271results about "Refining by solvent de-asphalting" patented technology

Disclosed is a process for the upgrading and demetallizing of heavy oils and bitumens. A crude heavy oil and/or bitumen feed is supplied to a solvent extraction process 104 wherein DAO and asphaltenes are separated. The DAO is supplied to an FCC unit 106 having a low conversion activity catalyst for the removal of metals contained therein. The demetallized distillate fraction is supplied to a hydrotreater 110 for upgrading and collected as a synthetic crude product stream. The asphaltene fraction can be supplied to a gasifier 108 for the recovery of power, steam and hydrogen, which can be supplied to the hydrotreater 110 or otherwise within the process or exported. An optional coker 234 can be used to convert excess asphaltenes and/or decant oil to naphtha, distillate and gas oil, which can be supplied to the hydrotreater 220.

A process derived hydrogen donor solvent is used to increase the maximum resid conversion and conversion rate in an ebullated bed resid hydrocracker. The hydrogen donor solvent precursor is produced by hydroreforming reactions within the resid hydrocracker, recovered as the resin fraction from a solvent deasphalting unit, regenerated in a separate hydrotreater reactor, and recycled to the ebullated bed resid hydrocracker. The major advantage of this invention relative to earlier processes is that hydrogen is more efficiently transferred to the resin residual oil in the separate hydrotreater and the hydrogen donor solvent effectively retards the formation of coke precursors at higher ebullated bed resid hydrocracker operating temperatures and resid cracking rates.

A solvent deasphalting of crude oil or petroleum heavy fractions and residues is carried out in the presence of a solid adsorbent, such as clay, silica, alumina and activated carbon, which adsorbs the contaminants and permits the solvent and oil fraction to be removed as a separate stream from which the solvent is recovered for recycling; the adsorbent with contaminants and the asphalt bottoms is mixed with aromatic and/or polar solvents to desorb the contaminants and washed as necessary, e.g., with benzene, toluene, xylenes and tetrahydrofuran, to clean adsorbant which is recovered and recycled; the solvent-asphalt mixture is sent to a fractionator for recovery and recycling of the aromatic or polar solvent. The bottoms from the fractionator include the concentrated PNA and contaminants and are further processes as appropriate.

The described invention discloses an innovative solvent deasphalter and hydroconversion-processing configuration for converting bitumen or heavy oils to produce a transportable synthetic crude oil (SCO). The innovative processing scheme disclosed herein maximizes the synthetic crude oil yield at a minimal investment compared to currently known methods.

A fuel is produced from bitumen by precipitating a substantial portion of asphaltenes from bitumen by contacting the bitumen with a lower alkane solvent. Suitable burners include a fluidized bed boiler, a circulating fluidized bed boiler and a pitch boiler which utilize either pre-combustion sulfur sorbents or post-combustion flue gas desulfurization. The sulfur in emissions can be used to produce sulfuric acid. The process uses a low cost fuel, generates steam, power and sulfuric acid and meets all emission requirements for SO_2, NO_x and PM.

A process is provided that is directed to a steam pyrolysis zone integrated with a hydrotreating zone and a solvent deasphalting zone to permit direct processing of crude oil feedstocks to produce petrochemicals including olefins and aromatics. The integrated hydrotreating, solvent deasphalting and steam pyrolysis process comprises charging the crude oil to a hydroprocessing zone operating under conditions effective to produce a hydroprocessed effluent reduced having a reduced content of contaminants, an increased paraffinicity, reduced Bureau of Mines Correlation Index, and an increased American Petroleum Institute gravity; charging the hydroprocessed effluent to a solvent deasphalting zone with an effective amount of solvent to produce a deasphalted and demetalized oil stream and a bottom asphalt phase; thermally cracking the deasphalted and demetalized oil stream in the presence of steam to produce a mixed product stream; separating the mixed product stream; purifying hydrogen recovered from the mixed product stream and recycling it to the hydroprocessing zone; recovering olefins and aromatics from the separated mixed product stream; and recovering pyrolysis fuel oil from the separated mixed product stream.

A method for separating and recovering ultrafine particulate solid material from a suspension or slurry of the solid material and a hydrocarbon liquid by precipitation or flocculation of a heavy fraction of the hydrocarbon liquid with an effective amount of a precipitation or flocculation agent such that the precipitated heavy fraction encapsulates the particulate solid material. The method further comprises coking the precipitated heavy fraction and grinding the coked product to an ultrafine size.

Integrated slurry hydrocracking (SHC) and coking methods for making slurry hydrocracking (SHC) distillates are disclosed. Representative methods involve passing a slurry comprising a deasphalted oil (DAO) produced in a solvent deasphalting (SDA) process, optionally with recycled SHC gas oil and recycled SHC pitch, and a solid particulate through an SHC reaction zone in the presence of hydrogen to obtain the SHC distillate. Recovery and recycle of SHC gas oil and pitch from the SHC effluent improves the overall conversion to naphtha and distillate products and decreases catalyst requirements.

A process and apparatus to remove asphaltenic contaminants from bitumen, heavy oil or residue to produce lower viscosity petroleum products and high purity asphaltenes.

A process for stabilization of heavy hydrocarbons to reduce sludge formation in storage tanks and/or transportation lines and to enhance the hydrocarbon yield includes mixing a paraffinic or heavy naphtha solvent having carbon numbers in the range 10 to 20 with the feedstock to solvent-flocculate a relatively small, predetermined portion of asphaltenes present in the feedstock, separating and flashing the sediment to recover a light hydrocarbon fraction, flashing the heavy hydrocarbon/solvent phase and recycling the solvent to stabilize the heavy hydrocarbons without significantly affecting the yield of valuable products.

A method and apparatus for upgrading a hydrocarbon feedstock is provided. The method includes the steps of (a) supplying a hydrocarbon feedstock to an oxidation reactor, wherein the hydrocarbon feedstock is oxidized in the presence of a catalyst under conditions sufficient to selectively oxidize sulfur compounds present in the hydrocarbon feedstock; (c) separating the hydrocarbons and the oxidized sulfur compounds by solvent extraction; (d) collecting a residue stream that includes the oxidized sulfur compounds; and (e) supplying the residue stream to a deasphalting unit.

The fuel properties of petroleum hydrocarbon waste having an API gravity varying from about 5 to 30 are improved by heating the hydrocarbon to a temperature of about 35° C. to 90° C. and mixing the heated hydrocarbon stream with a suitable solvent to reduce the viscosity of the hydrocarbon, which is then separated by a centrifuge to obtain an aqueous phase stream, an oil phase stream, and a separated solids stream. The oil phase stream has a viscosity range of about 250 centipoise (cP) to about 1000 cP. The oil phase stream is utilized in a refinery, while a slurry fuel is prepared with the separated solids stream and aqueous phase stream as a feedstock for road asphalt, a fuel for a combustor, or a fuel for a gasification process. The oil phase stream is used for fuels and feedstock for making carbon fiber.

Disclosed is a process for the upgrading of heavy oils and bitumens, where the total feed to the process can include heavy oil or bitumen, water, and diluent. The process can include the steps of solvent deasphalting 110 the total feed 105 to recover an asphaltene fraction 116, a deasphalted oil fraction 118 essentially free of asphaltenes, a water fraction 112, and a solvent fraction 114. The process allows removal of salts from the heavy oils and bitumens either into the aqueous products or with the asphaltene product.

For conversion of crude oil or a heavy hydrocarbon fraction having an initial boiling point of at least 300° C., conducting a catalytic hydroconversion in a three-phase reactor operating in a boiling bed with an upward flow of liquid and gas, separating resultant effluent into a light liquid fraction boiling at less than 300° C. and a heavy liquid fraction boiling above 300° C., deasphalting the heavy liquid fraction to obtain a deasphalted hydrocarbon fraction and residual asphalt, and recycling at least one portion of the deasphalted hydrocarbon fraction upstream of the hydroconversion stage.

A process for producing pipeline-ready or refinery-ready feedstock from heavy hydrocarbons using a high-performance solvent extraction process with high local solvent-to-process fluid ratios yet maintaining low overall solvent-to-process fluid ratios, by first performing mild thermal cracking on the heavy hydrocarbons and then separating asphaltene-rich fractions from a resulting thermally affected fluid so that the high solvent-to-oil ratio portion of the process acts only on those asphaltene-rich fractions, and producing a dry, solid asphaltene as an end-product.

A cost-effective solution is provided for eliminating refinery process waste, including spent catalytic and non-catalytic adsorbent materials, as well as adsorbate process reject materials derived from desorption, while minimizing conventional waste handling demands. An asphalt composition includes asphalt and spent adsorbent material from a solvent deasphalting unit. The asphalt can comprise asphaltic material obtained from a solvent deasphalting unit, and spent adsorbent material in the asphalt composition was previously utilized in the solvent deasphalting unit. The asphalt composition can also include process reject materials.

Systems and methods for processing one or more hydrocarbons are provided. A hydrocarbon can be selectively separated to provide one or more finished products and an asphaltenic hydrocarbon using a pretreatment process. The asphaltenic hydrocarbon can be selectively separated to provide a deasphalted oil and one or more asphaltenes. At least a portion of the deasphalted oil can be converted to one or more first products using a first post-treatment process. At least a portion of the one or more asphaltenes can be converted to one or more second products using a second post-treatment process.

The present invention is related to a process oil using as a raw material a deasphalted oil obtained by deasphalting a vacuum residual oil of a crude oil and a manufacturing method of the process oil, the process oil having properties of:

• • (a) a polycyclic aromatics (PCA) content of less than 3 mass %;
  • (b) a viscosity (100° C.) of 40 to 70 mm²/s;
  • (c) an aniline point of 85 to 100° C.;
  • (d) a flash point of 250° C. or higher;
  • (e) an aromatic hydrocarbon content of 40 to 55 mass %; and
  • (f) a polar substance content of 10 to 15 mass %.

The present invention is also related to a process oil and a manufacturing method of the process oil, the process oil obtained by mixing: an extract obtained by deasphalting and solvent-extracting a vacuum residual oil of a crude oil; and a lubricant base oil having a polycyclic aromatics (PCA) content of less than 3 mass %, and having properties of:

• • (a) a polycyclic aromatics (PCA) content of less than 3 mass %;
  • (i) a viscosity (100° C.) of 30 to 80 mm²/s;
  • (j) an aniline point of 90° C. or lower;
  • (k) a flash point of 240° C. or higher;
  • (l) a benzo(a)pyrene content of 1 mass ppm or less;
  • (m) a specified aromatic compound content of 10 mass ppm or less; and
  • (n) a polar substance content of 10 to 30 mass %.

Conversion of a heavy hydrocarbon fraction that is obtained either from a crude oil or from the distillation of a crude oil and that has an initial boiling point of at least 300° C. by hydroconversion of at least one portion of heavy hydrocarbon fraction in the presence of hydrogen in at least one three-phase reactor containing at least one hydroconversion catalyst, separation of the effluent to obtain a light liquid fraction that boils at a temperature that is less than 300° C. and a heavy liquid fraction that boils at a temperature that is greater than 300° C., and a deasphalting of at least one portion of the heavy liquid fraction that boils at a temperature that is greater than 300° C.

Petroleum resid, bitumen and/or heavy oil is upgraded by the separation of asphaltenes and/or resins from such resids, bitumen and/or heavy oils by contacting them with an ionic liquid with which the asphaltenes and/or resins interact.