Method of processing low-grade heavy oil

Patent metadata

Field	Value
Publication number	US-9725658-B2
Application number	US-201414296387-A
Country	US
Kind code	B2
Filing date	Jun 4, 2014
Priority date	Sep 29, 2013
Publication date	Aug 8, 2017
Grant date	Aug 8, 2017

Abstract

The present invention provides a method for processing low-grade heavy oil, comprising: providing a riser-bed reactor; preheating the low-grade heavy oil and injecting it into the riser reactor to react with solid catalyst particles at the temperature of 550-610° C.; oil-gas, after reacting with the solid catalyst particles in the riser reactor, being introduced into the fluidized bed reactor to continue to react at temperature of 440-520° C. and weight hourly space velocity of 0.5-5 h −1 ; and the oil-gas, after reacting in the fluidized bed reactor, being separated from coked solid catalyst particles carried therein, and the separated oil-gas being introduced into a fractionation system. The method can effectively remove carbon residues, heavy metals, asphaltenes and other impurities from the low-grade heavy oil, and obtain high liquid product yield in a simple process.

First claim

What is claimed is:

1. A method for processing low-grade heavy oil with carbon residue content of greater than 15 wt %, heavy metal content of greater than 260 μg/g and relative density of more than 0.985, comprising:
providing a riser-bed reactor including a riser reactor and a fluidized bed reactor connected in series with the riser reactor;
preheating the low-grade heavy oil and injecting the preheated low-grade heavy oil into the riser reactor to contact and react with solid catalyst particles in the riser reactor, wherein reaction temperature in the riser reactor is controlled to be in the range of 550-610° C.;
introducing oil-gas that is formed after reaction with the solid catalyst particles in the riser reactor, from the riser reactor into the fluidized bed reactor to continue to react in the fluidized bed reactor, wherein reaction temperature in a bed layer of the fluidized bed reactor is 440-520° C. and weight hourly space velocity is 0.5-5 h −1 ; and
separating oil-gas that is formed after reaction in the fluidized bed reactor, from coked solid catalyst particles carried therein, and introducing the separated oil-gas into a fractionation system;
wherein the solid catalyst particles have a specific surface area of greater than 80 m 2 ·g −1 and not more than 89.7 m 2 ·g −1 , a pore volume of greater than 0.22 ml/g, a wear index of less than 2.0%, a bulk density of 0.7-1.50 g/cm 3 , a matrix density of 1.8-2.8 g/cm 3 and a micro-activity index of 20-25, and the solid catalyst particles are made of a porous material, in which pores with a diameter of 10 nm or more account for 60% or more in the pore size distribution of the porous material, and wherein when the low-grade heavy oil contacts and reacts with the solid catalyst particles in the riser reactor, a catalyst-to-oil ratio is controlled at 7-10, and reaction time is 0.5-1.5 seconds.

2. The method according to claim 1 , wherein the low-grade heavy oil is preheated to 220-300° C. before being introduced into the riser reactor.

3. The method according to claim 1 , wherein the coked solid catalyst particles separated from the oil-gas enter a regenerator after being stripped by superheated steam for regeneration, and then are recycled to the riser-bed reactor.

4. The method according to claim 2 , wherein the coked solid catalyst particles separated from the oil-gas enter a regenerator after being stripped by superheated steam for regeneration, and then are recycled to the riser-bed reactor.

5. The method according to claim 3 , wherein, after regeneration, the coked solid catalyst particles are introduced into a heat extractor and recycled back to the riser reactor from a bottom thereof after heat exchange by the heat extractor, and temperature of the regenerated solid catalyst particles recycled to the riser reactor is kept at the range of 670-750° C.

6. The method according to claim 4 , wherein, after regeneration, the coked solid catalyst particles are introduced into a heat extractor and recycled back to the riser reactor from a bottom thereof after heat exchange by the heat extractor, and temperature of the regenerated solid catalyst particles recycled to the riser reactor is kept at the range of 670-750° C.

7. The method according to claim 3 , wherein, after regeneration, one part of the coked solid catalyst particles is returned to the riser reactor from a bottom portion thereof, and another part of the coked solid catalyst particles passes through a heat extractor for heat exchange and then is fed into the fluidized bed reactor.

8. The method according to claim 4 , wherein, after regeneration, one part of the coked solid catalyst particles is returned to the riser reactor from a bottom portion thereof, and another part of the coked solid catalyst particles passes through a heat extractor for heat exchange and then is fed into the fluidized bed reactor.

9. The method according to claim 3 , wherein the regeneration of the coked solid catalyst particles comprises coke-burning regeneration of the coked solid catalyst particles, or introducing oxygen and water vapor to regenerate the coked solid catalyst particles, and the regenerated solid catalyst particles are recycled to the riser reactor.

10. The method according to claim 4 , wherein the regeneration of the coked solid catalyst particles comprises coke-burning regeneration of the coked solid catalyst particles, or introducing oxygen and water vapor to regenerate the coked solid catalyst particles, and the regenerated solid catalyst particles are recycled to the riser reactor.

11. The method according to claim 3 , wherein oil-gas stripped out by superheated steam from the coked solid catalyst particles separated from the oil-gas is sent to the fractionation system, and the coked solid catalyst particles enter the regenerator for regeneration and regenerated solid catalyst particles are recycled back to the riser-bed reactor.

12. The method according to claim 4 , wherein oil-gas stripped out by superheated steam from the coked solid catalyst particles separated from the oil-gas is sent to the fractionation system, and the coked solid catalyst particles enter the regenerator for regeneration and regenerated solid catalyst particles are recycled back to the riser-bed reactor.

13. The method according to claim 3 , wherein a discharge port is provided at a bottom of the regenerator, and a part of the coked solid catalyst particles after being regenerated is discharged from the discharge port and sent to a heavy metal recovery process.

14. The method according to claim 4 , wherein a discharge port is provided at a bottom of the regenerator, and a part of the coked solid catalyst particles after being regenerated is discharged from the discharge port and sent to a heavy metal recovery process.

Assignees

• Univ China Petroleum Beijing
• China Nat Petroleum Corp

Inventors

• Wang Gang
• Gao Jinsen
• Xu Chunming
• Shen Baojian
• Wang Hongliang

Classifications

• C10G2300/1077

  Vacuum residues · CPC title

• C10G11/04

  Oxides · CPC title

• C10G11/02

  characterised by the catalyst used · CPC title

• C10G2400/04

  Diesel oil · CPC title

• C10G2400/02

  Gasoline · CPC title