Process for upgrading heavy oil using a highly active slurry catalyst composition
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IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
C10G-001/08
C10G-001/00
출원번호
US-0303426
(2005-12-16)
등록번호
US-7390398
(2008-06-24)
발명자
/ 주소
Farshid,Darush
Reynolds,Bruce
출원인 / 주소
Chevron U.S.A. Inc.
대리인 / 주소
Prater,Penny L.
인용정보
피인용 횟수 :
6인용 특허 :
7
초록▼
Applicants have developed a new residuum full hydroconversion slurry reactor system that allows the catalyst, unconverted oil and converted oil to circulate in a continuous mixture throughout an entire reactor with no confinement of the mixture. The mixture is partially separated in between the reac
Applicants have developed a new residuum full hydroconversion slurry reactor system that allows the catalyst, unconverted oil and converted oil to circulate in a continuous mixture throughout an entire reactor with no confinement of the mixture. The mixture is partially separated in between the reactors to remove only the products and hydrogen gas, while permitting the unconverted oil and the slurry catalyst to continue on into the next sequential reactor. A portion of the unconverted oil is then converted to lower boiling point hydrocarbons, once again creating a mixture of unconverted oil, products, hydrogen, and slurry catalyst. Further hydroprocessing may occur in additional reactors, fully converting the oil. Additional oil may be added at the interstage feed inlet, possibly in combination with slurry. The oil may alternately be partially converted, leaving a highly concentrated catalyst in unconverted oil which can be recycled directly to the first reactor.
대표청구항▼
What is claimed is: 1. A process for the hydroconversion of heavy oils, said process employing at least two upflow reactors in series with a separator in between each reactor, said process comprising the following steps: (a) combining a heated heavy oil feed, an active slurry catalyst composition a
What is claimed is: 1. A process for the hydroconversion of heavy oils, said process employing at least two upflow reactors in series with a separator in between each reactor, said process comprising the following steps: (a) combining a heated heavy oil feed, an active slurry catalyst composition and a hydrogen-containing gas to form a mixture; (b) passing the mixture of step (a) to the bottom of the first upflow reactor, which is maintained at hydroprocessing conditions, including elevated temperature and pressure; (c) removing a vapor stream comprising products and hydrogen, unconverted material and slurry catalyst from the top of the first reactor and passing it to a first separator; (d) in the first separator, removing the products and hydrogen overhead as vapor to further processing and unconverted material and slurry catalyst as a liquid bottoms stream; (e) combining the bottoms of step (d) with additional feed oil resulting in an intermediate mixture; (f) passing the intermediate mixture of step (e) to the bottom of the second upflow reactor, which is maintained at hydroprocessing conditions, including elevated temperature and pressure; (g) removing a vapor stream comprising products and hydrogen, unconverted material and slurry catalyst from the top of the second reactor and passing it to a second separator; (h) in the second separator, removing the products and hydrogen overhead as vapor to further processing and passing the liquid bottoms stream, comprising unconverted material and slurry catalyst, to further processing. 2. The process of claim 1, in which the liquid bottoms stream from the second upflow reactor, which is feed to one or more additional reactors is combined with additional feed oil prior to entering the additional reactor. 3. The process of claim 2, in which additional feed oil is selected from the group consisting of atmospheric residuum, vacuum residuum, tar from a solvent deasphalting unit, atmospheric gas oils, vacuum gas oils, deasphalted oils, olefins, oils derived from tar sands or bitumen, oils derived from coal, heavy crude oils, synthetic oils from Fischer-Tropsch processes, and oils derived from recycled oil wastes and polymers. 4. The process of claim 3, wherein the additional feed oil is a vacuum gas oil. 5. The process of claim 1, in which the additional feed oil further comprises slurry catalyst. 6. The process of claim 1 wherein the bottoms material of step (h) is recycled to step (a), the mixture of step (a) further comprising recycled unconverted material and slurry catalyst. 7. The process of claim 1 wherein the bottoms material of step (h) is passed to the bottom of a third reactor which is maintained at slurry hydroprocessing conditions, including elevated temperature and pressure. 8. The process of claim 1, in which a liquid recirculating reactor is employed in at least one of the reactors. 9. The process of claim 8, in which the recirculating reactor employs a pump. 10. The process of claim 1, in which hydroprocessing conditions employed in each reactor comprise a total pressure in the range from 1500 to 3500 psia, and a reaction temperature of from 700 to 900 F. 11. The process of claim 10, wherein the preferred total pressure range is from 2000 through 3000 psia and preferred range for reaction temperature is from 775 through 850 F. 12. The process of claim 1 wherein the separator located between each reactor is a flash drum. 13. The hydroconversion process of claim 1, wherein the heavy oil is selected from the group consisting of atmospheric gas oils, vacuum gas oils, deasphalted oils, olefins, oils derived from tar sands or bitumen: oils derived from coal, heavy crude oils, synthetic oils from Fischer-Tropsch processes, and oils derived from recycled oil wastes and polymers. 14. The hydroconversion process of claim 1, wherein the process is selected from the group consisting of hydrocracking, hydrotreating, hydrodesulphurization, hydrodenitrification, and hydrodemetalization. 15. The process of claim 1 wherein the active slurry catalyst composition of claim 1 is prepared by the following steps: (a) mixing a Group VIB metal oxide and aqueous ammonia to form a Group VIB metal compound aqueous mixture; (b) sulfiding, in an initial reaction zone, the aqueous mixture of step (a) with a gas comprising hydrogen sulfide to a dosage greater than 8 SCF of hydrogen sulfide per pound of Group VIB metal to form a slurry; (c) promoting the slurry with a Group VIII metal compound; (d) mixing the slurry of step (c) with a hydrocarbon oil having a viscosity of at least 2 cSt @ 212�� F. to form an intermediate mixture; (e) combining the intermediate mixture with hydrogen gas in a second reaction zone, under conditions which maintain the water in the intermediate mixture in a liquid phase, thereby forming an active catalyst composition admixed with a liquid hydrocarbon; and (f) recovering the active catalyst composition. 16. The process of claim 1, wherein at least 90 wt % of the feed is converted to lower boiling products. 17. A process for the hydroconversion of heavy oils, said process employing at least two upflow reactors in series with a separator located internally in the first reactor, said process comprising the following steps: (a) combining a heated heavy oil feed, an active slurry catalyst composition and a hydrogen-containing gas to form a mixture; (b) passing the mixture of step (a) to the bottom of the first upfIow reactor, which is maintained at hydroprocessing conditions, including elevated temperature and pressure; (c) separating internally in the first reactor a stream comprising product, hydrogen gases, unconverted material and slurry catalyst into two streams, one vapor stream comprising products and hydrogen gases and one liquid stream comprising unconverted material and slurry catalyst; (d) withdrawing the vapor stream comprising products and gases overhead to further processing, and passing the liquid stream comprising unconverted material and slurry catalyst from the first reactor as a bottoms stream; (e) combining the bottoms stream of step (d) with additional feed oil resulting in an intermediate mixture; (f) passing the intermediate mixture of step (e) to the bottom of the second upflow reactor, which is maintained at hydroprocessing conditions, including elevated temperature and pressure; (g) removing a vapor stream comprising product, hydrogen unconverted material and slurry catalyst from the top of the second reactor and passing it to a separator; (h) in the separator, removing the products and hydrogen overhead to further processing and passing the liquid bottoms material, comprising unconverted material and slurry catalyst to further processing. 18. The process of claim 16, in which feed to one or more additional reactors is combined with additional feed oil prior to entering the reactor. 19. A process for the hydroconversion of heavy oils, said process employing at least two upflow reactors in series with a separator located internally in both reactors, said process comprising the following steps: (a) combining a heated heavy oil feed, an active slurry catalyst composition and a hydrogen-containing gas to form a mixture; (b) passing the mixture of step (a) to the bottom of the first upflow reactor, which is maintained at hydroprocessing conditions, including elevated temperature and pressure; (c) separating internally in the first reactor a vapor stream comprising products and hydrogen, unconverted material and slurry catalyst into two streams, one vapor stream comprising products and hydrogen and one comprising unconverted material and slurry catalyst; (d) withdrawing the vapor stream comprising products and hydrogen overhead to further processing, and passing the liquid stream comprising unconverted material and slurry catalyst from the first reactor as a bottoms stream; (e) combining the bottoms stream of step (d) with additional feed oil resulting in an intermediate mixture; (f) passing the intermediate mixture of step (e) to the bottom of the second upflow reactor, which is maintained at hydroprocessing conditions, including elevated temperature and pressure; (g) separating internally in the second reactor a vapor stream comprising products and gases, unconverted material and slurry catalyst into two streams, one vapor stream comprising products and hydrogen and one liquid stream comprising unconverted material and slurry catalyst; (h) withdrawing the stream comprising products and hydrogen overhead to further processing, and passing the unconverted material and slurry catalyst from the first reactor as a liquid bottoms stream for further processing. 20. The process of claim 18, in which feed to one or more additional reactors is combined with additional feed oil prior to entering the reactor.
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이 특허에 인용된 특허 (7)
Comolli Alfred G. ; Lee Lap-Keung, Catalytic multi-stage process for hydroconversion and refining hydrocarbon feeds.
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