Heavy oil hydrocracking process

Patent metadata

Field	Value
Publication number	US-9410093-B2
Application number	US-201414216947-A
Country	US
Kind code	B2
Filing date	Mar 17, 2014
Priority date	Mar 15, 2013
Publication date	Aug 9, 2016
Grant date	Aug 9, 2016

Abstract

A process for the production of high yields of high quality products from heavy hydrocarbonaceous feedstock comprising a two-stage, close-coupled process. The first stage comprises a thermo-catalytic zone into which is introduced a mixture comprising the feedstock, coal, a liquid catalyst precursor, and hydrogen. The second, close-coupled stage comprises a catalytic-hydrotreating zone into which substantially all the effluent from the first stage is directly passed and processed under hydrotreating conditions.

First claim

What is claimed is:

1. A process for conversion of heavy oils to produce lower boiling hydrocarbon products comprising;
dispersing finely divided coal and a liquid catalyst precursor in a heavy oil feedstock, heating and passing the dispersed mixture together with hydrogen to a first reaction zone in which the liquid catalyst precursor is converted into fine solid catalyst particles,
reducing the product of the first reaction zone in temperature and passing the product to a second reaction zone having a supported hydrotreating catalyst,
with the first and second reaction zone close-coupled, the first reaction zone a thermo-catalytic reactor(s) and the second reaction zone a catalytic-hydrotreating reactor(s); and
recovering the product of the second reaction zone.

2. The process of claim 1 , wherein substantially all effluent from the thermo-catalytic zone is passed into the catalytic-hydrotreating zone.

3. The process of claim 1 , wherein some gaseous product is removed from the product of the thermo-catalytic reactor before passing to the catalytic-hydrotreating reactor.

4. The process of claim 1 , wherein the liquid catalyst precursor is comprised of a molybdenum compound.

5. The process of claim 4 , wherein liquid catalyst precursor comprises a solution of a dissolved catalyst material comprising molybdenum naphthenate.

6. The process of claim 5 , wherein the liquid catalyst precursor material is dissolved in an organic solvent.

7. The process of claim 1 , wherein the temperature of said first-reaction thermo-catalytic zone is maintained within a range of between 750° F. to 900° F.

8. The process of claim 1 , wherein the products from the catalytic-hydrotreating reactor are separated into gaseous, liquid and a liquid/solid bottom fractions and wherein a portion of the liquid and/or liquid/solid fraction bottoms is recycled back to the feed system.

9. The process of claim 1 , wherein the products from the catalytic-hydrotreating zone are separated into gaseous and liquid/solid bottom fractions and wherein a portion of the gaseous fraction containing hydrogen is recycled to the hydrotreating reaction zone.

10. The process of claim 1 , wherein the products from the catalytic-hydrotreating zone are separated into gaseous and liquid/solid bottom fractions and wherein a portion of the gaseous fraction containing hydrogen is recycled to thermo-catalytic reaction zone.

11. The process as claimed in claim 1 , wherein the temperature of the catalytic-hydrotreating zone is between 600° F. to 790° F.

12. The process as claimed in claim 1 , wherein the amount of heavy oil in the feedstock is converted to hydrocarbons boiling below 1000° F. is at least 50 percent.

13. The process as claimed in claim 1 , wherein the amount of heavy oil in the feedstock is converted to hydrocarbons boiling below 1000° F. is preferably at least 75 percent.

14. The process of claim 1 wherein said heavy oil feedstock is selected from the group consisting of crude petroleum, topped crude petroleum, reduced crudes, petroleum residua from atmospheric or vacuum distillations, solvent deasphalted tars and oils, heavy hydrocarbonaceous liquids derived from coal, bitumen, or coal tar pitches.

15. The process of claim 1 , wherein said heavy oil feedstock is co-processed with oils such as VGO, Coker Gas Oil, and/or FCC Cycle Oil.

16. The process of claim 1 , wherein the concentration of coal dispersed in the feed to the thermo-catalytic zone is between 0.5 and 40 percent by weight.

17. The process as claimed in claim 1 , wherein the concentration of coal dispersed in the feed to the thermo-catalytic zone is about 3 to 10 percent by weight.

18. The process of claim 1 , wherein the amount of solid catalyst in the thermo-catalytic zone once the liquid catalyst precursor is converted to fine catalyst particles is from about 0.1 to 5 percent by weight in relation to the total feedstock to the thermo-catalytic zone.

19. The process of claim 1 , wherein the residence time of the material in the thermo-catalytic reaction zone is from about 0.5 to 3 hours.

20. The process of claim 1 , wherein the residence time of material in the second reaction zone is from about 0.3 to 4 hours.

21. The process as claimed in claim 1 , wherein the supported catalyst in said catalytic-hydrotreating zone is maintained in a fixed, ebullated or moving bed(s) within the reaction zone.

22. The process as claimed in claim 1 , wherein the process in the second reaction zone is maintained at a hydrogen partial pressure from about 35 atmospheres to 300 atmospheres.

23. The process as claimed in claim 1 , wherein said metal contaminants in the feedstock include nickel, vanadium, and iron and where they are substantially removed from the feedstock in the thereto-catalytic stage.

Assignees

• Cash Dennis R
• Forder Graham J
• Mitchell David S
• Rosenthal Joel W
• Chevron Usa Inc

Inventors

• Cash Dennis R
• Forder Graham J
• Mitchell David S
• Rosenthal Joel W

Classifications

• C10G69/04 Primary

  including at least one step of catalytic cracking in the absence of hydrogen · CPC title

• C10G69/06

  including at least one step of thermal cracking in the absence of hydrogen · CPC title