Process to upgrade partially converted vacuum residua

Patent metadata

Field	Value
Publication number	US-2016145509-A1
Application number	US-201414550384-A
Country	US
Kind code	A1
Filing date	Nov 21, 2014
Priority date	Nov 21, 2014
Publication date	May 26, 2016
Grant date	—

Abstract

Processes for upgrading partially converted vacuum residua hydrocarbon feeds are disclosed. The upgrading processes may include: steam stripping the partially converted vacuum residua to generate a first distillate and a first residuum; solvent deasphalting the first residuum stream to generate a deasphalted oil and an asphaltenes fraction; vacuum fractionating the deasphalted oil to recover a deasphalted gas oil distillate and a heavy deasphalted residuum; contacting the first distillate and the deasphalted gas oil distillate and hydrogen in the presence of a first hydroconversion catalyst to produce a product; contacting the heavy deasphalted residuum stream and hydrogen in the presence of a second hydroconversion catalyst to produce an effluent; and fractionating the effluent to recover a hydrocracked atmospheric residua and a hydrocracked atmospheric distillate

First claim

What is claimed:

1 . A process for upgrading a partially converted vacuum residua, comprising:
stripping the partially converted vacuum residua utilizing a non-reactive stripping medium to generate a first distillate and a first residuum; solvent deasphalting the first residuum to generate a deasphalted oil and an asphaltenes fraction; vacuum fractionating the deasphalted oil to recover a deasphalted gas oil distillate and a heavy deasphalted residuum; contacting the first distillate and the deasphalted gas oil distillate and hydrogen in the presence of a first hydroprocessing catalyst to produce a first hydroprocessing effluent; contacting the heavy deasphalted residuum and hydrogen in the presence of a second hydroconversion catalyst to produce a second hydroprocessing effluent; and fractionating the second hydroprocessing effluent to recover a hydrocracked atmospheric residua and a hydrocracked atmospheric distillate.

2 . The process of claim 1 , wherein the partially converted vacuum residua comprises an effluent from an upstream conversion process.

3 . The process of claim 1 , further comprising solvent deasphalting the hydrocracked atmospheric residua with the first residuum.

4 . The process of claim 1 , further comprising separating the partially converted vacuum residua into a partially converted vacuum residua liquid and a partially converted vacuum residua vapor.

5 . The process of claim 4 , further comprising contacting the partially converted vacuum residua vapor in the presence of the first hydroconversion catalyst at conditions of temperature and pressure to produce the first hydroprocessing effluent.

6 . The process of claim 4 , further comprising combining the partially converted vacuum residua vapor with the deasphalted gas oil distillate.

7 . The process of claim 1 , wherein contacting the first distillate and the deasphalted gas oil distillate and hydrogen in the presence of a first hydroprocessing catalyst further comprises contacting the hydrocracked atmospheric distillate with the first hydroconversion catalyst.

8 . The process of claim 4 , wherein contacting the first distillate and the deasphalted gas oil distillate and hydrogen in the presence of a first hydroprocessing catalyst further comprises contacting the hydrocracked atmospheric distillate, the deasphalted gas oil distillate, and the partially converted vacuum residua vapor, or combinations thereof, with the first hydroconversion catalyst.

9 . The process of claim 1 , wherein the contacting the heavy deasphalted residuum stream and hydrogen in the presence of a second hydroconversion catalyst is done at conditions of a temperature in the range from about 360 to about 480° C.; a pressure in the range of about 70 to about 230 Bara; a liquid hourly space velocity of about 0.1 to about 3.0 hr−1 and a hydrogen to oil ratio of about 5000 to about 20,000 scf/bbl.

10 . The process of claim 1 , wherein the contacting the first distillate and the deasphalted gas oil distillate and hydrogen in the presence of a first hydroconversion catalyst is done at conditions of a temperature in the range from about 360 to about 480° C.; a pressure in the range of about 70 to about 230 Bara; a liquid hourly space velocity of about 0.1 to about 3.0 hr−1 and a hydrogen to oil ratio of about 5000 to about 20,000 scf/bbl.

11 . The process of claim 1 , wherein the overall conversion of the partially converted vacuum residua is at least about 98%.

12 . The process of claim 1 , further comprising gasifying the asphaltenes fraction to generate synthesis gas.

13 . The process of claim 12 , wherein the synthesis gas comprises hydrogen for contacting the deasphalted gas oil distillate and the heavy deasphalted residuum stream.

14 . The process of claim 2 , wherein the upstream conversion process comprises a hydrocracking unit, a vac resid coking unit, a hydrothermolysis unit, a hydropyrolysis unit, a pyrolysis unit, an oil shale retorting unit, a biomass pyrolysis unit, a biomass hydropyrolysis unit, a biomass hydrothermolysis unit, a tar sands extraction unit, a steam assisted gravity drainage process, a toe to heel air injection process, an in situ petroleum extraction process, or a combination thereof.

15 . The process of claim 1 , wherein the first hydroconversion catalyst is within a fixed bed and the second hydroconversion catalyst is within an ebullated bed reactor.

16 . The process of claim 1 , wherein the first hydroconversion catalyst is within a fixed bed and the second hydroconversion catalyst is within a slurry reactor.

17 . The process of claim 1 , wherein the non-reactive stripping medium is hydrogen, nitrogen, fuel gas or steam.

18 . A process for upgrading a partially converted vacuum residua, comprising:
stripping with a mass transfer device the partially converted vacuum residua to generate a first distillate and a first residuum; deasphalting with a solvent deasphalting unit the first residuum to generate a deasphalted oil and an asphaltenes fraction; fractionating with a vacuum fractionation unit the deasphalted oil to recover a deasphalted gas oil distillate and a heavy deasphalted residuum; contacting the first distillate and the deasphalted gas oil distillate and hydrogen in the presence of a first hydroprocessing catalyst an ebullated bed hydroconversion reactor to produce a first hydroprocessing effluent; contacting the heavy deasphalted residuum and hydrogen in the presence of a second hydroconversion catalyst in a fixed bed hydroconversion reactor system to produce a second hydroprocessing effluent; and fractionating with an atmospheric fractionation unit the second hydroprocessing effluent to recover a hydrocracked atmospheric residua and a hydrocracked atmospheric distillate.

19 . A system for upgrading partially converted residuum hydrocarbons, the system comprising:
a mass transfer device to strip a partially converted residuum hydrocarbon stream into a first distillate stream and a first residuum stream; a solvent deasphalting unit for recovering a deasphalted oil stream and an asphaltenes stream from the first residuum stream; a vacuum fractionation unit to fractionate the deasphalted oil stream to recover a deasphalted gas oil stream and a heavy deasphalted residuum stream; an ebullated bed hydroconversion reactor system for contacting the heavy deasphalted residuum stream and hydrogen with a first hydroconversion catalyst to produce a first effluent; an atmospheric fractionation unit to fractionate the first effluent to recover a hydrocarbon atmospheric distillate stream and a hydrocarbon atmospheric residuum stream; a fixed bed hydroconversion reactor system for contacting at least one of the first distillate stream, the deasphalted gas oil stream, and the hydrocarbon atmospheric distillate stream to produce a second effluent.

20 . The system of claim 19 , further comprising a gasification system for converting the asphaltenes stream to a synthesis gas.

21 . The system of claim 19 , further comprising a partial upgrading conversion unit to convert a residuum stream to the partially converted residuum stream.

22 . The system of claim 21 , wherein the partial upgrading conversion unit is selected from the group consisting of a hydrocracking unit, a vac resid coking unit, a hydrothermolysis unit, a hydropyrolysis unit, a pyrolysis unit, an oil shale retorting unit, a biomass pyrolysis unit, a biomass hydropyrolysis unit, a biomass hydrothermo

Assignees

• Lummus Technology Inc

Inventors

• Mukherjee Ujjal K
• Baldassari Mario C
• Greene Marvin I

Classifications

• C10G2300/1077

  Vacuum residues · CPC title

• C10G67/0454

  Solvent desasphalting · CPC title

• C10G2300/206

  Asphaltenes · CPC title

• C10J3/00

  Production of combustible gases containing carbon monoxide from solid carbonaceous fuels (destructive distillation processes C10B) · CPC title

• C10G7/06

  Vacuum distillation · CPC title