Mineral oils: processes and products – Chemical conversion of hydrocarbons – With subsequent treatment of products
Reexamination Certificate
1999-04-30
2001-01-09
Yildirim, Bekir L. (Department: 1764)
Mineral oils: processes and products
Chemical conversion of hydrocarbons
With subsequent treatment of products
C208S212000, C208S21600R, C208S25100H, C208S25100H, C208S253000, C208S299000, C208S309000, C208S31000R, C208S311000
Reexamination Certificate
active
06171471
ABSTRACT:
BACKGROUND OF THE PRESENT INVENTION
The present invention relates to improving the quality of heavy feeds, ranging from crude oil to vacuum residua. In particular, the present invention makes acceptable feed for fluidized catalytic crackers from vacuum residua or other heavy feeds which are unsuitable due to high metals, sulfur or microcarbon residue (MCR).
Mild Slurry Hydroprocessing (MSHP) with finely divided catalyst can provide a flexible, relatively low cost means for improving the quality of heavy feeds, ranging from crude oil to vacuum residua. Currently the preferred catalyst for the hydroprocessing are Mo-based high surface area Microcat catalysts, however, other finely dispersed materials, including multimetallic compounds may also be used, so long as the quantity of metal is sufficient to keep the toluene insolubles level below 0.5%, and no more than the amount which can be disposed of economically.
MSHP operates at temperatures of about 725-825° F., the temperature dependent on oil residence time, with reactor pressures in the GOFINER range (800-1500 psig) with a captive bed slurry reactor. An important feature of this process scheme is the use of finely divided catalysts, and a critical limitation is the filtration and catalyst recycle system. Therefore, it is desirable to have an upgrading system that does not require a catalyst recycling.
SUMMARY OF THE PRESENT INVENTION
The present invention is a slurry-type process for upgrading heavy oils to Fluidized Catalytic Converter (FCC) and steam cracking (S/C) feeds under temperature and pressure conditions similar to MSHP, but employing catalysts in concentrations small enough (e.g., <300 ppm Mo on feed) that they need not be recycled. The process involves a) heating an oil at MSHP conditions using between 100-250 ppm of a preformed molybdenum based high surface area Microcat and b) subjecting the product from step 1 to a solvent deasphalting or adsorption step to remove metals and microcarbon residue (MCR). The deasphaltened oil is suitable as an FCC feed, and the lighter ends might be suitable for steam cracking. The bottoms may be sent to a coker or partial oxidation unit, etc. An advantage of such a once-through process is that it avoids the need for solids separation devices such as internal or external filters and for recycle of the separated solids. Runs at higher temperature at shorter residence times give similar product qualities to lower temperature, longer residence time products. Shorter residence times translate into smaller and lower investment.
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Ferrughelli David T.
Gorbaty Martin L.
Exxon Research and Engineering Company
Hantman Ronald D.
Yildirim Bekir L.
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