Integrated process for producing anode grade coke

Patent metadata

Field	Value
Publication number	US-10954447-B2
Application number	US-202016781189-A
Country	US
Kind code	B2
Filing date	Feb 4, 2020
Priority date	Aug 4, 2015
Publication date	Mar 23, 2021
Grant date	Mar 23, 2021

Abstract

The invention relates to processes for producing anode grade coke from whole crude oil. The invention is accomplished by first deasphalting a feedstock, followed by processing resulting DAO and asphalt fractions. The DAO fraction is hydrotreated or hydrocracked, resulting in removal of sulfur and hydrocarbons, which boil at temperatures over 370° C., and gasifying the asphalt portion in one embodiment. This embodiment includes subjecting hydrotreated and/or unconverted DAO fractions to delayed coking. In an alternate embodiment, rather than gasifying the asphalt portion, it is subjected to delayed coking in a separate reaction chamber. Any coke produced via delayed coking can be gasified.

First claim

The invention claimed is:

1. A method for producing anode grade coke, comprising:
solvent deasphalting a hydrocarbon feedstock to produce an asphalt fraction and a deasphalted oil (DAO) fraction, in a first reaction chamber;
(ii) processing said DAO fraction and asphalt fraction in separate, second, third, and fourth reaction chambers;
(iii) hydrocracking said DAO fraction in said second reaction chamber to remove sulfur and nitrogen therefrom and to distill any hydrocarbons contained in said DAO which have a boiling point over 370° C., and produce an unconverted DAO fraction, wherein said second reaction chamber is a fixed bed, ebullated bed, or slurry bed chamber;
(iv) subjecting any unconverted DAO fraction to delayed coking in a third chamber, and
(v) gasifying said asphalt fraction via combining it with oxygen and steam, in said fourth reaction chamber, to produce hydrogen therefrom.

2. The method of claim 1 , further comprising gasifying any coke produced in step (iv).

3. The method of claim 1 , comprising introducing any hydrogen produced in said fourth reaction chamber into said second reaction chamber.

4. The method of claim 1 , wherein said hydrocarbon feedstock is a crude oil and said solvent deasphalting comprises mixing said crude oil with a paraffinic solvent containing C 3 -C 7 carbon atoms, at a temperature and a pressure below critical temperature and critical pressure of said solvent.

5. The method of claim 4 , wherein said solvent comprises n-butane and isobutane.

6. The method of claim 1 , further comprising contacting said hydrocarbon feedstock with a solid adsorbent.

7. The method of claim 4 , wherein said crude oil and solvent are combined at a weight ratio of from 10:1 to 200:1 w/w.

8. The method of claim 1 , comprising hydrocracking said DAO at a pressure of from 100-200 bars, a temperature of from 350° C. to 450° C., an LHSV of from 0.1 to 4.0 h −1 , and a hydrogen:DAO ratio of from 500 to 2,500 SLt/Lt,
wherein hydrocracking comprises hydrocracking said DAO in the presence of a catalyst, which contains from 2-40 wt % active metal, a pore volume of from 0.33-1.50 cc/gm, a surface area of 250-450 m 2 /g, and an average pore diameter of at least 50 Angstroms; and
wherein solvent deasphalting comprises mixing said hydrocarbon feedstock with a paraffinic solvent containing C 3 -C 7 carbon atoms, at a temperature and a pressure below critical temperature and critical pressure of said solvent.

9. The method of claim 1 , comprising hydrocracking said DAO in a series of multiple chambers.

10. The method of claim 1 , comprising hydrocracking said DAO in the presence of a catalyst, which contains from 2-40 wt % active metal, a pore volume of from 0.33-1.50 cc/gm, a surface area of 250-450 m 2 /g, and an average pore diameter of at least 50 Angstroms.

11. The method of claim 10 , wherein said active metal is a Group VI, VII, or VIIIB metal.

12. The method of claim 10 , wherein said active metal comprises Co, Ni, W, or Mo.

13. The method of claim 10 , wherein said catalyst is presented on a support.

14. The method of claim 13 , wherein said support comprises alumina, silica, or a zeolite.

15. The method of claim 14 , wherein said support is a zeolite with FAU, MOR, BEA or MFI topology.

16. The method of claim 15 , wherein said zeolite has been modified by treatment with at least one of steam, ammonia, or acid, and contains at least one transition metal.

17. The method of claim 16 , wherein said at least one transition metal is Zn or Ti.

18. The method of claim 1 , comprising gasifying said asphalt fraction at a temperature of from 900° C. to 1700° C., and a pressure of from 20 bars to 100 bars.

19. The method of claim 1 , further comprising adjusting the asphalt content and at least one of oxygen content and steam content in said fourth reaction chamber to provide a stoichiometric balance therebetween which results in partial combustion of said asphalt.

20. The method of claim 18 , wherein a stoichiometric ratio based on an oxygen:carbon ratio is from 0.2:1.0 to 10:0.2 by weight.

21. The method of claim 18 , comprising introducing asphalt and steam to said fourth reaction chamber in a ratio of from 0.1 to 1.0 to 10:0.1 based upon weight of carbon in said feedstock, wherein said feedstock is a crude oil.

22. A method for producing anode grade coke, comprising:
solvent deasphalting a hydrocarbon feedstock to produce an asphalt fraction and a deasphalted oil (DAO) fraction, in a first reaction chamber;
processing said DAO fraction and asphalt fraction in separate, second, third, and fourth reaction chambers;
hydrocracking said DAO fraction in a series of multiple chambers in said second reaction chamber to remove sulfur and nitrogen therefrom and to distill any hydrocarbons contained in said DAO which have a boiling point over 370° C., wherein said second reaction chamber is a fixed bed, ebullated bed, or slurry bed chamber;
subjecting any hydrotreated or unconverted DAO fraction to delayed coking in a third chamber, and
gasifying said asphalt fraction via combining it with oxygen and steam, in said fourth reaction chamber, to produce hydrogen therefrom.

Assignees

• Saudi Arabian Oil Co

Inventors

• Koseoglu Omer Refa

Classifications

• C10G21/003

  Solvent de-asphalting · CPC title

• C10B57/045 Primary

  containing mineral oils, bitumen, tar or the like or mixtures thereof · CPC title

• Y02P20/52

  using catalysts, e.g. selective catalysts · CPC title

• C10G25/00

  Refining of hydrocarbon oils in the absence of hydrogen, with solid sorbents · CPC title

• C10G47/20

  the catalyst containing other metals or compounds thereof · CPC title