparatus/device/section used in the entrained bed system have already been mentioned above in connection with the method and are not repeated.

Example

The following example illustrates, without limiting the scope of the invention, some of the performances of the method and of the system according to the invention, in particular the reduced fouling of the installations, in comparison with a method and a system according to the prior art. .

The example is based on a test using an analytical device, called Alcor Hot Liquid Process Simulator, or HLPS, from the company Alcor, stimulating the fouling effect of atmospheric residues (AR) in heat exchangers. The AR is pumped through a heater tube (laminar flow tube-in-shell heat exchanger) under controlled conditions and fouling deposits are formed on the heater tube. The temperature of the AR exiting the heat exchanger is related to the effect of deposits on the efficiency of the heat exchanger. The decrease in AR liquid outlet temperature from its initial maximum value is called Delta T and is correlated to the amount of deposits. The greater the decrease in Delta T, the greater the amount of fouling and deposits.

The HLPS test can be used to evaluate the fouling tendency of different ARs by comparing the decreasing slope of the AR liquid outlet temperature obtained under identical test conditions. The effectiveness of an organic additive can also be determined by comparing the test results from a neat sample (without an organic additive) to the sample mixed with the organic additive.

Two samples are tested: sample 1 is a mixture of a heavy hydrocarbon feedstock and a molecular or colloidal catalyst according to the prior art, and sample 2 is a mixture according to the invention comprising the same heavy hydrocarbon feedstock with the same molecular or colloidal catalyst, in addition to an organic additive.

The heavy hydrocarbon feedstock used (“Feed”) is an atmospheric residue (AR) whose main composition and properties are given in Table 1 below.

Table 1

Sample 1: Sample 1 is a mixture of the Feedstock and a catalyst precursor composition (CPC) which is molybdenum 2-ethylhexanoate diluted in vacuum gas oil (VGO).

The composition of VGO is given in Table 1 above. The CPC solution is obtained by mixing molybdenum 2-ethylhexanoate with VGO, at a temperature of 70° C. for a period of time of 30 minutes. The molybdenum content in the CPC solution containing VGO is 3500 ppm by weight.

The CPC solution is then mixed with the Filler (AR) at a temperature of 70°C and for a time period of 30 minutes.

The Mo content in Sample 1 is 283 ppm by weight (see Table 2 below).

Sample 2: sample 2 is a mixture of the Charge (AR) with the same solution of CPC (2-ethylhexanoate of molybdenum diluted with VGO) as in sample 1, and with an organic additive which is acid 2-Ethylhexanoic acid (2EHA). The CAS number for 2EHA is 149-57-5. The CPC solution, obtained as detailed for sample 1, is first mixed with the 2EHA, for a time period of 30 min, and at a temperature of 70°C.

Then, the CPC solution containing the organic additive 2EHA is mixed with the Filler (AR), at a temperature of 70° C. and for a time period of 30 minutes.

The Mo content in sample 2 is 283 ppmw (see Table 2 below). The concentration of organic additive 2EHA is 5761 ppm by weight (see Table 2 below).

The molar ratio of 2EHA/Mo = 13.6.

Table 2

The Mo content in the samples was determined according to ASTM D7260. The acid and ester type organic additive content was determined by weighing. The HLPS test conditions are given in Table 3 below.

Table 3

The results of the test for the different samples (Si for sample 1, S2 for sample 2) are shown in the graph of figure 7. The X axis represents the time in hours, and the Y axis represents the temperature difference DT between the temperature of the oil mixture (sample) exiting the tube at a time t [T _{Oil exiting} _l _t and the maximum temperature of the oil mixture (sample) exiting the tube

The results show that sample 1 has a strong tendency to fouling since its Delta T drops rapidly. Sample 2 which contains an organic additive, e.g. 2EHA, according to the invention has a lower Delta T than sample 1, showing that the fouling behavior is significantly reduced under the action of said organic additive.

Claims

1. Process for the hydroconversion of a heavy hydrocarbon feedstock (101) containing a fraction of at least 50% by weight having a boiling point of at least 300°C, and containing metals and asphaltenes, comprising the following steps:

(a) preparing a conditioned heavy hydrocarbon feedstock (103) by mixing said heavy hydrocarbon feedstock (101) with a catalyst precursor formulation (104) in such a manner that a colloidal or molecular catalyst is formed when reacts with sulfur, said catalyst precursor formulation (104) comprising:

- a catalyst precursor composition (105) comprising molybdenum, and

- an organic chemical compound (102) comprising at least one carboxylic acid function and/or at least one ester function and/or at least one acid anhydride function, and

- a molar ratio between said organic chemical compound (102) and molybdenum in said catalyst precursor formulation (104) being between 0.1:1 and 20:1;

(b) heating the conditioned heavy hydrocarbon feedstock (103) from step (a) in at least one preheater;

(c) introducing said heated conditioned heavy hydrocarbon feedstock (106) from step (b) into at least one entrained bed reactor and operating said entrained bed reactor in the presence of hydrogen and under hydroconversion conditions to producing a recovered material (107); and the colloidal or molecular catalyst being formed in situ in the heavy hydrocarbon feedstock conditioned in step (b) and/or in step (c).

2. Process according to claim 1, wherein step (a) comprises simultaneously mixing said organic chemical compound (102) with said catalyst precursor composition (105), preferably previously diluted with a hydrocarbon diluent, and with said heavy hydrocarbon feedstock (101), preferably at a temperature below a temperature at which a substantial portion of the catalyst precursor composition begins to thermally decompose, such as at a temperature between room temperature and 300°C, and for a period of time from 1 second to 30 minutes.

3. The method of claim 1 wherein step (a) comprises (a1) premixing said organic chemical compound (102) with said catalyst precursor composition (105) to produce said catalyst precursor formulation ( 104) and (a2) mixing said catalyst precursor formulation (104) with said heavy hydrocarbon feedstock (101).

4. A method according to claim 3, wherein in step (a1) said catalyst precursor composition (105) is mixed at a temperature below a temperature at which a portion substantial portion of the catalyst precursor composition begins to thermally decompose, preferably at a temperature between room temperature and 300°C.

5. A process according to any preceding claim, wherein a hydrocarbon oil diluent is used to form the catalyst precursor formulation (104), said hydrocarbon oil diluent preferably being selected from the group consisting of a gas oil. vacuum, decanting oil or recycle oil, light gas oil, vacuum residues, deasphalted oils, and resins.

6. A method according to any preceding claim, wherein the organic chemical compound (102) is selected from the group consisting of ethylhexanoic acid, naphthenic acid, caprylic acid, adipic acid, pimelic acid, suberic acid, azelaic acid, and sebacic acid, ethyl octanoate, ethyl 2-ethylhexanoate, 2-ethylhexyl 2-ethylhexanoate, benzyl 2-ethylhexanoate, diethyl adipate, dimethyl adipate, bis(2-ethylhexyl) adipate, dimethyl pimelate, dimethyl suberate, monomethyl suberate, hexanoic anhydride, caprylic anhydride, and their mixtures.

7. A method according to claim 6, wherein the organic chemical compound (102) comprises 2-ethylhexanoic acid, and is preferably 2-ethylhexanoic acid.

8. The method of claim 6, wherein the organic chemical compound (102) comprises ethyl octanoate or 2-ethylhexyl 2-ethylhexanoate, and is preferably ethyl octanoate or 2-ethylhexyl hexanoate. 2-ethylhexyl.

9. A process according to any preceding claim, wherein the catalyst precursor composition comprises an oil-soluble organo-metallic compound or complex selected from the group consisting of molybdenum 2-ethylhexanoate, molybdenum naphthanate , molybdenum hexacarbonyl, and is preferably molybdenum 2-ethylhexanoate.

10. A method according to any preceding claim, wherein the molar ratio between said organic chemical compound (102) and molybdenum of said catalyst precursor formulation (104) is between 0.75: 1 and 7: 1. , and preferably between 1:1 and 5:1.

11. Process according to any one of the preceding claims, in which the colloidal or molecular catalyst comprises molybdenum disulphide.

12. A method according to any preceding claim, wherein step (b) comprises heating to a temperature between 280°C and 450°C, more preferably between 300°C and 400°C, and more preferably in a range of 320°C to 365°C.

13. Process according to any one of the preceding claims, in which the heavy hydrocarbon feedstock (101) comprises at least one of the following feedstocks: a crude oil, bitumen from bituminous sands, bottoms of atmospheric distillation columns, vacuum distillation column bottoms, residues, visbreaker bottoms, coal tar, heavy oil from oil shale, liquefied coal, heavy bio-oils, and heavy oils including waste plastics and/or or a plastic pyrolysis oil.

14. Process according to any one of the preceding claims, in which the heavy hydrocarbon feedstock (101) has sulfur at a content greater than 0.5% by weight, a Conradson carbon residue of at least 0.5% by weight, C ₇ asphaltenes at a content greater than 1% by weight, transition and/or post-transition metals and/or metalloids at a content greater than 2 ppm by weight, and alkali and/or alkaline metals - earthy at a content greater than 2 ppm by weight.

15. Process according to any one of the preceding claims, in which the said hydroconversion step (c) is carried out under an absolute pressure of between 2 MPa and 38 MPa, at a temperature of between 300°C and 550°C. , at an hourly volumetric speed WH relative to the volume of each entrained bed reactor of between 0.05 h ¹ and 10 h ¹ and under a quantity of hydrogen mixed with the charge entering the entrained bed reactor of between 50 and 5,000 normal cubic meters (Nm ³ ) per cubic meter (m ³ ) of load.

16. A process according to any preceding claim, wherein the molybdenum concentration in the conditioned hydrocarbon feedstock is in a range of 10 ppm to 10,000 ppm by weight of the heavy hydrocarbon feedstock.