Systems and methods of producing a crude product

a technology of crude feed and system, applied in the direction of fuels, physical/chemical process catalysts, products, etc., can solve the problems of difficult and expensive transportation and/or processing of crude using conventional facilities, difficult water removal of less viscous crude and/or crude mixtures using conventional means, and disadvantaged crudes often contain relatively high residue levels

Inactive Publication Date: 2005-06-23
SHELL OIL CO
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0013] Inventions described herein generally relate to systems and methods for contacting a crude feed with one or more catalysts to produce a total product comprising a crude product and, in some embodiments, non-co

Problems solved by technology

Disadvantaged crudes often contain relatively high levels of residue.
Such crudes tend to be difficult and expensive to transport and/or process using conventional facilities.
During processing, water removal from the less viscous crudes and/or crude mixtures may be difficult using conventional means.
When processing of hydrogen deficient hydrocarbons, consistent quantities of hydrogen generally need to be added, particularly if unsaturated fragments resulting from cracking processes are produced.
Hydrogen is costly to produce and/or costly to transport to treatment facilities.
It may be costly to regenerate the catalytic activity of a catalyst contaminated by coke.
High temperatures used during regeneration may also diminish the activity of the catalyst and/or cause the catalyst to deteriorate.
Disadvantaged crudes with a relatively high TAN may contribute to corrosion of metal components during transporting and/or processing of the disadvantaged crudes.
The use of corrosion-resistant metal often involves significant expense, and thus, the use of corrosion-resistant metal in existing equipment may not be desirable.
The use of corrosion inhibitors may negatively affect equipment used to process the crudes and/or the quality of products produced from the crudes.
Such deposits may cause a decline in the activity of the catalyst.
Organically bound heteroatoms may, in some situa

Method used

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  • Systems and methods of producing a crude product
  • Systems and methods of producing a crude product
  • Systems and methods of producing a crude product

Examples

Experimental program
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Effect test

example 1

[0286] Preparation of a K—Fe Sulfide Catalyst. A K—Fe sulfide catalyst was prepared by combining 1000 grams of iron oxide (Fe2O3) and 580 g of potassium carbonate with 412 grams of de-ionized water to form a wet paste. The wet paste was dried at 200° C. to form an iron oxide / potassium carbonate mixture. The iron oxide / potassium carbonate mixture was calcined at 500° C. to form an iron oxide / potassium carbonate mixture. The iron oxide / potassium carbonate mixture was reacted with hydrogen to form a reduced intermediate solid that included iron metal. Hydrogen addition was performed over 48 hours at 450° C. and 11.5-12.2 MPa (about 1665-1765 psi). The intermediate solid was passed through a 40-mesh sieve with minimal force.

[0287] The intermediate solid was added incrementally at a rate to control the evolution of heat and produced gas to a VGO / m-xylene / elemental sulfur mixture at 100° C. After addition of the intermediate solid, the resulting mixture was incrementally heated to 300° C...

example 2

[0289] Contact of a Crude Feed With a Hydrogen Source in the Presence of a K—Fe Sulfide Catalyst. A 600 mL continuously stirred tank reactor (composed of 316 stainless steel) was fitted with a bottom inlet feed port, a single vapor effluent port, three thermocouples located in the reactor interior, and a shaftdriven 1.25-inch diameter six-blade Rushton turbine.

[0290] The K—Fe sulfide catalyst (110.3 grams) prepared as described in Example 1 was charged to the reactor. Hydrogen gas was metered at about 8,000 Nm3 / m3 (50,000 SCFB) into the reactor and mixed with bitumen (Lloydminster region of Canada). The bitumen entered the reactor through the bottom inlet feed port to form a hydrogen / crude feed mixture. During the reaction run period of about 185 hours, hydrogen gas and crude feed were continuously fed into the reactor and product was continuously removed through the effluent vapor port of the reactor. Crude feed was fed at a rate of 67.0 g / hr to maintain the crude feed liquid leve...

example 3

[0301] Preparation of a K—Fe Sulfide Catalyst in the Absence of Hydrocarbon Diluent. A K—Fe sulfide catalyst was prepared by combining 1000 g of iron oxide and 173 g of potassium carbonate with 423 g of de-ionized water to form a wet paste. The wet paste was processed as described in Example 1 to form the intermediate solid. The intermediate solid was passed through a 40-mesh sieve with minimal force.

[0302] In contrast to Example 2, the intermediate solid was mixed with elemental sulfur in the absence of a hydrocarbon diluent. In a dry-box using an argon atmosphere, the intermediate solid was mixed with powdered elemental sulfur, placed in a sealed carbon steel cylinder, heated to 400° C., and maintained at 400° C. for about 1 hour. The sulfurized catalyst was recovered from the carbon steel reactor as a solid. The potassium-iron sulfide catalyst was crushed to a powder using a mortar and pestle such that the resulting catalyst powder passed through a 40-mesh sieve.

[0303] The resu...

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Abstract

Contact of a crude feed with one or more catalysts produces a total product that includes a crude product. The crude feed has a residue content of at least 0.2 grams of residue per gram of crude feed. At least a portion of the crude product may be produced as a vapor. The crude product is a liquid mixture at 25° C. and 0.101 MPa. One or more properties of the crude product may be changed by at least 10% relative to the respective properties of the crude feed.

Description

PRIORITY CLAIM [0001] This application claims priority to Provisional patent application No. 60 / 531,506 entitled “METHODS OF PREPARING IMPROVED CRUDE FEED” filed on Dec. 19, 2003, and to Provisional patent application No. 60 / 618,814 entitled “SYSTEMS AND METHODS OF PRODUCING A CRUDE PRODUCT” filed on Oct. 14, 2004.FIELD OF THE INVENTION [0002] The present invention generally relates to systems and methods for treating crude feed, and to compositions that are produced, for example, using such systems and methods. More particularly, embodiments described herein relate to systems and methods for conversion of a crude feed that has a residue content of at least 0.2 grams of residue per gram of crude feed to a crude product that is (a) a liquid mixture at 25° C. and 0.101 MPa, and (b) has one or more properties that are improved in comparison to the same properties of the crude feed. DESCRIPTION OF RELATED ART [0003] Crudes that have one or more unsuitable properties that do not allow th...

Claims

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Application Information

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IPC IPC(8): B01J27/02C01B3/26C10G45/00C10G47/00C10G47/06C10G65/02C10G65/04C10L1/00C10L1/04
CPCC10G45/00C10L1/04C10G65/04Y02P20/141
Inventor WELLINGTON, SCOTT LEEBROWNSCOMBE, THOMAS FAIRCHILDMILAM, STANLEY NEMEC
Owner SHELL OIL CO
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