Process for co-producing commercially valuable products from byproducts of heavy oil and bitumen upgrading process
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
C10G-002/00
C10G-045/00
C01B-003/34
C10G-045/58
C10G-021/00
C10G-067/04
C01B-021/087
C07C-001/04
C07C-029/151
C07C-273/04
C01B-003/38
C10J-003/00
C10K-003/06
C10G-047/00
C01B-003/50
C01B-003/52
C01B-003/56
C01B-031/20
C10G-007/00
C10G-009/00
출원번호
US-0844055
(2015-09-03)
등록번호
US-9732281
(2017-08-15)
발명자
/ 주소
Kresnyak, Steve
출원인 / 주소
Expander Energy Inc.
대리인 / 주소
MBM Intellectual Property Law LLP
인용정보
피인용 횟수 :
0인용 특허 :
45
초록▼
The present invention is directed to modifications of bitumen and heavy oil upgrading and refining processes to synthesize synthetic crude oil and other valuable synthesized hydrocarbon products in an efficient manner along with the production of commercially valuable co-products from by-products fo
The present invention is directed to modifications of bitumen and heavy oil upgrading and refining processes to synthesize synthetic crude oil and other valuable synthesized hydrocarbon products in an efficient manner along with the production of commercially valuable co-products from by-products formed by the upgrading process.
대표청구항▼
1. A process for co-producing commercially valuable products from by-products of a process for upgrading or refining heavy oil or bitumen to formulate synthesized hydrocarbons, comprising: (a) forming a non-distilled bottom fraction from a source of heavy oil or bitumen feedstock;(b) feeding said bo
1. A process for co-producing commercially valuable products from by-products of a process for upgrading or refining heavy oil or bitumen to formulate synthesized hydrocarbons, comprising: (a) forming a non-distilled bottom fraction from a source of heavy oil or bitumen feedstock;(b) feeding said bottom fraction to a syngas generating circuit for formulating a hydrogen lean syngas stream via a non-catalytic partial oxidation reaction;(c) providing a first hydrogen rich syngas stream from a syngas generator;(d) subjecting a portion of said first hydrogen rich syngas stream to a hydrogen separator unit to provide a purified hydrogen by-product stream and a second hydrogen rich syngas stream;(e) subjecting at least a portion of said hydrogen lean syngas stream, said first hydrogen rich syngas stream, said second hydrogen rich syngas stream or a combination thereof, to a carbon dioxide removal operation to obtain a purified hydrogen rich syngas stream an a carbon dioxide by-product stream;(f) reacting said purified hydrogen rich syngas stream in a Fischer-Tropsch reactor to formulate synthesized hydrocarbons; and(g) converting said purified hydrogen by-product stream and/or said carbon dioxide by-product stream into said commercially valuable co-products. 2. The process according to claim 1, wherein said valuable co-products are selected from the group consisting of methanol, ammonia, urea or any combination thereof. 3. The process as set forth in claim 1, wherein said hydrogen rich syngas generator is selected from the group consisting of a steam methane reformer (SMR), autothermal reformer (ATR), any series or parallel combination thereof and a hybrid combination thereof (XTR). 4. The process according to claim 1, comprising subjecting air to an air separation unit to generate a nitrogen stream and an oxygen stream, wherein said oxygen stream is for the non-catalytic partial oxidation reaction and optionally for the syngas generator when said generator comprises an ATR and/or optionally for enriching a sour syngas treatment operation. 5. The process according to claim 1, wherein said commercially valuable co-product is methanol, which is obtained by reacting a portion of said first hydrogen rich syngas stream, said second hydrogen rich syngas stream, said hydrogen lean syngas stream, said purified hydrogen rich syngas stream, or a combination thereof, with said CO2 by-product stream, at least a portion of said purified hydrogen by-product stream or a combination thereof. 6. The process according to claim 4, wherein said commercially valuable co-product is ammonia, which is obtained by reacting said nitrogen stream with at least a portion of said purified hydrogen by-product stream. 7. The process according to claim 6, wherein said ammonia is reacted with said CO2 by-product stream to form urea. 8. The process according to claim 1, wherein said purified hydrogen rich syngas stream is obtained by purification of at least a portion of said first hydrogen rich syngas stream via pressure swing adsorption, membrane or liquid absorption, or by treating at least a portion of said first hydrogen rich syngas stream to a water gas shift (WGS) reaction prior to pressure swing adsorption, membrane or liquid absorption with optional removal of an additional CO2 by-product stream from the said second hydrogen rich syngas stream. 9. The process according to claim 8, wherein the additional CO2 by-product stream is used for conversion into said commercially valuable co-products. 10. The process according to claim 1, wherein said bottom fraction is converted to a sour hydrogen lean syngas stream. 11. The process according to claim 10, further including the step of treating said sour hydrogen lean syngas stream to the said sour syngas treatment operation to form a sweet hydrogen lean syngas stream and an additional CO2 by-product stream for conversion into said commercially valuable co-products. 12. The process according to claim 1, wherein said synthesized hydrocarbons include at least one of Fischer-Tropsch vapours, paraffinic naphtha, light Fischer-Tropsch liquid, heavy Fischer-Tropsch liquid, or Fischer-Tropsch wax. 13. The process according to claim 12, wherein said Fischer-Tropsch vapours are further treated to a CO2 removal operation to form an additional CO2 by-product stream for conversion into said commercially valuable co-products. 14. The process according to claim 12, further including the step of processing said synthesized hydrocarbons in a hydroprocessing unit. 15. The process according to claim 14, wherein said hydroprocessing unit includes at least one operation selected from the group consisting of hydrocracking, thermocracking, hydrotreating, isomerization, fractionation and combinations thereof. 16. The process according to claim 1, wherein CO2 is further captured in a CO2 removal operation from flue gas streams resulting from furnaces, boilers, power generation and any other combustion units used in the upgrader to form an additional CO2 by-product stream for conversion into said commercially valuable co-products. 17. The process according to claim 1, wherein CO2 is further provided from any other external source other than the upgrader to form an additional CO2 by-product stream for conversion into said commercially valuable co-products. 18. The process according to claim 1, wherein the bitumen and heavy oil upgrader is capable of near zero green house gas CO2 emissions. 19. The process according to claim 1, wherein said bitumen is an in situ source. 20. The process according to claim 1, wherein said bitumen is a mineable source.
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