Integrated heavy liquid fuel coking with chemical looping concept

Patent metadata

Field	Value
Publication number	US-9790437-B2
Application number	US-201414510497-A
Country	US
Kind code	B2
Filing date	Oct 9, 2014
Priority date	Oct 9, 2014
Publication date	Oct 17, 2017
Grant date	Oct 17, 2017

Abstract

A process for power generation using a chemical looping combustion concept is integrated with heavy liquid fuel coking in a cracking reactor, and is configured such that petcoke deposits on metal oxide particles from the cracking reactor are used as fuel in the chemical looping combustion reaction. The process is also configured such that metal oxide particles provide the heat necessary for the cracking reaction to be initiated in the cracking reactor.

First claim

What is claimed is:

1. A method for chemical looping with integrated hydrocarbon cracking comprising the steps of:
injecting at least one liquid hydrocarbon feed into a first reactor which operates under first reaction conditions to cause cracking of the at least one liquid hydrocarbon feed in the presence of an oxygen carrier to produce a first product stream and petcoke which deposits on the oxygen carrier;
transferring the oxygen carrier with petcoke deposited thereon from the first reactor to a second reactor;
operating the second reactor under second reaction conditions to produce a second product stream and to reduce the oxygen carrier that has petcoke deposited thereon, wherein the second reaction conditions comprise a gasification process in which the petcoke deposited on the oxygen carrier reacts with steam and CO 2 that is injected into the second reactor to form a gas stream comprising syngas, whereby the oxygen carrier is reduced;
transferring at least a first portion of the reduced oxygen carrier to the first reactor, wherein the reduced oxygen carrier provides heat and energy which allows the first reactor to operate under the first reaction conditions;
transferring at least a second portion of the reduced oxygen carrier to a third reactor which operates under third reaction conditions to oxidize the reduced oxygen carrier; and
transferring the oxidized oxygen carrier from the third reactor back to the second reactor.

2. The method of claim 1 , wherein the first reactor comprises a cracking reactor, the second reactor comprises a fuel reactor, and the third reactor comprises an air reactor.

3. The method of claim 1 , wherein the at least one liquid hydrocarbon feed comprises a heavy liquid fuel.

4. The method of claim 1 , wherein the oxygen carrier comprises metal oxides.

5. The method of claim 4 , wherein the metal oxides are disposed in a bed that is within the first reactor.

6. The method of claim 1 , further comprising the steps of splitting, in a splitter reactor, the first portion of the reduced oxygen carrier from the second reactor into a one portion that is returned back to the first reactor and another portion that is returned to the second reactor, and maintaining, via the splitter reactor, the pressure balance between the first reactor and the second reactor by controlling circulation of the reduced oxygen carriers between the first reactor and the second reactor.

7. The method of claim 1 , further comprising the steps of splitting, in a splitter reactor, the oxidized oxygen carrier from the third reactor into a portion that is returned back to the second reactor and another portion that is returned back to the third reactor, and maintaining, via the splitter reactor, the pressure balance between the second reactor and the third reactor by controlling circulation of the oxidized oxygen carriers between the second reactor and the third reactor.

8. The method of claim 1 , further comprising transferring the second product stream from the second reactor to a gas turbine for producing energy, wherein the second product stream includes syngas.

9. A process for chemical looping combustion with integrated hydrocarbon cracking, comprising the steps of:
injecting a heavy liquid fuel and metal oxides into a cracking reactor;
cracking the heavy fuel in the cracking reactor in the presence of the metal oxides to produce petroleum-based products and petcoke deposits on the metal oxides;
delivering the metal oxides with petcoke deposited thereon from the cracking reactor to a fuel reactor;
gasifying the metal oxides with petcoke deposited thereon in the fuel reactor in the presence of steam to produce a product gas stream, unburned gases, and reduced metal oxides;
delivering the product gas stream, unburned gases, and the reduced metal oxides from the fuel reactor to a riser;
separating the reduced metal oxides from the unburned gases and the product gas stream in a separation section;
delivering the separated reduced metal oxides to an air reactor; and
oxidizing the reduced metal oxides in the air reactor to produce oxidized metal oxides and flue gas, wherein the oxidized metal oxides are delivered back to the fuel reactor.

10. The process of claim 9 , wherein the fuel reactor is one of a turbulent bed, fluidized bed, and circulating fluidized bed.

11. The process of claim 9 , wherein the cracking reactor is one of a turbulent bed, fluidized bed, and circulating fluidized bed.

12. The process of claim 9 , wherein the petroleum-based products comprise products selected from the group consisting of naphtha, gasoline, diesel fuel, petcoke, gas oil, and LPG.

13. The process of claim 9 , further including the step of delivering the petroleum-based products from the cracking reactor to a separation device.

14. The process of claim 13 , further including the step of recycling the petroleum-based products from the separation device to the cracking reactor to increase the yield of petcoke deposited on the reduced metal oxides.

15. The process of claim 9 , wherein the product gas stream comprises CO and H 2 .

16. The process of claim 15 , wherein the product gas stream comprises syngas.

17. The process of claim 16 , wherein the syngas is used in a combine cycle turbine to produce electricity.

18. The process of claim 9 , wherein the unburned gases contains sulfur.

19. The process of claim 9 , further including the step of injecting a sulfur-absorbing material into the riser.

20. The process of claim 19 , wherein the sulfur-absorbing material is limestone.

21. The process of claim 9 , further including the steps of transporting the reduced metal oxides from the separation section to a splitter reactor, maintaining, via the splitter reactor, the pressure balance between the cracking reactor and the fuel reactor by controlling circulation of the reduced metal oxides between the cracking reactor and the fuel reactor, and transporting portions of the reduced metal oxides from the splitter reactor to the cracking reactor and the fuel reactor.

22. The process of claim 9 , further including the step of transporting the oxidized metal oxides and flue gas from the air reactor to a separation device, wherein the oxidized metal oxides are separated from the flue gas.

23. The process of claim 22 , further including the steps transporting the oxidized metal oxides from the separation device to a splitter reactor, maintaining, via the splitter reactor, the pressure balance between the fuel reactor and the air reactor by controlling circulation of the oxidized metal oxides between the fuel reactor and the air reactor, and transporting portions of the oxidized metal oxides from the splitter reactor to the fuel reactor and the air reactor.

24. The process of claim 9 , further including the step of injecting an air stream into the air reactor to oxidize the reduced oxygen carrier.

Assignees

• Saudi Arabian Oil Co

Inventors

• Hoteit Ali
• Younes Mourad
• Jamal Aqil

Classifications

• C10G9/28 Primary

  with preheated moving solid material · CPC title

• C10G51/04 Primary

  including only thermal and catalytic cracking steps · CPC title

• C10G9/005 Primary

  Coking (in order to produce liquid products mainly) · CPC title

• C10G11/04

  Oxides · CPC title

• F23C10/04

  the particles being circulated to a section, e.g. a heat-exchange section or a return duct, at least partially shielded from the combustion zone, before being reintroduced into the combustion zone · CPC title