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WO2006010068A1 - Produits d'hydrocarbures synthetiques - Google Patents

Produits d'hydrocarbures synthetiques Download PDF

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Publication number
WO2006010068A1
WO2006010068A1 PCT/US2005/024394 US2005024394W WO2006010068A1 WO 2006010068 A1 WO2006010068 A1 WO 2006010068A1 US 2005024394 W US2005024394 W US 2005024394W WO 2006010068 A1 WO2006010068 A1 WO 2006010068A1
Authority
WO
WIPO (PCT)
Prior art keywords
hydrocarbons
diesel
fraction
distillate
middle distillate
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2005/024394
Other languages
English (en)
Inventor
Rafael L. Espinoza
Keith H. Lawson
Priya Rangarajan
Robin G. Cnossen
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
ConocoPhillips Co
Original Assignee
ConocoPhillips Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US10/886,861 external-priority patent/US7345211B2/en
Application filed by ConocoPhillips Co filed Critical ConocoPhillips Co
Priority to JP2007520569A priority Critical patent/JP2008506023A/ja
Priority to EP05772423A priority patent/EP1776439A4/fr
Publication of WO2006010068A1 publication Critical patent/WO2006010068A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G65/00—Treatment of hydrocarbon oils by two or more hydrotreatment processes only
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G63/00—Treatment of naphtha by at least one reforming process and at least one other conversion process
    • C10G63/02—Treatment of naphtha by at least one reforming process and at least one other conversion process plural serial stages only
    • C10G63/04—Treatment of naphtha by at least one reforming process and at least one other conversion process plural serial stages only including at least one cracking step
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G2/00—Production of liquid hydrocarbon mixtures of undefined composition from oxides of carbon
    • C10G2/30—Production of liquid hydrocarbon mixtures of undefined composition from oxides of carbon from carbon monoxide with hydrogen
    • C10G2/32—Production of liquid hydrocarbon mixtures of undefined composition from oxides of carbon from carbon monoxide with hydrogen with the use of catalysts
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G69/00—Treatment of hydrocarbon oils by at least one hydrotreatment process and at least one other conversion process
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G OR C10K; LIQUIFIED PETROLEUM GAS; USE OF ADDITIVES TO FUELS OR FIRES; FIRE-LIGHTERS
    • C10L1/00—Liquid carbonaceous fuels
    • C10L1/04—Liquid carbonaceous fuels essentially based on blends of hydrocarbons
    • C10L1/08—Liquid carbonaceous fuels essentially based on blends of hydrocarbons for compression ignition
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G2400/00—Products obtained by processes covered by groups C10G9/00 - C10G69/14
    • C10G2400/04—Diesel oil
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G2400/00—Products obtained by processes covered by groups C10G9/00 - C10G69/14
    • C10G2400/06—Gasoil

Definitions

  • Natural gas found in deposits in the earth, is an abundant energy resource.
  • natural gas commonly serves as a fuel for heating, cooking, and power generation, among other things.
  • the process of obtaining natural gas from an earth formation typically includes drilling a well into the formation. Wells that provide natural gas are often remote from locations with a demand for the consumption of the natural gas.
  • Formations that include small amounts of natural gas may include primarily oil, with the natural gas being a byproduct of oil production that is thus termed associated gas.
  • associated gas has typically been flared, i.e., burned in the ambient air.
  • current environmental concerns and regulations discourage or prohibit this practice.
  • naturally occurring sources of crude oil used for liquid fuels such as gasoline and middle distillates (such as kerosene, diesel fuel, and home heating oil) have been decreasing, and supplies are not expected to meet demand in the coming years.
  • Middle distillates typically include heating oil, jet fuel, diesel fuel, and kerosene.
  • Fuels that are liquid under standard atmospheric conditions have the advantage that, in addition to their value, they can be transported more easily in a pipeline than natural gas, since they do not require energy, equipment, and expense required for liquefaction.
  • hydrocarbons having carbons linked in a straight chain are aliphatic hydrocarbons and may include paraffins and/or olefins. Paraffins are particularly desirable as the basis of synthetic diesel fuel.
  • the Fischer-Tropsch product stream contains hydrocarbons having a range of numbers of carbon atoms and thus having a range of molecular weights. Therefore, the Fischer- Tropsch products produced by conversion of natural gas commonly contain a range of hydrocarbons including gases, liquids and waxes. Depending on the molecular weight product distribution, different Fischer-Tropsch product mixtures are ideally suited to different uses.
  • Fischer-Tropsch product mixtures containing liquids may be processed to yield gasoline, as well as middle distillates (such as kerosene, diesel fuel).
  • Hydrocarbon waxes may be subjected to an additional processing step for conversion to liquid and/or gaseous hydrocarbons.
  • High quality diesel is a desirable product from the Fischer-Tropsch process.
  • the high quality diesel is typically prepared by hydrocracking Fischer-Tropsch wax and blending the hydrocracker product with the diesel range components produced directly in the Fischer-Tropsch process.
  • the hydrocracking reaction is typically accompanied by paraffin hydroisomerization, which typically produces a diesel having improved cold flow properties.
  • drawbacks include the diesel having a decreased cetane number. Further drawbacks include the cost accompanied by the catalysts used in the hydrocracking reaction.
  • a process for producing a synthetic diesel comprises feeding a syngas to a hydrocarbon synthesis reactor, wherein at least a portion of the syngas is reacted to generate a hydrocarbon synthesis product comprising C 5+ hydrocarbons and hydrotreating a hydrocarbon feed comprising the hydrocarbon synthesis product to provide a hydrotreated hydrocarbon stream.
  • the process further comprises fractionating a fractionator feedstream comprising the hydrotreated hydrocarbon stream to at least produce a light middle distillate, a heavy middle distillate, and a waxy fraction; and thermally cracking at least a portion of the waxy fraction to produce a thermal cracker effluent.
  • the process further comprises hydrotreating at least a portion or a fraction of the thermal cracker effluent to form a hydrotreated thermally cracked product; and isomerizing at least a portion of the heavy middle distillate to produce an isomerized heavy middle distillate product.
  • the light middle distillate is a light diesel distillate
  • the heavy middle distillate is a heavy diesel distillate.
  • the invention comprises a process for producing diesel. The process comprises feeding a syngas to a hydrocarbon synthesis reactor, wherein at least a portion of the syngas is reacted to generate a hydrocarbon synthesis product comprising C 5+ hydrocarbons.
  • the process further comprises providing a fractionator feed comprising the hydrocarbon synthesis product and separating the fractionator feed in a fractionator to produce at least a light diesel distillate, a heavy diesel distillate, and a waxy fraction.
  • the process comprises cracking in a thermal cracker at least a portion of the waxy fraction to produce the thermally-cracked effluent and optionally, hydrotreating at least a portion of or at least a fraction of the thermally-cracked effluent.
  • the process comprises hydrotreating the light diesel distillate to produce a hydrotreated light diesel distillate and optionally, hydroprocessing the heavy diesel distillate.
  • the process comprises isomerizing the heavy diesel distillate to produce an isomerized effluent.
  • a third embodiment of the invention comprises a synthetic middle distillate suitable for use as a liquid fuel or fuel blend comprising primarily about C 10 -C 22 hydrocarbons, said synthetic middle distillate comprising at least two fractions, a light fraction characterized by a 5% boiling point less than about 36O 0 F and a 95% boiling point between about 500 0 F and 55O 0 F, wherein said light fraction has at least about 90 percent linear hydrocarbons; and a heavy fraction characterized by a 5% boiling point between about 500 0 F and 55O 0 F and a 95% boiling point greater than about 63O 0 F, wherein said heavy fraction has at least about 30 percent branched hydrocarbons.
  • a further embodiment includes a synthetic middle distillate suitable for use as a fuel or a fuel blend comprising hydrocarbons of varying boiling points from lightest hydrocarbons to heaviest hydrocarbons.
  • the synthetic middle distillate comprises at least a first boiling range and a second boiling range.
  • the distillate includes the first boiling range comprising up to about 60 percent by volume of the lightest hydrocarbons in the synthetic middle distillate and further comprising at least about 80 percent of linear hydrocarbons.
  • the distillate further includes the second boiling range comprising up to about 40 percent by volume of the heaviest hydrocarbons in the synthetic middle distillate and further comprising at least about 30 percent branched hydrocarbons.
  • Heteroatomic compounds are organic compounds that comprise not only carbon and hydrogen, but also other atoms such as nitrogen, sulfur, and/or oxygen.
  • the non-carbon and non- hydrogen atoms e.g., oxygen, sulfur and nitrogen, respectively
  • heteroatoms are alcohols, aldehydes, or ketones.
  • heteroatomic compounds comprising nitrogen are amines.
  • acetone (CH 3 COCH 3 ) and dipropyl amine ((C S H T ) 2 NH) are heteroatomic compounds.
  • to "hydroprocess” means to treat an organic stream with hydrogen.
  • thermal cracking generally refers to the breaking down of high molecular weight material into lower molecular weight material by applying heat without the use of a catalyst. There is typically little skeletal isomerization during the thermal cracking step.
  • a "diesel” is any hydrocarbon cut having at least a portion that falls within the diesel range.
  • the diesel range in this application includes hydrocarbons that boil in the range of about 300 0 F to about 750 0 F (about 150 to about 400 0 C), preferably in the range of about 350 0 F to about 650 0 F (about 170 to about 350 °C).
  • the diesel fuel may contain hydrocarbons boiling above or below the diesel fuel range to the extent that such additional hydrocarbons can allow the jet fuel to meet desired diesel fuel specifications.
  • a "jet fuel” is any hydrocarbon cut having at least a portion that falls within the jet fuel range.
  • the term "naphtha” when used in this disclosure refers to a liquid product having between about C 5 to about C 9 carbon atoms in the backbone and will have a boiling range generally below that of diesel, but wherein the upper end of the boiling range could overlap that of the initial boiling point of diesel.
  • the term "wax” when used in this disclosure refers to a synthetic hydrocarbon wax and is typically obtained as the highest boiling fraction or one of the highest boiling fractions from a Fischer-Tropsch derived product. The synthetic hydrocarbon wax is most often a solid at room temperature.
  • the synthetic hydrocarbon wax contains at least 20% by weight of C 2 0+ hydrocarbonaceous compounds with a boiling point typically greater than 65O 0 F; preferably at least 40% by weight of C 2 o + hydrocarbonaceous compounds, more preferably at least 60% by weight of C 20+ hydrocarbonaceous compounds, and most preferably at least 80% by weight of C 20+ hydrocarbonaceous compounds.
  • the synthetic hydrocarbon wax preferably contains a wax product derived from a Fischer-Tropsch process.
  • a "fraction" of a stream results from the separation by distillation or fractionation of said stream, such that the compositions of the fraction and the stream are substantially different.
  • the Cio-Ci ⁇ (or Cio-C ⁇ ) hydrocarbons further comprise not more than 10% branched hydrocarbons.
  • the Qo-Cie (or Q 0 -C 17 ) hydrocarbons comprise at least about 80 percent linear paraffins.
  • the C 10 -C 16 (or C 10 -C 1 7) hydrocarbons comprise at least about 90 percent linear paraffins.
  • the Ci O -Ci 6 (or C IO -C ⁇ ) hydrocarbons can be characterized by a 5% boiling point less than about 360 0 F and a 95% boiling point between about 500°F and 550 0 F.
  • the gas hourly space velocity is defined as the volume of gas reactants per time per reaction zone volume, wherein the volume of reactant gases is preferably at standard conditions of pressure (101 kPa) and temperature (O 0 C), and further wherein the reaction zone volume is defined by the portion of the reaction vessel volume where the reaction takes place and is typically occupied by a gaseous phase comprising reactants, products and/or unreactive gas (inerts); a liquid phase comprising liquid/wax products and/or other liquids; and a solid phase comprising the catalyst.
  • the reaction zone pressure is typically in the range of about 80 psia (552 kPa) to about 1 ,000 psia (6,895 kPa), more preferably from about 80 psia (552 kPa) to about 800 psia (5,515 kPa), and still more preferably from about 140 psia (965 kPa) to about 750 psia (5,170 kPa). Most preferably, the reaction zone pressure is from about 250 psia (1,720 kPa) to about 650 psia (4,480 kPa).
  • Hydrocarbon synthesis product 45 is fed to hydrotreating unit 15, in which hydrocarbon synthesis product 45 is hydrotreated.
  • Hydrotreating is well known in the art and typically involves treating a hydrocarbon stream with hydrogen without making any substantial change to the carbon backbone of the molecules in the hydrocarbon stream.
  • Hydrotreating preferably converts substantially all alkenes (also called olefins) to paraffins. Olefins are known to cause chemical instability in diesel fuel. This instability frequently manifests itself in the formation of gums, which may form solid deposits in the fuel system and engine. This instability is typically measured by the oxidation stability ASTM D2274 test.
  • hydrocarbon synthesis product 45 can further comprise some oxygenates, but should have very low sulfur and nitrogen contents.
  • the hydrotreating catalysts can comprise a Group VIA metal, for example molybdenum (Mo) and/or tungsten (W); a Group VIII metal, for example nickel (Ni), palladium (Pd), platinum (Pt), ruthenium (Ru), iron (Fe), and/or cobalt (Co); or any combination of two or more thereof.
  • a Group VIA metal for example molybdenum (Mo) and/or tungsten (W)
  • a Group VIII metal for example nickel (Ni), palladium (Pd), platinum (Pt), ruthenium (Ru), iron (Fe), and/or cobalt (Co); or any combination of two or more thereof.
  • the nickel, palladium, platinum, tungsten, molybdenum, ruthenium, and any combination of two or more thereof are typically highly active catalysts, and the iron and cobalt are typically less active catalysts.
  • a mild hydrotreating step may be performed over a hydrotreating catalyst comprising at least one metal selected from the group consisting of Ni, Pd, Pt, Mo, W, and Ru, preferably comprising Ni, Co, Mo, W or any combination of two or more thereof, more preferably comprising Ni.
  • Such mild hydrotreating step can be performed under mild conditions at temperatures above 350 °F (170 0 C), preferably from 350 0 F (170 0 C) to about 750 0 F (400 0 C), more preferably from 360 0 F (180 0 C) to about 750 0 F (400 0 C), with a hydrogen partial pressure in the hydrotreater outlet between about 100 psia and about 2,000 psia (about 690 - 13,800 kPa).
  • a mild hydrotreatment can have the benefits of converting substantially all unsaturated hydrocarbons to saturated hydrocarbons, removing a substantial portion (> 90%) or all of the heteroatoms from the hydrocarbon stream, and optionally, capturing most of the solid
  • an "ultra-low severity hydrotreatment” step may be used to retain some of the oxygenates present in the hydrocarbon stream comprising primarily Fischer-Tropsch C 5+ hydrocarbon products, while removing the olefins in the hydrocarbon stream.
  • Oxygenates (particularly alcohols) derived from Fischer-Tropsch synthesis have been shown to advantageously increase the lubricity of the diesel product provided by the Fischer-Tropsch synthesis.
  • Others have reported methods to maintain the oxygenates in the diesel fraction of a FT product stream by not hydrotreating a portion of the diesel fraction directly provided by the Fischer-Tropsch synthesis in order to retain oxygenates, but the non-hydrotreated portion may result in leaving olefins in the diesel product.
  • an "ultra-low severity" hydrotreatment step of the hydrocarbon stream comprising primarily Fischer-Tropsch C 5+ hydrocarbon products is highly desirable to retain some oxygenates in at least one of the resulting diesel fractions obtained thereafter, and it is expected that the remaining oxygenates can increase the lubricity of that resulting diesel fraction.
  • Two important factors in determining whether a hydrotreating process does not convert a substantial amount of oxygenates to paraffins are catalyst composition and temperature.
  • Highly active catalysts such as those comprising Ni, Pd, Pt, W, Mo, Ru or any combination of two or more thereof, can be operated at relatively low temperatures (to maintain "ultra-low severity" hydrotreating conditions) between about 180 0 F and about 480 0 F (about 80°C and about 250 0 C), more preferably between about 180 °F and about 350 0 F (about 80 0 C and about 180 0 C), still more preferably between about 180 0 F and about 300 0 F (about 80 0 C and about 15O 0 C).
  • a highly active catalyst such as a nickel-based catalyst begins to convert a substantial amount of oxygenates at about 250 0 F (about 121 0 C).
  • less active catalysts such as those comprising Fe or Co do not begin to convert a substantial amount of the oxygenates until a temperature of about 350 0 F (about 180 0 C) is reached.
  • a preferred temperature range for "ultra-low severity" hydrotreating is between about 350 0 F and about 570 0 F (about 180 0 C and about 300 0 C).
  • pressure and liquid hourly space velocity may be varied by one of ordinary skill in the art to affect the desired "ultra-low severity" hydrotreating.
  • the hydrogen partial pressure is between about 100 psia and about 1,000 psia (about 690 - 6,900 kPa), more preferably between about 300 psia and about 500 psia (about 2,000 - 3,500 kPa).
  • the liquid hourly space velocity is preferably between 1 and 10 hr "1 , more preferably between 0.5 and 6 hr '1 , still more preferably between about 1 and about 5 hr "1 .
  • the hydrotreating catalyst for "ultra-low severity" hydrotreatment can be with or without support, although it is preferably supported and can comprise promoters to improve catalyst performance and/or support structural integrity.
  • Hydrotreated product stream 50 leaves hydrotreating unit 15 and is fed to fractionator 20 where it is separated into distillation cuts, which include a light fraction 55; a naphtha 60; a light diesel 65; a heavy diesel 70; and a waxy fraction 75.
  • distillation cuts include a light fraction 55; a naphtha 60; a light diesel 65; a heavy diesel 70; and a waxy fraction 75.
  • the present invention is not limited to forming distillates 60, 65, and 70 but can comprise forming more or less distillates.
  • other distillates can also include jet fuel, heating oil, and kerosene.
  • Methods of fractionation are well known in the art, and hydrotreated product stream 50 can be fractionated by any suitable fractionation method.
  • Fractionator 20 preferably comprises an atmospheric distillation column and optionally may further comprise a vacuum distillation column or a short-path distillation unit.
  • Waxy fraction 75 feeding thermal cracker 25 can comprise the bottoms of an atmospheric distillation column fed that is fed by hydrotreated product stream 50; a light wax cut or a heavy wax cut (such as vacuum bottoms) from a vacuum distillation column; or any combination thereof.
  • waxy fraction 75 refers to a higher boiling fraction than heavy diesel distillate 70.
  • waxy fraction 75 contains at least 30% by weight of C 20+ hydrocarbonaceous compounds, preferably at least 50% by weight of C 2 o + hydrocarbonaceous compounds, more preferably at least 70% by weight of C 20+ hydrocarbonaceous compounds. In preferred embodiments, waxy fraction 75 contains at least 90% by weight of C 20+ hydrocarbonaceous compounds. In alternate embodiments, waxy fraction 75 contains at least 10% by weight of C 3 o + hydrocarbonaceous compounds, preferably at least 20% by weight of C 30+ hydrocarbonaceous compounds. In yet other embodiments, waxy fraction 75 contains at least 10% by weight of C 4 o + hydrocarbonaceous compounds, preferably at least 20% by weight of C 40+ hydrocarbonaceous compounds. Waxy fraction 75 preferably comprises the bottoms of an atmospheric distillation tower in fractionator 20.
  • Light fraction 55 typically comprises hydrocarbon products normally in the gaseous phase at ambient temperature and referred to as Cs- hydrocarbons.
  • Light diesel 65 and heavy diesel 70 comprise primarily a diesel cut, with light diesel 65 comprising lighter hydrocarbons (i.e., with a lower boiling range) than heavy diesel 70.
  • Light diesel 65 can have a boiling range generally below that of heavy diesel 70, but wherein the upper end of the boiling range of light diesel 65 can overlap that of the initial boiling point of heavy diesel 70.
  • light diesel 65 comprises mainly C 10 - C 16 hydrocarbons.
  • at least a portion of light diesel 65 comprises linear hydrocarbons.
  • light diesel 65 comprises at least about 80 percent linear hydrocarbons; still more preferably at least about 90 percent linear hydrocarbons; most preferably at least about 93 percent linear hydrocarbons.
  • heavy diesel 70 comprises mainly Ci 7 -C 23 hydrocarbons. Heavy diesel 70 can have a boiling range generally below that of waxy fraction 75. In some embodiments, the upper end of the boiling range of heavy diesel 70 can overlap that of the initial boiling point of waxy fraction 75, while in alternate embodiments, the upper end of the boiling range of heavy diesel 70 and the initial boiling point of waxy fraction 75 do not overlap.
  • at least a portion of heavy diesel 70 comprises linear hydrocarbons.
  • light diesel 65 has a very low content in branched hydrocarbons (i.e., less than 10 wt% branched hydrocarbons) or substantially free of branched hydrocarbons (i.e., less than 5 wt% branched hydrocarbons).
  • light diesel 65 and heavy diesel 70 comprise at least 90 percent normal paraffins.
  • Light diesel 65 is preferably characterized by a 5% boiling point less than about 360 0 F and a 95% boiling point between about 500 0 F and about 550 0 F.
  • Heavy diesel 70 is preferably characterized by a 5% boiling point between about 500 0 F and 550 0 F and a 95% boiling point greater than about 630 0 F.
  • Waxy fraction 75 is fed to thermal cracker 25, in which at least a portion of waxy fraction
  • Waxy fraction 75 is thermally cracked.
  • Waxy fraction 75 can be cracked to produce any desired hydrocarbon, preferably linear hydrocarbons.
  • substantially all of waxy fraction 75 is fed to thermal cracker 25.
  • a purge (not shown in Figure 1) taken from waxy fraction 75 may be performed in order to remove some material resilient to the thermal cracking.
  • the purge stream typically represents not more than about 2 percent by volume of fraction 75, preferably less than about 1 percent by volume of fraction 75.
  • the small purge stream from waxy fraction 75 may be necessary to prevent the accumulation of small amount of solids (such as catalyst particles or subparticles).
  • Thermal cracking of hydrocarbons is well known in the art, and thermal cracking of waxy fraction 75 to primarily linear hydrocarbons can be accomplished by any suitable thermal cracking process.
  • Thermal cracking basically aims at the reduction of molecular size by application of heat without addition of catalyst or hydrogen.
  • Long chain paraffinic hydrocarbon molecules break down into a number of smaller ones by rupture of a carbon-to-carbon bond (the smaller molecules so formed may break down further). When this occurs, the number of hydrogen atoms present in the parent molecule can be insufficient to provide the full complement for each carbon atom, so that a majority of olefins or "unsaturated" compounds are typically formed.
  • the rupturing can take place in many ways, and a free radical mechanism for the bond rupture is generally assumed.
  • a temperature level of 350-500oC the larger hydrocarbon molecules become unstable and tend to break spontaneously into smaller molecules.
  • Temperature and residence time are important process variables, while pressure plays a secondary role.
  • the cracking conditions to be applied and the amount and type of cracked products can depend largely on the type of feedstock.
  • Modern reaction chambers for thermal cracking are equipped with internals so as to reduce backmixing effects, thus maximizing the viscosity reduction. Since only one cracking stage is involved, this layout is also named one-stage cracking.
  • the preferred cracking temperature applied is about 380-700 0 C, more preferably about 380-550 0 C; and at a pressure of about 500-1 ,100 kPa (about 60-150 psig). More severe conditions are necessary when the feedstock (waxy fraction 75) to the thermal cracker 25 has a smaller molecular size and is therefore more difficult to crack than larger hydrocarbon molecules.
  • Thermal cracker effluent 80 is quenched at the reaction chamber outlet to stop the cracking reaction (to prevent excessive coke formation).
  • Thermal cracker 25 can be operated at any suitable conditions.
  • the optimal temperature and other conditions in the thermal cracking zone for the cracking operation can vary somewhat depending on the composition of the feed and its boiling range. In general, the temperature is high enough to maintain at least a portion of the feed in the vapor phase but not so high that the feed is overcracked, i.e., the temperature and conditions are not so severe that excessive Cs- hydrocarbons are generated.
  • thermal cracker 25 preferably operates at temperatures between about 380 0 C and about 700 0 C, preferably between about 380 0 C and about 55O 0 C and at pressures between about 500 kPa and about 2,000 kPa.
  • thermal cracker 25 in order to maximize the production of smaller hydrocarbons from the Fischer-Tropsch wax will depend upon the endpoint of the feed (waxy fraction 75). In general, the higher the carbon number, the higher the temperature required to achieve maximum conversion. Maximum conversion may be obtained to the detriment of desired product selectivity (i.e., middle distillate such as diesel or jet fuel).
  • a desired conversion in thermal cracker 25 is between 10% and 70%; preferably between 12% and 65%; more preferably between 15% and 60%.
  • optimal residence time of waxy fraction 75 in thermal cracker 25 can vary depending on the temperature and pressure in the reaction zone, typical residence times are generally in the range of from about 0.5 seconds to about 500 seconds, with the preferred range being between about 2.5 seconds and about 300 seconds; with the more preferred range being between about 10 seconds and about 250 seconds; with the most preferred range being between about 20 seconds and about 200 seconds. Accordingly, some routine experimentation may be necessary to identify the optimal cracking conditions for a specific feed.
  • thermal cracker effluent 80 is fed to hydrotreating unit 15 wherein the portion of thermal cracker effluent 80 is hydrotreated with hydrogen gas over a hydrotreating catalyst so as to convert some or preferably most of the unsaturated hydrocarbonaceous compounds (formed during thermal cracking) to paraffins.
  • Figure 1 shows that thermal cracker effluent 80 is combined with hydrocarbon synthesis product 45 before entering hydrotreating unit 15.
  • thermal cracker effluent 80 and hydrocarbon synthesis product 45 are fed separately to hydrotreating unit 15.
  • a portion of thermal cracker effluent 80 is combined with hydrocarbon synthesis product 45 to form the feed to hydrotreating unit 15.
  • heavy diesel 70 can be hydroisomerized by any suitable technique to provide branching in order to lower the pour point, and thus improve the cold flow properties and/or for any other purpose.
  • Typical conditions for hydroisomerization involve temperatures from about 180 0 C to 380 0 C, pressures from about 1 ,100 kPa to about 15,000 kPa (about 150-2,200 psig), and space velocities from about 0.1 to about 5 hr "1 .
  • Catalysts for hydroisomerization are generally dual-functional catalysts consisting of an acidic component and a metal component. Both components are required to conduct the isomerization reaction. Typical metal components are nickel, molybdenum, tungsten, platinum, palladium, or any combination of two or more thereof, with platinum most commonly used.
  • the choice and the amount of metal in the catalyst can be sufficient to achieve greater than 10 percent isomerized hexadecane products in the test described in U.S. Pat. No. 5,282,958.
  • the acidic catalyst components useful for the hydroisomerization include amorphous silica-alumina, fluorided alumina, molecular sieves (i.e., ZSM-12, ZSM-21 , ZSM-22, ZSM-23, ZSM-35, ZSM-38, ZSM-48, ZSM-57, SSZ-32, SAPO-1 1 , SAPO-31, SAPO-41 , MAPO-1 1 , MAPO-31 , Y zeolite, L zeolite, and beta zeolite), and any combination of two or more thereof.
  • molecular sieves i.e., ZSM-12, ZSM-21 , ZSM-22, ZSM-23, ZSM-35, ZSM-38, ZSM-48, ZSM-57, SSZ
  • At least a portion (or substantially all of) one light fraction comprising mainly C 5 -C 8 hydrocarbons obtained from the optional second fractionator 32 located downstream to isomerization reactor 30 may be combined with naphtha 60.
  • This light fraction comprising mainly C 5 -C 8 hydrocarbons obtained from the optional second fractionator 32, post-isomerization may have some isomerized light hydrocarbons, and its addition to naphtha 60 can thus increase the degree of isomerization of the resulting naphtha blend.
  • the hydrotreating catalysts comprise at least one of a Group VI metal, such as molybdenum and tungsten, and/or at least one of a Group VIII metal, such as nickel, palladium, platinum, ruthenium, iron, and cobalt.
  • a Group VI metal such as molybdenum and tungsten
  • a Group VIII metal such as nickel, palladium, platinum, ruthenium, iron, and cobalt.
  • the nickel, palladium, platinum, tungsten, molybdenum, ruthenium, and combinations thereof are typically highly active catalysts, and the iron and cobalt are typically less active catalysts for hydrotreating.
  • “Ultra-low severity” hydrotreating can take place with hydrotreating catalysts comprising at least one of the following metals: a metal from the group consisting of molybdenum (Mo), tungsten (W) and combination thereof; a metal from the group consisting of nickel (Ni), palladium (Pd), platinum (Pt), ruthenium (Ru), iron (Fe), cobalt (Co) and combinations thereof.
  • the hydrogen partial pressure is between about 100 psia and about 1 ,000 psia (690 to about 6,900 kPa), more preferably between about 300 psia and about 500 psia (2,060 to about 3,450 kPa).
  • the liquid hourly space velocity is preferably between 1 and 10 hr "1 , more preferably between 0.5 and 6 hr "1 , still more preferably between about 1 and about 5 hr "1 .
  • at least a portion of light diesel 65 comprises linear hydrocarbons. More preferably, light diesel 65 comprises at least about 90 percent linear hydrocarbons.
  • at least a portion of heavy diesel 70 comprises linear hydrocarbons.
  • Hydroprocessing of heavy diesel 70 produces hydroprocessed heavy diesel 90.
  • at least a portion of hydroprocessed heavy diesel 90 comprises linear hydrocarbons. More preferably, hydroprocessed heavy diesel 90 comprises at least about 60 percent linear hydrocarbons. If hydroprocessing unit 105 comprises hydrotreatment, hydroprocessed heavy diesel 90 preferably comprises at least about 80 percent linear paraffins.
  • hydroprocessing in hydroprocessing unit 105 can further comprise hydrocracking heavy diesel 70.
  • the hydrocracking in hydroprocessing unit 105 takes place over a bi-functional hydrocracking catalyst comprising a hydrogenation component and a cracking component (typically an acid component).
  • the hydrogenation component may include Pt, Pd, Ni, Co, W, Mo, or combinations thereof.
  • the hydrogenation component in the bi- functional hydrocracking catalyst preferably includes Pt, Pd, or combinations thereof.
  • the cracking component for the hydrocracking catalyst in hydroprocessing unit 105 may be an amorphous cracking material and/or a zeolitic material.
  • a preferred cracking component comprises an amorphous silica-alumina; however, SAPO-type molecular sieves (such as SAPO -1 1 ; -31 ; -37; - 41), Y-type zeolites, ZSM-type zeolites (such as ZSM -5; -1 1 ; -48), SSz-32 zeolite, and dealuminated zeolites may also be used.

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  • Chemical & Material Sciences (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)

Abstract

La présente invention se rapporte à un procédé de production de distillats moyens synthétiques, et à des distillats moyens synthétiques produits à l'aide dudit procédé. Dans un mode de réalisation, le procédé selon l'invention consiste : à fractionner un produit de synthèse d'hydrocarbures, afin de produire au moins un distillat moyen léger, un distillat moyen lourd, et une fraction cireuse ; à procéder au craquage thermique de la fraction cireuse ; et à isomériser le distillat moyen lourd. L'on forme un composant de diesel synthétique ou de mélange en combinant au moins une partie du distillat moyen léger, au moins une partie ou fraction du produit ayant été soumis au craquage thermique, et au moins une partie ou fraction du produit isomérisé. Dans certains modes de réalisation, le produit de synthèse d'hydrocarbures et/ou le produit ayant été soumis au craquage thermique peuvent être hydrotraités. Dans d'autres modes de réalisation, un distillat moyen synthétique comprend au moins deux fractions, à savoir une fraction légère renfermant au maximum 10 % d'hydrocarbures ramifiés, et une fraction lourde renfermant au moins 30 % d'hydrocarbures ramifiés.
PCT/US2005/024394 2004-07-08 2005-07-08 Produits d'hydrocarbures synthetiques Ceased WO2006010068A1 (fr)

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GB2458070B (en) * 2006-12-14 2011-08-03 Chevron Usa Inc Improved process for making Fischer-Tropsch olefinic naphtha and hydrogenated distillates
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WO2009017832A1 (fr) * 2007-08-01 2009-02-05 Velocys, Inc. Procédés d'utilisation de microcanaux pour séparer des gaz en utilisant des absorbants liquides, en particulier des absorbants à liquide ionique (il)
US8029604B2 (en) 2007-08-01 2011-10-04 Velocys, Inc. Methods for applying microchannels to separate methane using liquid absorbents, especially ionic liquid absorbents from a mixture comprising methane and nitrogen
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KR20070057781A (ko) 2007-06-07
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US20060016722A1 (en) 2006-01-26
EP1776439A1 (fr) 2007-04-25

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