Axens

Institut Francais Du Pe'trole

Institute Francais Du Petrole

Other

Ifp Energies Nouvelles

Hri, Inc.

Ifp North America, Inc.

Axens North America, Inc.

James J Colyar

John E Duddy

James B MacArthur

Eric D Peer

Lawrence Wisdom

Christophe Gueret

Fr&eacute;d&eacute;ric Morel

Frederick A Zenz

St&eacute;phane Kressmann

Stéphane Kressmann

Allen S Li

Michael Peluso

The integration of hydrogen and methanol production within a coal liquefaction, petroleum refinery or biomass conversion facility resulting in the unanticipated benefits of lower carbon dioxide (CO) production, net emissions, and higher carbon and thermal efficiencies is the subject of this invention.

Integrated coal liquefaction, petroleum or biomass facility with decreased carbon dioxide production and higher carbon and thermal efficiencies

The invention described herein relates to a novel process to create carbon black feed stocks derived from coal by utilizing direct coal liquefaction resulting in an economic process for producing carbon black feedstock. Moreover, relative to the current state of the art (use of FCC slurry oil), the invention process will be significantly more profitable when oil prices increase.

Carbon black feedstock from direct coal liquefaction

This invention relates to the conversion or hydrotreatment of petroleum or coal derived liquids in a novel ebullated-bed reactor system. The novel processing scheme results in a much simpler and less costly (investment and annual operating) ebullated-bed reaction system through the elimination of the high pressure, high temperature separator, hydrogen purification plant, and recycle gas compressor as well as a smaller hydrogen make-up compressor all resulting in substantial operational and construction efficiency.

Generation ebullated-bed reactor system

The invention described herein relates to a novel process for reducing the carbon dioxide emissions from a coal and/or biomass liquefaction facility by utilizing a steam methane reformer unit in the complex designed to produce additional hydrogen which can be thereafter utilized in the process, as required for the plant fired heaters (including the SMR furnace), and for the production of plant steam. The plant light ends (C, C, etc.), which are normally utilized as fuel gas streams are the primary feeds to the SMR Unit along with the tail gas purge from a gasification complex within the facility.

Coal liquefaction complex with minimal carbon dioxide emissions

The described invention discloses an innovative solvent deasphalter and hydroconversion-processing configuration for converting bitumen or heavy oils to produce a transportable synthetic crude oil (SCO). The innovative processing scheme disclosed herein maximizes the synthetic crude oil yield at a minimal investment compared to currently known methods.

Partial uprading utilizing solvent deasphalting and DAO hydrocracking

The described invention discloses an innovative hydroconversion-processing configuration for converting bitumen or heavy oils to produce a transportable synthetic crude oil (SCO). The innovative processing scheme disclosed herein maximizes the synthetic crude oil yield at a minimal investment compared to currently known methods.

High conversion partial upgrading process

This invention utilizes a novel method and set of operating conditions to efficiently and economically process a potentially very fouling hydrocarbon feedstock. A multi-stage catalytic process for the upgrading of coal pyrolysis oils is developed. Coal Pyrolysis Oils are highly aromatic, olefinic, unstable, contain objectionable sulfur, nitrogen, and oxygen contaminants, and may contain coal solids which will plug fixed-bed reactors. The pyrolysis oil is fed with hydrogen to a multi-stage ebullated-bed hydrotreater and hydrocracker containing a hydrogenation or hydrocracking catalyst to first stabilize the feed at low temperature and is then fed to downstream reactor(s) at higher temperatures to further treat and hydrocrack the pyrolysis oils to a more valuable syncrude or to finished distillate products. The relatively high heat of reaction is used to provide the energy necessary to increase the temperature of the subsequent stage thus eliminating the need for additional external heat input. A refined heavy oil product stream is recycled to the fresh feed to minimize feedstock fouling of heat exchangers and feed heaters.

Process for upgrading coal pyrolysis oils

The invention described herein relates to a novel process that eliminates the need for post combustion COcapture from fired heaters (at atmospheric pressure and in dilute phase) in a petroleum refinery to achieve environmental targets by capturing COin a centralized facility and providing fuel gas low in carbon to the fired heaters. It combines the pre-combustion capture of carbon dioxide with production of a hydrogen fuel source within a refinery to drastically reduce the carbon dioxide emissions of the plant. The hydrogen fuel is utilized for the process fired heaters and the fuel quality (carbon content) can be set to meet the refinery's emissions objectives. Moreover, the carbon dioxide captured can be sequestered and/or utilized for enhanced oil recovery (EOR).

Reduction of greenhouse gas emission from petroleum refineries

This invention relates to a novel integrated hydroconversion process for converting heavy atmospheric or vacuum residue feeds and also converting and reducing impurities in the vacuum gas oil liquid product. This is accomplished by utilizing two residue hydroconversion reaction stages, two vapor-liquid separators, and at least two additional distillate ebullated-bed hydrocracking/hydrotreating reaction stages to provide a high conversion rate of the residue feedstocks.

Process for multistage residue hydroconversion integrated with straight-run and conversion gasoils hydroconversion steps

An improved process for heavy oil conversion and upgrading and a combined method for heavy oil conversion and vacuum gas-oil treatment are described herein. The method utilizes the creation and recycle of a separate product from the vacuum still, which is thereafter recycled back to the heavy oil conversion reactor. The result is the production of a higher quality medium gas oil product relative to the overall vacuum gas oil product which is acceptable for use in a typical vacuum gas oil treatment process. Additionally, there is a higher diesel yield selectivity from the heavy oil conversion unit.

Selective heavy gas oil recycle for optimal integration of heavy oil conversion and vacuum gas oil treating

This invention relates to a novel integrated method for economically processing vacuum residue from heavy crude oils. This is accomplished by utilizing a solvent deasphalter (SDA) in the first step of the process with a C/C/Csolvent such that the DAO product can thereafter be processed in a classic fixed-bed hydrotreater or hydrocracker. The SDA feed also includes recycled stripper bottoms containing unconverted residue/asphaltenes from a downstream steam stripper unit. The asphaltenes from the SDA are sent to an ebullated-bed reactor for conversion of the residue and asphaltenes. Residue conversion in the range of 60-80% is achieved and asphaltene conversion is in the range of 50-70%. The overall residue conversion, with the DAO product considered non-residue, is in the range of 80 W %-90 W % and significantly higher than could be achieved without utilizing the present invention.

Integrated SDA and ebullated-bed process

This invention relates to a novel method for economically processing vacuum residue from heavy crude oils by selectively processing the difficult and easy components in reactors whose design and operating conditions are optimized for the specific feed. The process utilizes an integrated solvent deasphalting (SDA)/ebullated-bed design wherein the heavy vacuum residue feedstock is initially sent to an SDA unit operated with C/Csolvent to achieve a high deasphalted oil (DAO) yield. The resulting SDA products, namely asphaltenes and DAO are separately treated in ebullated-bed reactor(s) systems whose design and operating conditions are optimized for a particular feedstock. The resulting net conversion, associated distillate yield and product qualities are greatly improved relative to treatment of the entire residue feedstock in a common ebullated-bed reactor system.

Effective integration of solvent deasphalting and ebullated-bed processing

For converting hydrocarbons: step a) treating a hydrocarbon feed with hydrogen in at least one three-phase reactor ( ), containing ebullated bed hydroconversion catalyst; a step b) passing effluent from step a) to a separation zone ( ) to recover a fraction F containing at least a portion of gas, gasoline and atmospheric gas oil contained in the effluent from step a), and a fraction F containing compounds with boiling points of more than that of the atmospheric gas oil; step c) hydrodesulphurizing at least a portion of fraction F and step d) passing at least a portion of fraction F to catalytic cracking section ( ).

Process for converting petroleum fractions, comprising an ebullated bed hydroconversion step, a separation step, a hydrodesulphurization step and a cracking step

This invention teaches an improved ebullated-bed reactor hydrotreating/hydrocracking process for treating heavy vacuum gas oil (HVGO) and deasphalted oil (DAO) feeds. The reactor is designed to operate at minimum catalyst bed expansion so as to maximize reactor kinetics and approach plug flow reactor process performance. Further, the invention allows for the production of a uniform product quality and production output that does not substantially vary with time.

Simplified ebullated-bed process with enhanced reactor kinetics

A process for catalytic multi-stage hydrogenation of heavy carbonaceous feedstocks using catalytic ebullated bed reactors is operated at selected flow and operating conditions so as to provide improved reactor operations and produce increased yield of lower boiling hydrocarbon liquid and gas products. The disclosed process advantageously takes advantage of an external gas/liquid separation unit associated with the first stage reactor to allow for a more efficient and effective catalytic hydrocracking process. The more efficient process is primarily a result of the increased catalyst loading and lower gas hold-up in the ebullated reactors.

Growing community of inventors

Newtown, PA, United States of America

James J Colyar