IPC분류정보
국가/구분 |
United States(US) Patent
등록
|
국제특허분류(IPC7판) |
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출원번호 |
US-0506937
(2009-07-21)
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등록번호 |
US-8236169
(2012-08-07)
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발명자
/ 주소 |
- Nguyen, Joseph V
- Brait, Axel
- Chabot, Julie
- Kou, Bo
- Maris, Erin
- Bhaduri, Rahul S.
- Kuperman, Alexander E.
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출원인 / 주소 |
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인용정보 |
피인용 횟수 :
0 인용 특허 :
69 |
초록
▼
A process for hydroprocessing heavy oil feedstock is disclosed. The process operates in once-through mode, employing a plurality of contacting zones and at least a separation zone to convert at least a portion of the heavy oil feedstock to lower boiling hydrocarbons, forming upgraded products. The c
A process for hydroprocessing heavy oil feedstock is disclosed. The process operates in once-through mode, employing a plurality of contacting zones and at least a separation zone to convert at least a portion of the heavy oil feedstock to lower boiling hydrocarbons, forming upgraded products. The contacting zones operate under hydrocracking conditions, employing a slurry catalyst for upgrading the heavy oil feedstock. At least an additive material selected from inhibitor additives, anti-foam agents, stabilizers, metal scavengers, metal contaminant removers, metal passivators, and sacrificial materials, in an amount of less than 1 wt. % of the heavy oil feedstock, is added to at least one of the contacting zones. In one embodiment, the additive material is an anti-foam agent. In another embodiment, the additive material is a sacrificial material for trapping heavy metals in the heavy oil feed and/or deposited coke, thus prolonging the life of the slurry catalyst.
대표청구항
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1. A process for hydroprocessing a heavy oil feedstock, the process employing a plurality of contacting zones operating in parallel mode and at least a separation zone, including a first contacting zone and at least a second contacting zone, the process comprising: providing a hydrogen containing ga
1. A process for hydroprocessing a heavy oil feedstock, the process employing a plurality of contacting zones operating in parallel mode and at least a separation zone, including a first contacting zone and at least a second contacting zone, the process comprising: providing a hydrogen containing gas feed;providing a heavy oil feedstock;providing an additive material selected from the group consisting of inhibitor additives, anti-foam agents, stabilizers, metal scavengers, metal contaminant removers, metal passivators, sacrificial materials, and mixtures thereof, in an amount of less than 1 wt. % of the heavy oil feedstock;providing a slurry catalyst comprising an active metal catalyst having an average particle size of at least 1 micron in a hydrocarbon oil diluent;combining at least a portion of the hydrogen containing gas feed, at least a portion of the heavy oil feedstock, at least a portion of the additive material and at least a portion of the slurry catalyst in the first contacting zone and the second contacting zone under hydrocracking conditions to convert at least a portion of the heavy oil feedstock to lower boiling hydrocarbons, forming upgraded products and additional upgraded products;sending a first effluent stream from the first contacting zone comprising the upgraded products and a second effluent stream from the second contacting zone comprising the additional upgraded products, the slurry catalyst, the hydrogen containing gas, and unconverted heavy oil feedstock to a first separation zone, wherein volatile upgraded products are removed with the hydrogen containing gas as a first overhead stream, and the slurry catalyst and unconverted heavy oil feedstock are removed as a first non-volatile stream, wherein the first non-volatile stream contains less than 30% solid;collecting the first overhead stream for further processing; andcollecting the first non-volatile stream for further processing. 2. The process of claim 1, wherein the additive is an anti-foam agent selected from the group of silicone compounds. 3. The process of claim 2, wherein the anti-foam agent is a siloxane compound having a viscosity of at least 60,000 cSt. 4. The process of claim 3, wherein the anti-foam agent is polydimethyl siloxane (PDMS) having a viscosity of at least 100,000 cSt. 5. The process of claim 1, wherein the additive is an inhibitor additive selected from the group of oil soluble polynuclear aromatic compounds, elastic modulus lowering agents, fatty amine derivatives,and metal soaps. 6. The process of claim 1, wherein the additive is a sacrificial material having a BET surface area of at least 1 m2/g for trapping metals in the heavy oil feed and coke. 7. The process of claim 6, wherein the additive is a spent slurry catalyst. 8. The process of claim 7, wherein the spent slurry catalyst has a BET surface area of at least 1 m2/g 9. The process of claim 1, wherein the additive is a sacrificial material has a total pore volume of at least 0.005 cm3/g. 10. The process of claim 1, wherein the additive is a sacrificial material selected from the group of fumed silica, iron oxides, Al2O3, MgO, MgAl2O4, zeolites, microspheres of calcined kaolin clay, titania, active carbon, carbon black, and mixtures thereof. 11. The process of claim 1, wherein the additive is a sacrificial material having at least 20% of its pore volume constituted by pores of at least 100 Angstrom. 12. The process of claim 1, wherein the additive is carbon black having an average particle size ranging from 1 to 100 microns and a BET surface area of at least 10 m 2 /g. 13. The process of claim 1, wherein the additive is carbon black having a BET surface area ranging from 10 to 2,000 m 2 /g. 14. The process of claim 1, wherein the additive is a sacrificial material having its surface treated by at least one of inhibitors and anti-foam agents. 15. The process of claim 1, wherein the additive is a metal passivator selected from the group of alkaline earth metal compounds, antimony, and bismuth. 16. The process of claim 1, wherein the additive is a metal scavenger selected from the group of macroporous organofunction polysiloxanes. 17. The process of claim 1, wherein the active metal catalyst has an average particle size ranging from 1 to 20 microns. 18. The process of claim 1, wherein the slurry catalyst comprises clusters of colloidal sized particles of less than 100 nm in size. 19. The process of claim 1, wherein the slurry catalyst comprises an active metal catalyst at a concentration of greater than 1000 wppm of active metal catalyst to heavy oil feedstock. 20. The process of claim 19, wherein the slurry catalyst comprises an active metal catalyst at a concentration of 1000 wppm to 3 wt. % of active metal catalyst to heavy oil feedstock. 21. The process of claim 20, wherein the slurry catalyst comprises an active metal catalyst at a concentration of at least 1200 wppm of active metal catalyst to heavy oil feedstock. 22. The process of claim 1 further comprising: adding an amount of water of up to 30 wt % of the first heavy oil feedstock to the first contacting zone. 23. The process of claim 1, further comprising: adding an additional hydrocarbon oil feed other than the heavy oil feedstock, in an amount ranging from 2 to 30 wt. % of the heavy oil feedstock, to the first contacting zone. 24. The process of claim 23, wherein the additional hydrocarbon oil feed is selected from vacuum gas oil, naphtha, medium cycle oil, light cycle oil, heavy cycle oil, solvent donor, and aromatic solvents. 25. The process of claim 1, for treating a heavy oil feedstock having a TAN of at least 0.1; a viscosity of at least 10 cSt; an API gravity at most 15; at least 0.0001 grams of Ni/V/Fe; at least 0.005 grams of heteroatoms; at least 0.01 grams of residue; at least 0.04 grams C5 asphaltenes; and at least 0.002 grams of MCR per gram of heavy oil feedstock. 26. The process of claim 1, wherein the first contacting zone operates at an exit pressure X, and X is at most 100 psi higher than an entry pressure Y of a contacting zone or a separating zone in series with the first contacting zone. 27. The process of claim 1, wherein the plurality of contacting zones are configured in a permutable fashion for the plurality of contacting zones to operate in: a sequential mode; a parallel mode; a combination of parallel and sequential mode; all online; some online and some on stand-by; some online and some off-line; a parallel mode with the effluent stream from the contacting zone being sent to at least a separation zone in series with the contacting zone; a parallel mode with the effluent stream from the contacting zone being combined with an effluent stream from at least another contacting zone and sent to the separation zone; and combinations thereof. 28. The process of claim 1, wherein the slurry catalyst feed to the second contacting zone is a different slurry catalyst from the slurry catalyst feed to the first contacting zone. 29. The process of claim 1, wherein the plurality of contacting zones operate in a parallel mode, and further comprising: providing to a second contacting zone, also operated under hydrocracking conditions, at least a portion of hydrogen containing gas feed, at least a portion of the heavy oil feedstock, and at least a portion of the slurry catalyst feed;combining the at least a portion of hydrogen containing gas feed, the at least a portion of heavy oil feedstock, and the at least a portion of slurry catalyst in the second contacting zone to convert at least the at least a portion of the heavy oil feedstock to lower boiling hydrocarbons, forming additional upgraded products;sending a second effluent stream from the second contacting zone comprising the additional upgraded products, the slurry catalyst, the hydrogen containing gas, and unconverted heavy oil feedstock to a second separation zone, wherein additional volatile upgraded products are removed with the hydrogen containing gas as a second overhead stream, and the slurry catalyst and unconverted heavy oil feedstock are removed as a second non-volatile stream containing less than 30% solid;collecting the second overhead stream for further processing in a product purification unit; andcollecting the second non-volatile stream for further processing including slurry catalyst separation and recovery.
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