Removing catalyst fines from heavy oils

Patent metadata

Field	Value
Publication number	US-11879100-B2
Application number	US-202217732335-A
Country	US
Kind code	B2
Filing date	Apr 28, 2022
Priority date	Apr 28, 2022
Publication date	Jan 23, 2024
Grant date	Jan 23, 2024

Abstract

Catalyst fines can be removed from heavy oils, such as marine fuel oils, by introducing an additive in an effective amount to at least partially remove the catalyst fines, where the additive is an oxyalkylated acid-catalyzed alkylphenol formaldehyde resin and/or a Mannich condensate base resin copolymer.

First claim

What is claimed is:

1. A method for at least partially removing catalyst fines from a heavy oil containing them, the method comprising:
introducing an additive into the heavy oil containing catalyst fines in an effective amount to at least partially remove the catalyst fines, where the additive is selected from the group consisting of:
an oxyalkylated acid-catalyzed alkylphenol formaldehyde resin;
a Mannich condensate base resin copolymer; and
combinations thereof; and

at least partially removing the catalyst fines from the heavy oil by a physical process.

2. The method of claim 1 where the alkyl phenol in either or both of the oxyalkylated acid-catalyzed alkylphenol formaldehyde resin and the Mannich condensate base resin copolymer has from 1 to 28 carbon atoms where the total moles of alkylene oxide ranges from about 0.1 to about 20 moles per mole of alkyl phenol group in the resin, where the alkylene oxide is selected from the group consisting of ethylene oxide and propylene oxide.

3. The method of claim 1 where the additive is the oxyalkylated acid-catalyzed alkylphenol formaldehyde resin, and the molecular weight of the oxyalkylated acid-catalyzed alkylphenol formaldehyde resin ranges from about 2,000 to about 10,000 grams/mole.

4. The method of claim 1 where the additive is the Mannich condensate base resin copolymer, and the Mannich condensate base resin copolymer comprises the reaction of an alkylphenol with an amine, and formaldehyde and where the amine is a polyalkyleneamine having 2 to 5 amino groups therein.

5. The method of claim 1 where the additive is the oxyalkylated acid-catalyzed alkylphenol formaldehyde resin, and where the oxyalkylated acid-catalyzed alkylphenol formaldehyde resin is selected from the group consisting of:
alkoxylated p-t-alkyl phenol resins where the alkyl group is selected from the group consisting of methyl, ethyl, propyl, butyl, and combinations thereof;
resins of formula (I):

where x ranges from 1 to 12, y ranges from 1 to 300, and n is such that the weight average molecular weight ranges from about 100 to about 15,000;
resins of formula (II):

where R is hydrogen or methyl, m ranges from 1 to 100, and p ranges from 1 to 50.

6. The method of claim 1 where the additive is the Mannich condensate base resin copolymer, where the Mannich condensate base resin copolymer is made by reacting an alkyl phenol with an amine and formaldehyde, where:
the alkyl group on the alkyl phenol ranges from C1 to C28;
the amine is a polyethyleneamine having from 1 to 5 amine groups; and
where the molar ratio of alkyl phenol to polyethyleneamine ranges from 1:1 to 1:5.

7. The method of claim 1 where the heavy oil is selected from the group consisting of marine fuels, refinery residua, decant oil, and combinations thereof.

8. The method of claim 1 where the effective amount of the additive based on the heavy oil ranges from about 10 ppm to about 10,000 ppm.

9. The method of claim 1 where both the oxyalkylated acid-catalyzed alkylphenol formaldehyde resin and the Mannich condensate base resin copolymer are introduced, and the weight ratio between the oxyalkylated acid-catalyzed alkylphenol formaldehyde resin and the Mannich condensate base resin copolymer ranges from about 10/90 to about 90/10.

10. The method of claim 1 where the heavy oil is at a temperature from about 2° C. to about 250° C.

11. The method of claim 1 where the physical removal process is selected from the group consisting of gravity settling, centrifugation, and combinations thereof.

12. The method of claim 1 where the catalyst fines comprise aluminum and silicon.

Assignees

• Baker Hughes Oilfield Operations Llc

Inventors

• Murugesan Sankaran
• Pinappu Sai Reddy
• Weers Jerry J
• Weaver Carl E

Classifications

• C10G29/20 Primary

  Organic compounds not containing metal atoms · CPC title

• C10G31/06

  by heating, cooling, or pressure treatment · CPC title

• C10G31/10 Primary

  with the aid of centrifugal force · CPC title

• C10L1/146

  Macromolecular compounds according to different macromolecular groups, mixtures thereof · CPC title

• C10G2300/107

  Atmospheric residues having a boiling point of at least about 538 °C · CPC title