Process for conversion of a hydrocarbon stream

• US 10,072,222 B2
• Filed: 12/16/2015
• Issued: 09/11/2018
• Est. Priority Date: 12/17/2014
• Status: Active Grant

• Current Assignee: Topsoe
• Original Assignee: Haldor Topsã¸E A/S (Haldor Topsã¸E Holding A/S)
• Inventors: Andersen, Stefan, Alkilde, Ole Frej
• Primary Examiner(s): McCaig, Brian A
• Application Number:
  US15/532,444
• Publication Number:
  US 20170267938A1
• Time in Patent Office: 1,000 Days
• CPC Class Codes: C10G 2300/1055 Diesel having a boiling range of about 230 - 330 °C
• CPC Class Codes: C10G 2300/1074 Vacuum distillates
• CPC Class Codes: C10G 2300/1077 Vacuum residues
• CPC Class Codes: C10G 2300/301 Boiling range
• CPC Class Codes: C10G 2300/4006 Temperature
• CPC Class Codes: C10G 2300/4012 Pressure
• CPC Class Codes: C10G 2400/04 Diesel oil
• CPC Class Codes: C10G 47/02 characterised by the catalyst used
• CPC Class Codes: C10G 47/12 Inorganic carriers
• CPC Class Codes: C10G 47/16 Crystalline alumino-silicate carriers
• CPC Class Codes: C10G 67/02 plural serial stages only
• CPC Class Codes: C10G 7/00 Distillation of hydrocarbon oils
• CPC Class Codes: C10G 7/06 Vacuum distillation

Abstract

In a broad aspect the present disclosure relates to a process plant and a process for upgrading a hydrocarbon mixture, withdrawn as a direct stream from a crude distillation unit and an initial boiling point below 200° C., and a fraction of at least 5% boiling above 500° C., 550° C. or 650° C. comprising the steps of a. directing said hydrocarbon mixture to a vacuum flasher unit, b. withdrawing a heavy hydrocarbon fraction from said vacuum flasher unit, c. withdrawing a light hydrocarbon mixture for hydrocrackingfrom said vacuum flasher unit, d. directing said light hydrocarbon mixture for hydrocracking and a stream rich in hydrogen to con-tact a material catalytically active in hydrocracking, e. withdrawing a hydrocracked stream of hydrocarbon from said hydrocracker. with the associated benefit of limiting the amount of asphaltenes, metals and other heavy components contacting said material catalytically active in hydrocracking.

Claims

1. A process for upgrading a hydrocarbon mixture, withdrawn as a direct stream from a crude distillation unit and having an initial boiling point below 200°

C., and a fraction of at least 5 mass % boiling above 500°

C., comprising the steps of

a. directing said hydrocarbon mixture to a vacuum flasher unit,

b. withdrawing a heavy bottoms fraction from said vacuum flasher unit,

c. withdrawing an overhead fraction for hydrocracking from said vacuum flasher unit,

d. directing said overhead fraction for hydrocracking and a stream rich in hydrogen to a reaction step to contact a material catalytically active in hydrocracking, and

e. withdrawing a hydrocracked stream of hydrocarbon from said hydrocracker.

2. A process according to claim 1 in which said hydrocarbon mixture is withdrawn as an overflash stream or a part of an overflash stream from a crude oil distillation unit.

3. A process according to claim 1, in which the hydrocarbon mixture directed to said vacuum flasher unit has a temperature of at least 250°

C.

4. A process according to claim 1, in which the hydrocarbon mixture directed to said vacuum flasher unit has a temperature of less than 450°

C.

5. A process according to claim 1, in which pressure of said vacuum flasher unit is below 90 kPa.

6. A process according to claim 1, in which pressure of said vacuum flasher unit is above 0.5 kPa.

7. A process according to claim 1, in which the hydrocarbon mixture is directed to said vacuum flasher unit at substantially the same temperature at which it was withdrawn from the crude distillation unit.

8. A process according to claim 1, further comprising the steps of adding steam to said vacuum flashing unit or stripping the overhead fraction.

9. A process according to claim 1, further comprising the step of withdrawing a hydrocarbon mixture of which at least 80% boils between 150°

C. and 360°

C. from said vacuum flasher unit.

10. A process according to claim 1, in which the material catalytically active in hydrocracking comprising a metal component selected from Group VIII and/or VIB of the Periodic System and being supported on a carrier containing one or more oxides taken from the group consisting of alumina, silica, titania, silica-alumina, molecular sieves, zeolites, ZSM-11, ZSM-22, ZSM-23, ZSM-48, SAPO-5, SAPO-11, SAPO-31, SAPO-34, SAPO-41, MCM-41, zeolite Y, ZSM-5, and zeolite beta.

11. A process according to claim 1, in which the reaction step in the presence of a material catalytically active in hydrocracking is carried out

a temperature between 200°

C. and 400°

C.,

a pressure between 15 and 200 barg,

a liquid hourly space velocity between 0.2 hr<sup>−

1</sup> and 5 hr<sup>−

1</sup>,

and a hydrogen to hydrocarbon ratio between 100 and 2000 Nm³/m³.

12. A process according to claim 11 in which the reaction step is carried out under a severity ensuring less than 5% of the product boiling above 360°

C.

14. A process plant according to claim 12 in which said vacuum flash unit further comprises column packing or trays, and has at least one further hydrocarbon fraction outlet, said further hydrocarbon outlet is above the overhead fraction outlet.

13. A process plant comprising a crude oil distillation column having an inlet, multiple distillation outlets, an overflash outlet and an overflash inlet, a vacuum flash unit having an inlet, a gas outlet, an overhead fraction outlet and a residual bottoms outlet and a hydrocracking reactor having an inlet and an outlet, and containing a material catalytically active in hydrocracking,

said process plant being configured for directing a crude oil to the inlet of the distillation column, for said overflash outlet being in fluid communication with the inlet of the vacuum flash unit, the overhead fraction outlet of said vacuum flash unit being in fluid communication with the inlet of the hydrocracking reactor,

the inlet of said hydrocracking reactor being further in fluid communication with a hydrogen source and the outlet of said hydrocracking reactor being configured for withdrawal of a stream boiling in the diesel range optionally for further processing.