Systems and methods for enhanced inorganic contaminant removal from hydrocarbon feedstock

Patent metadata

Field	Value
Publication number	US-12098330-B2
Application number	US-202318209004-A
Country	US
Kind code	B2
Filing date	Jun 13, 2023
Priority date	Oct 29, 2020
Publication date	Sep 24, 2024
Grant date	Sep 24, 2024

Abstract

Systems and methods to enhance the removal of inorganic contaminants, including metals, from hydrocarbon feedstocks at a refinery. One or more embodiments of such systems and methods may be used to provide a renewable hydrocarbon feedstock having a reduced amount of metal contaminants. The reduction of metal contaminants in the renewable hydrocarbon feedstock mitigates catalyst fouling and/or deactivation during downstream refinery processing of the renewable hydrocarbon feedstock.

First claim

The invention claimed is:

1. A process to reduce contaminants in renewable hydrocarbon feedstocks, the process comprising:
removing inorganic contaminants from untreated water;
deionizing the water having the inorganic contaminants removed therefrom by ion exchange, thereby to generate deionized water;
passing the deionized water through an aerator, thereby to increase a concentration of dissolved oxygen in the deionized water;
mixing the deionized water with a renewable feedstock having hydrocarbon compounds and inorganic contaminants, thereby to create a deionized water and renewable feedstock mixture, the renewable feedstock includes (a) one or more of plant oils, algal and microbial oils, waste vegetable oils, yellow and brown grease, tallow, soap stock, pyrolysis oils from plastic or cellulose, and (b) petroleum fractions;
reacting the deionized water and renewable feedstock mixture at a temperature, pressure and non-laminar flow so as to inhibit rearrangement reactions of the renewable feedstock hydrocarbon compounds;
maintaining the temperature, pressure and non-laminar flow for a first interval of time so as to transfer at least a portion of the inorganic contaminants of the renewable feedstock into the deionized water;
after the first time interval, and for a second time interval, separating the deionized water containing the inorganic contaminants from the renewable feedstock, thereby to create contaminant-rich water and a reduced-contaminant renewable feedstock; and
after the second time interval, passing the reduced-contaminant renewable feedstock to a downstream process.

2. The process of claim 1 , wherein the deionized water comprises greater than 15% by volume of the deionized water and renewable feedstock mixture, and wherein the non-laminar flow has a Reynolds number greater than 2,000.

3. The process of claim 1 , wherein the deionized water comprises greater than 30% by volume of the deionized water and renewable feedstock mixture.

4. The process of claim 1 , wherein the deionized water comprises between about 10% to about 50% by volume of the deionized water and renewable feedstock mixture.

5. The process of claim 1 , wherein the first time interval comprises a time interval between about 30 seconds to about 5 minutes.

6. The process of claim 1 , wherein the temperature comprises a temperature between about 200° C. and about 450° C.

7. The process of claim 1 , further comprising, prior to the step of separating the deionized water containing the inorganic contaminants from the renewable feedstock, injecting additional deionized water into the deionized water and renewable feedstock mixture.

8. The process of claim 7 , wherein an amount of the additional deionized water comprises between about 3% to about 10% by volume of the deionized water and renewable feedstock mixture.

9. The process of claim 1 , wherein the second time interval comprises a time period between 60 minutes and 180 minutes.

10. The process of claim 1 , wherein the pressure comprises a pressure between about 500 psig and about 6,000 psig.

11. The process of claim 1 , wherein the deionized water in the deionized water and renewable feedstock mixture becomes less deionized as metal inorganic containments are transferred therein.

12. The process of claim 1 , wherein the conductivity of the deionized water comprises a conductivity less than about 1 μS/cm.

13. A process to reduce contaminants in renewable hydrocarbon feedstocks, the process comprising:
generating deionized water;
aerating the deionized water in an aerating unit, thereby to generate an aerated, deionized water;
injecting the aerated, deionized water into a renewable feedstock stream at a refinery, thereby to create a mixture of aerated, deionized water and renewable feedstock, the renewable feedstock includes one or more of plant oils, algal and microbial oils, waste vegetable oils, yellow and brown grease, tallow, soap stock, pyrolysis oils from plastic or cellulose;
passing the mixture into a reactor at a pre-selected temperature, pressure and non-laminar flow;
maintaining the temperature, pressure and non-laminar flow of the reactor for a first interval of time, thereby to transfer at least a portion of inorganic contaminants of the renewable feedstock into the aerated, deionized water;
after the first time interval, passing the mixture to a separation unit;
separating the aerated, deionized water containing the inorganic contaminants from the renewable feedstock in the separation unit so as to create contaminant-rich water and a reduced-contaminant renewable feedstock for a second time interval; and
after the second time interval, passing the reduced-contaminant renewable feedstock to a downstream process.

14. The process of claim 13 , further comprising passing untreated water through a reverse osmosis unit to remove inorganic contaminants therefrom, thereby to generate water to be deionized.

15. The process of claim 14 , wherein the deionized water has a conductivity less than about 5 μS/cm, wherein the deionized water comprises between about 10% to about 50% by volume of the deionized water and renewable feedstock mixture, and wherein the non-laminar flow has a Reynolds number greater than 2,000.

16. The process of claim 15 , wherein the temperature comprises a temperature between about 200° C. and about 450° C. and the pressure comprises a pressure between about 500 psig and about 6,000 psig, and wherein the deionized water has a conductivity less than about 5 μS/cm.

17. The process of claim 16 , wherein the renewable feedstock further includes petroleum fractions.

18. The process of claim 13 , further comprising prior to passing the aerated deionized water and renewable feedstock mixture to the separation unit, injecting additional aerated deionized water into the aerated deionized water and renewable feedstock mixture, and wherein the deionized water has a conductivity less than about 5 μS/cm.

19. The process of claim 18 , wherein an amount of the additional deionized water comprises between about 3% to about 10% by volume of the deionized water and renewable feedstock mixture.

20. The process of claim 13 , wherein the conductivity of the deionized water comprises a conductivity less than about 1 μS/cm.

21. The process of claim 13 , further comprising adding an acid to the aerated, deionized water prior to injecting the aerated, deionized water into the renewable feedstock stream.

22. A refinery system to reduce contaminants in renewable hydrocarbon feedstocks, the system comprising:
a source of a renewable feedstock having hydrocarbons compounds and inorganic contaminants, the renewable feedstock includes (a) one or more of plant oils, algal and microbial oils, waste vegetable oils, yellow and brown grease, tallow, soap stock, pyrolysis oils from plastic or cellulose, and (b) petroleum fractions;
a source of water;
a deionized water generator in fluid communication with the source of water, the deionized water generator operating to generate a stream of deionized water having a conductivity less than a selected threshold;
a mixer in fluid communication with the source of renewable feedstock and in fluid communication with the deionized water stream, the mixer configured to receive and mix the deionized water stream and renewable feedstock stream so as to create a mixture of deionized water and renewable feedstock;
a cleaning unit, positioned at a refinery, in fluid communication with the mixer to receive

Assignees

• Marathon Petroleum Co Lp

Inventors

• Cox Mark D

Classifications

• C10G9/06

  by pressure distillation · CPC title

• C02F2209/44

  Time · CPC title

• C02F2209/02

  Temperature · CPC title

• C02F2209/001

  Upstream control, i.e. monitoring for predictive control · CPC title

• C02F2103/365

  from petrochemical industry (e.g. refineries) · CPC title