Production of high yield of syngas through regeneration of coked upgrading agent

Patent metadata

Field	Value
Publication number	US-10487279-B2
Application number	US-201615240336-A
Country	US
Kind code	B2
Filing date	Aug 18, 2016
Priority date	Nov 6, 2015
Publication date	Nov 26, 2019
Grant date	Nov 26, 2019

Abstract

The present invention relates to a process of increasing syngas production during an upgradation process of petroleum residual oil by circulation of rejuvenated upgrading material through a heat removal zone such as an Auxiliary Reformer and by regeneration of spent upgrading material.

First claim

The invention claimed is:

1. A process of increasing syngas production during an upgradation process of petroleum residual oil, the process comprising:
a) introducing spent upgrading agent from a Riser to a Reformer along with steam and air or oxygen containing gases for production of syngas;
b) burning of residual coke present on partially rejuvenated upgrading agent obtained from the Reformer in a Combustor;
c) introducing rejuvenated upgrading agent from the Combustor, and a hydrocarbon in presence of steam and air or oxygen containing gases to an Auxiliary Reformer having cerium, nickel and rhodium based reforming catalyst for production of additional syngas; and
d) circulating rejuvenated upgrading agent from the Auxiliary Reformer to the Riser;
wherein, the Riser is operated at an outlet temperature of 550° C. to 650° C.; the Reformer is operated at a temperature of 700° C. to 850° C. and pressure of 2-30 atm; the Combustor is operated at a temperature in the range of 7500° to 950° C.; and the Auxiliary Reformer is operated at a temperature range of 650° C. to 750° C.;
wherein, the rejuvenated upgrading agent and partially rejuvenated upgrading agent is a porous fluidizable micro spherical solid particles belonging to Geldart Group A classification;
wherein, the Auxiliary Reformer is maintained at a temperature in the range of 50° C. to 300° C. below the Combustor, and 50° C. to 100° C. above the Riser.

2. The process as claimed in claim 1 , wherein the spent upgrading agent is separated from the cracked products obtained from the Riser, in a Stripper, prior to introducing to the Reformer.

3. The process as claimed in claim 1 , comprising optionally injecting hydrocarbon stream to the Reformer to produce syngas.

4. The process as claimed in claim 1 , wherein the burning of residual coke present on partially rejuvenated upgrading agent in the Combustor is conducted with a stream of oxygen containing gases.

5. The process as claimed in claim 1 , wherein the production of syngas in the Auxiliary Reformer is carried out by endothermic reforming of hydrocarbon stream with steam and air or oxygen containing gases, thereby cooling the rejuvenated upgrading material and allowing an increase in the circulation of the rejuvenated upgrading material to the Riser.

6. The process as claimed in claim 1 , wherein the circulation of rejuvenated upgrading agent from the Auxiliary Reformer to the Riser allows a delta coke in the range of 1 to 3 wt %.

7. The process as claimed in claim 1 , wherein the process comprises passing the steam and hydrocarbon stream to the Auxiliary Reformer in a ratio of 2 to 5.

8. The process as claimed in claim 1 , wherein the rejuvenated upgrading material and partially rejuvenated upgrading material has a particle size in the range of 20-200 microns, particle density in the range of 1200-1600 kg/m 3 and surface area in the range of 80-400 m 2 /g and comprises of microspheres composed of alumina, silica alumina, kaoline clay or mixture thereof.

9. The process as claimed in claim 1 , wherein the residual oil comprises of concarbon, nickel, vanadium, sodium, nitrogen and sulfur impurities.

10. A process of increasing syngas production during an upgradation process of petroleum residual oil, the process comprising:
a) introducing spent upgrading agent from a Riser to a Reformer along with steam, optionally air or oxygen containing gases for production of syngas;
b) burning of residual coke present on partially rejuvenated upgrading agent obtained from the Reformer in a Combustor;
c) circulating rejuvenated upgrading agent from the Combustor back to the Reformer;
d) introducing rejuvenated upgrading agent from the Reformer, and a hydrocarbon optionally in presence of steam and air or oxygen containing gases to an Auxiliary Reformer having cerium, nickel and rhodium based reforming catalyst for production of additional syngas; and
e) circulating rejuvenated upgrading agent from the Auxiliary Reformer to the Riser;
wherein, the Riser is operated at an outlet temperature of 550° C. to 650° C., the Reformer is operated at a temperature of 700° C. to 850° C. and pressure of 2-30 atm; the Combustor is operated at a temperature in the range of 750° C. to 950° C.; and the Auxiliary Reformer is operated at a temperature range of 650° C. to 750° C.;
wherein, the rejuvenated upgrading agent and partially rejuvenated upgrading agent is a porous fluidizable micro spherical solid particles belonging to Geldart Group A classification;
wherein the Auxiliary Reformer is maintained at a temperature in the range of 50° C. to 300° C. below the Combustor, and 50° C. to 100° C. above the Riser.

11. The process as claimed in claim 10 , wherein circulating the rejuvenated upgrading material from the Combustor back to the Reformer maintains the temperature of the Reformer by transferring a part of heat generated in the Combustor to Reformer.

Assignees

• Indian Oil Corp Ltd

Inventors

• Saidulu Gadari
• Mukthiyar Sadhullah
• Bhanuprasad Sayapaneni Gopinath
• Nath Vineeth Venu
• Bindu Doosa Hima
• Kumaran Satheesh Vetterkunnel
• Bhattacharyya Debasis
• Kumar Brijesh
• Das Biswapriya

Classifications

• C10J2300/0956

  Air or oxygen enriched air · CPC title

• C01B2203/0283

  containing a CO-shift step, i.e. a water gas shift step · CPC title

• C10J3/721 Primary

  Multistage gasification, e.g. plural parallel or serial gasification stages · CPC title

• C01B2203/0244

  the reforming step being an autothermal reforming step, e.g. secondary reforming processes · CPC title

• C10G11/185

  Energy recovery from regenerator effluent gases · CPC title