Upgraded ebullated bed reactor with increased production rate of converted products

A technology for ebullated bed reactors and conversion products, which is applied in the field of ebullated bed hydroprocessing methods and systems, and can solve the problems of asphaltene and carbon slag, which are difficult to handle, fouling, and limit downstream processing.

Active Publication Date: 2018-10-23
HEADWATERS TECH INNOVATION LLC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

Asphaltenes and carbon residues are difficult to process and often cause fouling of conventional catalysts and hydrotreating equipment because they contribute to coke formation
Furthermore, carbon residues limit the downstream processing of high-boiling fractions, for example when they are used as feedstock for coking processes

Method used

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  • Upgraded ebullated bed reactor with increased production rate of converted products
  • Upgraded ebullated bed reactor with increased production rate of converted products
  • Upgraded ebullated bed reactor with increased production rate of converted products

Examples

Experimental program
Comparison scheme
Effect test

Embodiment 1-4

[0142] Examples 1-4 were carried out in the above-mentioned pilot plant and tested the ability of an upgraded ebullating bed reactor using a dual catalyst system to produce a relatively high conversion while maintaining or reducing deposit formation. Increased conversion includes higher resid conversion, C 7 Asphaltene conversion and micro carbon residue (MCR) conversion. The heavy oil feedstock used in this study was Ural vacuum residue (VR). As described above, the conditioned feedstock is prepared by mixing an amount of catalyst precursor mixture with an amount of heavy oil feedstock into a final conditioned feedstock containing the desired amount of dispersed catalyst. The exception to this is the test where no dispersed catalyst was used, in which case heavy vacuum gas oil was substituted for the catalyst precursor mixture in the same proportion. Feed the prepared raw materials into Figure 5 A pilot plant system that operates with specific parameters. Relevant proce...

Embodiment 1

[0147] Example 1 was a baseline test in which Ural VR was hydrotreated at a temperature of 789°F (421°C) and a resid conversion of 60.0%. In Example 2, the temperature was raised to 801°F (427°C) and the resid conversion (based on 1000°F+, %) increased to 67.7%. This resulted in a significant increase of 0.78% to 1.22% in product IP-375 deposits (separator substrate basis, wt%) and 0.67% to 0.98% in product IP-375 deposits (feed oil basis, wt%), C 7 Asphaltene conversion ranged from 40.6% to 43.0%, and MCR conversion ranged from 49.3% to 51.9%. This indicates that the heterogeneous catalysts used alone in Examples 1 and 2 cannot withstand an increase in temperature and conversion without a significant increase in deposit formation.

[0148] In Example 3 using a dual catalyst system including dispersed catalyst (providing 30 ppm Mo), the reactor temperature was increased to 801°F (427°C) and the resid conversion increased to 67.0%. The feed rate was slightly increased from 0....

Embodiment 3

[0149] The dual catalyst system of Example 3 is also significantly better than the heterogeneous catalyst used alone in Example 2, including the addition of C 7 Asphaltene conversion was further increased from 43.0% to 46.9%, and MCR conversion was further increased from 51.9% to 55.2%, while product IP-375 deposits (separator substrate basis, wt %) were significantly reduced from 1.22% to 0.76 %, and significantly reduced product IP-375 deposits (feed oil basis, weight %) from 0.98% to 0.61%.

[0150] In Example 4 using a two-catalyst system including dispersed catalyst (providing 50 ppm Mo), the reactor temperature was 801°F (427°C), the conversion was 65.9%, and the feed rate was 0.25 (LHSV, volumetric feed / volume reactor / hour). Compared with Example 1, the product IP-375 deposit (separator substrate basis, weight %) decreased significantly from 0.78% to 0.54%, and the product IP-375 deposit (feed oil basis, weight %) decreased from 0.67% Significantly down to 0.45%. In...

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Abstract

An ebullated bed hydroprocessing system is upgraded using a dual catalyst system that includes a heterogeneous catalyst and dispersed metal sulfide particles to increase rate of production of converted products. The rate of production is achieved by increasing reactor severity, including increasing the operating temperature and at least one of throughput or conversion. The dual catalyst system permits increased reactor severity and provides increased production of converted products without a significant increase in equipment fouling and / or sediment production. In some cases, the rate of production of conversion products can be achieved while decreasing equipment fouling and / or sediment production.

Description

technical field [0001] The present invention relates to heavy oil hydroprocessing processes and systems, such as ebullating bed hydroprocessing processes and systems, which employ a dual catalyst system and operate with increased reactor severity. Background technique [0002] There is an increasing need to more efficiently utilize and extract fuel value from low-quality heavy oil feedstocks. Low quality feedstocks are characterized by including relatively high amounts of hydrocarbons that nominally boil at 524°C (975°F) or above. They also contain relatively high concentrations of sulfur, nitrogen and / or metals. High-boiling fractions derived from these low-quality feedstocks typically have high molecular weights (usually indicated by higher densities and viscosities) and / or low hydrogen-to-carbon ratios, which are consistent with the presence of high concentrations of undesired components, including asphaltenes and carbon residue). Asphaltenes and carbon residues are di...

Claims

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Application Information

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Patent Type & Authority Applications(China)
IPC IPC(8): C10G49/12C10G49/26
CPCC10G49/12C10G49/26C10G2300/703C10G75/00C10G2300/206C10G2300/301C10G2300/70C10G65/02C10G65/00
Inventor 大卫·M·芒廷兰德布雷特·M·西尔弗曼迈克尔·A·鲁特尔李·史密斯
Owner HEADWATERS TECH INNOVATION LLC
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