Synthetic Crude Oil Blending via Hydroconversion Catalyst
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Solution Overview
Problem
Current methods for converting associated gas from subterranean reservoirs into synthetic crude oil are costly and result in products with high wax content, making blending with natural crude oil difficult due to high melting points and impurities, which increases transportation and refining challenges.
Innovation Solution
A system comprising a separation complex, synthesis gas generator, and conversion reactor using both synthesis gas conversion and hydroconversion catalysts to produce a low-impurity synthetic crude oil that can be blended with natural crude oil, with the hydroconversion component reducing the pour point of the synthetic crude oil to below 60°C, allowing for safe transportation and refining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional Fischer-Tropsch process is used to convert associated gas into synthetic crude oil, then synthetic fuels such as diesel, jet fuel, and naphtha are produced, but the product contains high wax content with high melting point, making it difficult to blend with natural crude oil and requiring expensive specialized transportation
Solution Approach 1:
The patent changes the operating parameters of the Fischer-Tropsch process, specifically operating at higher temperatures (200-400°C) and pressures (1-100 atm) to alter the product distribution and reduce wax content. The synthesis gas conversion catalyst is designed to produce synthetic crude oil with less than 5 wt% C21+ normal paraffins, directly addressing the high melting point issue through parameter optimization.
Solution Approach 2:
The patent uses a composite catalyst system combining synthesis gas conversion catalyst (e.g., iron, cobalt, nickel, ruthenium, or their alloys) with hydroconversion catalyst (e.g., zeolites, silica-alumina, or other acidic supports) to achieve both Fischer-Tropsch synthesis and hydroconversion functions. This composite approach produces synthetic crude oil with reduced wax content and improved blendability with natural crude oil.
2Adaptability or versatility
If conventional Fischer-Tropsch product is blended with natural crude oil, then some blending is possible, but blending greater than 2 wt% causes pour point to exceed 60°C, limiting the blending quantity
Solution Approach 1:
The patent modifies the product properties by changing the Fischer-Tropsch process parameters to produce synthetic crude oil with a pour point at or below 60°C. This is achieved through catalyst selection and operating condition optimization that reduces heavy wax content (C21+ normal paraffins to less than 5 wt%), enabling blending greater than 2 wt% with natural crude oil while maintaining acceptable pour point specifications.
Solution Approach 2:
The patent creates a synthetic crude oil product that copies the desirable properties of natural crude oil, specifically matching the pour point and wax content characteristics. By producing synthetic crude oil with less than 5 wt% C21+ normal paraffins and pour point ≤60°C, it replicates the blendability of natural crude oils, allowing seamless integration into existing crude oil handling and refining infrastructure.
3Adaptability or versatility
If conventional Fischer-Tropsch product containing substantial olefins, alcohols, and acids is blended with crude oil, then blending occurs, but the crude oil becomes difficult to refine and may lead to discount in crude sale price
Solution Approach 1:
The patent optimizes process parameters including temperature (200-400°C), pressure (1-100 atm), and catalyst composition to control the chemical composition of the synthetic crude oil. By adjusting these parameters, the process minimizes the formation of problematic compounds such as olefins, alcohols, and acids, while maintaining high yields of blendable hydrocarbons with pour point ≤60°C, thereby improving refining ease and market value.
Solution Approach 2:
The patent employs a composite catalyst system that combines synthesis gas conversion functionality with hydroconversion functionality. This composite catalyst (e.g., cobalt on zeolite, iron on silica-alumina, or nickel on acidic supports) simultaneously performs Fischer-Tropsch synthesis and hydroconversion reactions, producing synthetic crude oil with reduced impurities including olefins, alcohols, and acids, while maintaining desirable pour point and blendability properties.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enables the production of a low-impurity synthetic crude oil that can be blended with natural crude oil in quantities greater than 2 wt%, achieving a pour point at or below 60°C, thus overcoming the challenges of wax content and impurities, reducing transportation and refining issues, and lowering capital expenses.
Implementation Method 1
a synthesis gas generator which converts the natural gas into synthesis gas
Implementation Method 2
a conversion reactor which utilizes both a synthesis gas conversion catalyst and a hydroconversion catalyst to convert the synthesis gas into a tail gas and a liquid effluent stream
Implementation Method 3
the hydroconversion component reducing the pour point of the synthetic crude oil to below 60°C
Data Source
AI summary
A process and system are described for the processing of gas associated with crude oil production, i.e. associated gas. A separation complex is used to separate produced fluids produced from a hydrocarbon reservoir into crude oil, liquefied petroleum gas, water, and natural gas. At least a portion of the natural gas is converted into synthesis gas in a synthesis gas generator. A combination of a synthesis gas conversion catalysts and hydroconversion catalysts are used in a synthesis gas reactor to convert the synthesis gas into a liquid effluent stream containing liquefied petroleum gas and a synthetic crude oil. The liquefied petroleum gas and synthetic crude oil from the synthesis gas reactor is sent to the separation complex. Liquefied petroleum gas is separated both from the synthetic crude oil and a natural crude oil obtained from the produced fluids. The system and process permits synthetic crude oil to be blended with the natural crude oil producing a blended stabilized crude oil having 2 wt % or more of the synthetic crude oil and with a pour point of 60° C. or less. Use of a common facility for separation operations on the natural crude oil and synthetic crude oil thus reduces capital costs and allows converted associated gases to be shipped with the natural crude oil on a conventional crude oil tanker.