Chevron U.s.a. Inc.

Chevron Research and Technology Company, a Division of Chevron U.s.a.

Richard O Moore, Jr

Roger D Van Gelder

Dennis John O'Rear

Krishniah Parimi

Darush Farshid

Mohammad M Habib

Philip L Winslow

Ben Smith

Clive Jones

Grant C Hilton

William L Schinski

Andrew Rainis

Michael Moir

Jerome F Mayer

Donald Kuehne

Kirk T O'Reilly

Randall B Pruet

Lucy Melinda Bull

Paul D Cambern

Philippus Rudolf Heydenrich

Quintin John Beukes

Gianni Guilio Eligio Bacco Rodriquez

Mark Schnell

An integrated process for producing liquid fuel and lubricating base oil from Fischer-Tropsch derived products which comprises (a) recovering separately from a Fischer-Tropsch synthesis reactor a Fischer-Tropsch wax and condensate; (b) hydroprocessing the wax and recovering a waxy intermediate and a hydrogen-rich normally, liquid fraction; (c) mixing the condensate and at least part of the hydrogen-rich normally liquid fraction to form a Fischer-Tropsch condensate mixture; (d) hydrotreating the condensate mixture and recovering a Fischer-Tropsch condensate product; (e) recovering from the condensate product a liquid fuel; (f) separately dewaxing the waxy intermediate and recovering a base oil; (g) hydrofinishing the base oil; (h) recovering from the hydrofinishing zone a stabilized base oil and a hydrogen-rich gas; and (i) recycling the hydrogen-rich gas to the wax hydroprocessing zone wherein the total pressure in the hydrofinishing zone is at least as high as the total pressure in the wax hydroprocessing zone.

Integrated process for the production of lubricating base oils and liquid fuels from Fischer-Tropsch materials using split feed hydroprocessing

Novel methods of treating a Fischer-Tropsch product stream with an acid are disclosed. Such methods are capable of removing contamination from the Fischer-Tropsch product stream such that plugging of the catalyst beds of a subsequent hydroprocessing step is substantially reduced.

Acid treatment of a fischer-tropsch derived hydrocarbon stream

The present invention is directed to a method for hydroprocessing Fischer-Tropsch products. The invention in particular relates to an integrated method for producing liquid fuels from a hydrocarbon stream provided by Fischer-Tropsch synthesis. The method involves separating the Fischer-Tropsch products into a light fraction (FT condensate) and a heavy fraction. The heavy fraction is subjected to hydrocracking conditions, preferably through multiple catalyst beds, to reduce the chain length. The products of the hydrocracking reaction following the last catalyst bed are subjected to a separation step. The lighter material is combined with the Fischer-Tropsch condensate and hydrotreated. The hydrotreatment conditions hydrogenate double bonds, reduce oxygenates to paraffins, and desulfurize and denitrify the products. The heavier material from the separation step is sent to the lube plant for hydroisomerization, or is subjected to subsequent fraction steps to produce fuels and middle distillates.

Process for the upgrading of the products of Fischer-Tropsch processes

Novel methods of treating a Fischer-Tropsch derived hydrocarbon stream with an active filtering catalyst are disclosed. Such methods are capable of removing soluble (and ultra-fine particulate) contamination, fouling agents, and/or plugging precursors from the Fischer-Tropsch derived hydrocarbon stream such that plugging of the catalyst beds of a subsequent hydroprocessing process is substantially avoided.

Catalytic filtering of a Fischer-Tropsch derived hydrocarbon stream

A method of minimizing the formation of polymers and other heavy molecular weight products upon heating of a hydrocarbon stream in a hydroconversion process is described. Specifically, sufficient hydrogen-containing gas is added to the hydrocarbon stream before heating to reduce its fouling tendency. The hydrogen-containing gas is added in an amount less than about 500 standard Cubic Feet per Barrel (SCFB). preferably less than about 100 SCFB and more preferably less than about 50 SCFB.

Method for retarding fouling of feed heaters in refinery processing

The present invention relates to the use of deactivatable biocides in cooling water systems of industrial processes that require dissipation of heat. The present invention relates to methods of inhibiting growth and reproduction of microorganisms in the cooling water comprising adding the deactivatable biocides to the cooling water and irreversibly deactivating the deactivatable biocides before or upon disposal of the cooling water.

Process for disposing biocide-containing cooling water

Embodiments of the present invention are directed to methods for hydroprocessing Fischer-Tropsch products. The embodiments in particular are related to integrated methods for producing liquid fuels from a hydrocarbon stream provided by a Fischer-Tropsch synthesis process. The methods involves separating the Fischer-Tropsch products into a light fraction and a heavy fraction. The light fraction is pre-conditioned to remove contaminants such as CO prior to being subjected to hydroprocessing, either separately, or after having been being recombined with the heavy fraction. Any of the hydroprocessing steps may be accomplished in a single reactor.

Methods for pre-conditioning fischer-tropsch light products preceding upgrading

A method for hydroprocessing hydrocarbon products, preferably Fischer-Tropsch products, and a reactor useful for performing the method, are disclosed. The reactor includes one or more first catalyst beds comprising a catalyst useful for conducting relatively severe hydroprocessing and one or more second catalyst beds comprising a catalyst useful for conducting relatively mild hydroprocessing. The second catalyst beds are located at a position in the reactor where they can receive the products from the first catalyst bed(s), at least one of each of the first and second catalyst bed(s) comprises a catalyst grading scheme sufficient to remove at least a portion of any particulates from their respective feeds, and the reactor is set up to receive hydrocarbon feeds at a position above or within the first catalyst bed(s) and above or within the second catalyst bed(s). A first hydrocarbon feed with a relatively high boiling point is introduced to the first catalyst bed(s) and is subjected to relatively severe hydroprocessing. A feed comprising 1) the products from the hydroprocessing of the first hydrocarbon feed and 2) a second hydrocarbon feed with a relatively low boiling point is introduced to the second catalyst beds and is subjected to relatively mild hydroprocessing. The catalyst grading scheme minimizes pressure drop build-up through the catalyst beds. The hydrocarbon feeds are preferably derived, in whole or in part, from Fischer-Tropsch synthesis, although they can include products from petroleum refining or other suitable sources. In one embodiment, the relatively high boiling fraction is a predominantly C &plus; fraction and the relatively low boiling fraction is a predominantly C fraction.

Graded catalyst bed for split-feed hydrocracking/hydrotreating

A process is disclosed for preparing a finished fuel product from a stabilized product mixture, which is produced from the effluent of a Fischer-Tropsch synthesis process. In the process, a Fischer-Tropsch synthesis process is conducted at a site which is remote from the market site where the products from the process are ultimately marketed. The Fischer-Tropsch effluent product is hydroprocessed, and the hydroprocessed effluent separated to remove a C &minus; fraction and to yield a stabilized product mixture which can be exported to the market site. At the market site, the stabilized product mixture is fractionated into at least one finished fuel product. A heavy fraction may also be recovered at the market site for separation into at least one lubricating oil base stock and then conversion at hydroisomerization conditions to form a lubricating base oil.

Method of fuel production from fischer-tropsch process

The present invention is directed to a method for hydroprocessing Fischer-Tropsch products. The invention in particular relates to an integrated method for producing liquid fuels from a hydrocarbon stream provided by Fischer-Tropsch synthesis. The method involves separating the Fischer-Tropsch products into a light fraction with normal boiling points below 700&deg; F. and including predominantly C components and a heavy fraction with normal boiling points above 650&deg; F. and including predominantly C components. The heavy fraction is subjected to hydrocracking conditions, preferably through multiple catalyst beds, to reduce the chain length. The light fraction is used as all or part of a quench fluid between each catalyst bed.

Liquid or two-phase quenching fluid for multi-bed hydroprocessing reactor

The present invention is directed to a method for hydroprocessing Fischer-Tropsch products. The invention in particular relates to an integrated method for producing liquid fuels from a hydrocarbon stream provided by Fischer-Tropsch synthesis. The method involves separating the Fischer-Tropsch products into a light fraction and a heavy fraction. The heavy fraction is subjected to hydrocracking conditions, preferably through multiple catalyst beds, to reduce the chain length. The products of the hydrocracking reaction following the last catalyst bed, optionally after a hydroisomerization step, are combined with the light fraction. The combined fractions are hydrotreated, and, optionally, hydroisomerized. The hydrotreatment conditions hydrogenate double bonds, reduce oxygenates to paraffins, and desulfurize and denitrify the products. Hydroisomerization converts at least a portion of the linear paraffins into isoparaffins.

Method for upgrading Fischer-Tropsch wax using split-feed hydrocracking/hydrotreating

An integrated process for producing desulfurized hydroprocessed products from Fischer-Tropsch synthesis is disclosed. The process involves isolating and desulfurizing a methane-rich stream from a natural gas source in a first separation zone and a desulfurization zone. The methane-rich stream is converted to syngas and subjected to a hydrocarbon synthesis step, for example, a Fischer-Tropsch synthesis step. The products from the hydrocarbon synthesis step typically include a C &minus; fraction, a C fraction, and a C &plus; wax fraction. These fractions are isolated in a second separation zone, typically via fractional distillation. The C &minus; fraction can be recycled through the first separation zone to provide a second methane-rich fraction for conversion to synthesis gas. The C &minus; fraction can optionally be treated, for example, with hydrotreatment or hydroisomerization catalysts and conditions before or after passage through the first separation zone. The hydrocarbons in the C and C &plus; wax fractions are subjected to additional process steps, for example, hydrotreatment, hydroisomerization, hydrocracking (particularly in the case of the wax fraction), preferably in the presence of sulfur-containing compounds. The products of the additional process steps are sent to a third separation zone, and yield one or more fractions useful, for example, in fuel-related products (preferably C hydrocarbons) as well as an additional C4&minus; fraction. The additional C4&minus; fraction, which can include sulfur impurities resulting from the hydroconversion reaction, can also be desulfurized in the desulfurization zone along with the natural gas. This eliminates the need for a second desulfurization zone. The desulfurization zone can be scaled up from its normal size, if desired, to accommodate the additional sulfur removal resulting from the hydroconversion.

Removing sulfur from hydroprocessed fischer-tropsch products

An integrated process for improved hydrocarbon recovery from a natural gas resource is disclosed. A methane-rich stream, an LPG stream and optionally a C5&plus;  stream are isolated from a natural gas source in a first separation zone and desulfurized. The methane-rich stream is converted to syngas and subjected to hydrocarbon synthesis, for example, Fischer-Tropsch synthesis. The products from the hydrocarbon synthesis typically include a C4&minus; fraction, a C5-C20 fraction, and a C20&plus; wax fraction. These fractions are isolated in a second separation zone. The C4&minus; fraction is recycled through the first separation zone to provide methane for conversion to synthesis gas and an additional LPG fraction. The C4&minus; fraction can be treated, for example, with hydrotreating or hydroisomerization catalysts and conditions before or after the separation. The C5-C20 fraction and the C20&plus; wax and heavy fraction are subjected to additional process steps, for example, hydro treatment, hydroisomerization, and/or hydrocracking. The products are sent to a third separation zone, and yield an additional C4&minus; fraction, as well as higher molecular weight products. The additional C4&minus; fraction can also be sent to the first separation zone and treated in an analogous fashion to the C4&minus; fraction from the hydrocarbon synthesis. Any sulfur-containing compounds resulting from the additional processing of the hydrocarbon synthesis products (i.e., hydroconversion reactions) can be treated along with the sulfur-containing compounds in the natural gas, eliminating the need for a second sulfur-treatment plant.

Hydrocarbon recovery in a fischer-tropsch process

An integrated process for producing a hydrocarbon stream, preferably including predominantly C normal and iso-paraffins, is disclosed. The process involves isolating a C &minus; stream and, optionally a C &plus; stream (&ldquo;natural gas condensate&rdquo;) from a natural gas source. The C &minus; stream is converted to syngas, and the syngas used in a hydrocarbon synthesis process, for example, Fischer-Tropsch synthesis. In one embodiment, one or more fractions from the hydrocarbon synthesis are blended with one or more crude oil derived fractions, and, optionally, the natural gas condensate, such that the overall sulfur content of the blend is less than about 200 ppm. If necessary, the crude oil fractions and/or natural gas condensate can be treated to lower the sulfur content so that the blend has an acceptable sulfur level. The fraction from the hydrocarbon synthesis may include, for example, C hydrocarbons, C &plus; hydrocarbons, or C &plus; hydrocarbons. In this embodiment, the hydroprocessing catalysts are noble metal-containing catalysts, which tend to be sensitive to sulfur concentrations above about 200 ppm. The catalysts preferably have high selectivity for C &plus; products, such that a significant C &minus; fraction is not formed. In another embodiment, one or more fractions from the hydrocarbon synthesis are blended with one or more crude oil derived fractions, and, optionally, the natural gas condensate, such that the overall sulfur content of the blend is more than about 200 ppm. The fraction from the hydrocarbon synthesis may include, for example, C hydrocarbons, C &plus; hydrocarbons, or C &plus; hydrocarbons. In this embodiment, conventional sulfur-tolerant hydroprocessing catalysts can be used.

Co-hydroprocessing of Fischer-Tropsch products and crude oil fractions

An integrated process for producing a hydrocarbon stream including C normal and iso-paraffins is disclosed. A de-sulfurized methane-rich stream and a natural gas condensate are isolated from the natural gas source. The methane-containing stream is converted into syngas, which is then subjected to a hydrocarbon synthesis process, for example, Fischer-Tropsch synthesis. One or more fractions from the hydrocarbon synthesis are blended with the natural gas condensate for co-hydroprocessing, where the blended stream includes less than about 200 ppm sulfur. Olefins and oxygenates are hydrotreated to form paraffins. Paraffins are subjected to hydroisomerization conditions to form isoparaffins. Hydrocarbons with chain lengths above a desired value, for example, C , are hydrocracked. The hydrogenolysis that would otherwise form undesired C fractions is minimized by judicious selection of noble metal catalysts.

Growing community of inventors

San Rafael, CA, United States of America

Richard O Moore, Jr