Treatment of crude oil fractions, fossil fuels, and products thereof with sonic energy

Abstract

In crude oil fractions, fossil fuels, and organic liquids in general in which it is desirable to reduce the levels of sulfur-containing and nitrogen-containing components, the process reduces the level of these compounds via the application of sonic energy. The process can be performed both with and without the added presence of an oxidizing agent, and with or without elevated temperature and / or pressure. The invention is performed either as a continuous process or a batch process.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS [0001] The present application is a continuation-in-part of pending U.S. application Ser. No. 09 / 853,127, filed by Gunnerman et al., entitled A TREATMENT OF CRUDE OIL FRACTIONS, FOSSIL FUELS, AND PRODUCTS THEREOF WITH ULTRASOUND, the teachings of which are expressly incorporated herein by reference.STATEMENT RE: FEDERALLY SPONSORED RESEARCH / DEVELOPMENT [0002] Not Applicable BACKGROUND OF THE INVENTION [0003] 1. Field of the Invention [0004] This invention resides in the field of chemical processes for the treatment of crude oil fractions and the various types of products derived and obtained from these sources. In particular, this invention addresses reformation processes as ring-opening reactions and the saturation of double bonds, to upgrade fossil fuels and convert organic products to forms that will improve their performance and expand their utility. This invention also resides in the removal of sulfur-containing compounds, nitrogen-contai...

AI Technical Summary

Benefits of technology

[0018] In addition to the foregoing, API gravities of fossil fuels and crude oil fractions are raised (i.e., the densities lowered) as a result of treatments in accordance with the invention. Moreover, the invention raises the cetane index of petroleum fractions and cracking products whose boiling points or ranges are in the diesel range. The term “diesel range” is used herein in the industry sense to denote the portion of crude oil that distills out after naphtha, and generally within the temperature range of approximately 200° C. (392° F.) to 370° C. (698° F.). Fractions and cracking products whose boiling ranges are contained in this range, as well as those that overlap with this range to a majority extent, are included. Examples of refinery fractions and streams within the diesel range are fluid catalytic cracking (FCC) cycle oil fractions, coker distillate fractions, straight run diesel fractions, and blends. The invention also imparts other beneficial changes such as a lowering of boiling pints and a removal of components that are detrimental to the performance of the fuel and those that affect refinery processes and increase the cost of production of the fuel. Thus, for example, FCC cycle oils can be treated in accordance with the invention to sharply reduce their aromatics content.

[0020] By virtue of the conversions that occur as a result of the process of this invention, hydrocarbon streams experience changes in their cold flow properties, including their pour points, cloud points, and freezing points. Sulfur compounds, nitrogen compounds, and metal-containing compounds are also reduced, and the use of a process in accordance with this invention significantly lessens the burden on conventional processes such as hydrodesulfurization, hydro-denitrogenation, and hydrodemetallization, which can therefore be performed with greater effectiveness and efficiency.

Problems solved by technology

Sulfur from sulfur compounds causes corrosion in pipeline, pumping, and refining equipment, the poisoning of catalysts used in the refining and combustion of fossil fuels, and the premature failure of combustion engines.

Sulfur also causes an increase in particulate (soot) emissions from trucks and buses by degrading the soot traps used on these vehicles.

The burning of sulfur-containing fuel produces sulfur dioxide which enters the atmosphere as acid rain, inflicting harm on agriculture and wildlife, and causing hazards to human health.

The Clean Air Act of 1964 and its various amendments have imposed sulfur emission standards that are difficult and expensive to meet.

The treatment of fuels to achieve sulfur emissions low enough to meet these requirements is difficult and expensive, and the increase in fuel prices that this causes will have a major influence on the world economy.

A considerable amount of unreacted H2S remains however, with its attendant health hazards.

A further limitation of hydrodesulfurization is that it is not equally effective in removing all sulfur-bearing compounds.

Thiophene, benzothiophene, dibenzothiophene, other condensed-ring thiophenes, and substituted versions of these compounds, which account for as much as 40% of the total sulfur content of crude oils from the Middle East and 70% of the sulfur content of West Texas crude oil, are particularly refractory to hydrodesulfurization.

Despite such advantages, however, oxidative desulfurization is presently ineffectual for use in large scale refining operations insofar as currently deployed oxidative desulfurization techniques only partially oxidize the sulfur species present to sulfoxides, as opposed to sulfones.

In this regard, present oxidative desulfurization techniques are too ineffectual and cannot achieve sufficient oxidation necessary to implement on a large scale basis.

Moreover, to the extent the sulfur species is only partially oxidized (i.e., to sulfoxide), eventual removal of the sulfur species, which is typically accomplished either through solvent extraction or absorption based upon the differential polarity of the sulfones assumed to be present through such process, fails to facilitate the removal of the sulfoxide components based upon its lesser degree of polarity (i.e., as compared to sulfones).

These processes require a source of hydrogen or an on-site hydrogen production unit, which entails high capital expenditures and operating costs.

In both of these processes, there is also a risk of hydrogen leaking from the reactor.