Supercritical reactor systems and processes for petroleum upgrading

• US 10,384,179 B2
• Filed: 03/03/2017
• Issued: 08/20/2019
• Est. Priority Date: 12/15/2015
• Status: Active Grant

• Current Assignee: Saudi Arabian Oil Company (Government of Saudi Arabia)
• Original Assignee: Saudi Arabian Oil Company (Government of Saudi Arabia)
• Inventors: Choi, Ki-Hyouk, Alabdulhadi, Abdullah T., Al-Abdullah, Mohammad A.
• Primary Examiner(s): Robinson, Renee
• Application Number:
  US15/448,913
• Publication Number:
  US 20170175005A1
• Time in Patent Office: 900 Days
• CPC Class Codes: B01J 3/008 Processes carried out under supercritical conditions
• CPC Class Codes: B01J 3/02 Feed or outlet devices therefor
• CPC Class Codes: C10G 11/10 with stationary catalyst bed
• CPC Class Codes: C10G 2300/70 Catalyst aspects
• CPC Class Codes: C10G 2300/703 Activation
• CPC Class Codes: C10G 2300/805 Water
• CPC Class Codes: C10G 2300/807 Steam
• CPC Class Codes: C10G 31/08 by treating with water
• CPC Class Codes: C10G 49/18 in the presence of hydrogen-generating compounds, e.g. ammonia, water, hydrogen sulfide
• CPC Class Codes: C10G 51/026 only catalytic cracking steps
• CPC Class Codes: C10G 65/02 plural serial stages only
• CPC Class Codes: C10G 65/10 including only cracking steps
• CPC Class Codes: C10G 65/12 including cracking steps and other hydrotreatment steps
• CPC Class Codes: C10G 75/00 Inhibiting corrosion or fouling in apparatus for treatment or conversion of hydrocarbon oils, in general C10G7/10, C10G9/16 take precedence
• CPC Class Codes: C10G 75/04 by addition of antifouling agents
• CPC Class Codes: Y02P 20/54 using solvents, e.g. supercritical solvents or ionic liquids

Abstract

Supercritical upgrading reactors and reactor systems are provided for upgrading a petroleum-based composition using one or more purging fluid inlets to prevent plugging of the catalyst layer in the reactor. Processes for upgrading petroleum-based compositions by utilizing a reactor having at least one purging fluid inlet are also provided.

Claims

1. A reactor for upgrading a petroleum-based composition comprising:

a first catalyst layer disposed in a central region of the reactor,

a second catalyst layer disposed vertically below the first catalyst layer in the reactor,

an insert coaxially disposed inside a metal tubular wall of the reactor, and

a plurality of purging fluid inlets disposed proximate to the first catalyst layer, the second catalyst layer, or both, where

the purging fluid inlets comprise one or more linear pipes extending horizontally within the reactor;

the purging fluid inlets penetrate the insert; and

the reactor operates at a temperature greater than a critical temperature of water and a pressure greater than a critical pressure of water.

2. The reactor of claim 1, where at least one of the first catalyst layer, the second catalyst layer, or the purging fluid inlets are supported by the insert.

3. The reactor of claim 1, where the purging fluid inlets further comprise one or more angled linear pipes, the angle being relative to a horizontal plane defined by the first catalyst layer, the second catalyst layer, or both.

4. The reactor of claim 1, where the purging fluid inlets further comprise one or more non-linear pipes, the non-linear pipes including at least one bend or curvature relative to a straight section of the non-linear pipe.

5. The reactor of claim 4, where the bend is oriented at an angle θ

relative to a plane defined by a straight section of the non-linear pipe.

6. The reactor of claim 1, where at least one of the purging fluid inlets further comprises an annular ring having one or more openings, multiple pipes having one or more openings, or both.

7. A process for upgrading a petroleum-based composition comprising:

combining a supercritical water stream with a pressurized, heated petroleum-based composition in a mixing device to create a combined feed stream;

introducing the combined feed stream into an upgrading reactor system comprising at least one downflow supercritical upgrading reactor operating at a temperature greater than a critical temperature of water and a pressure greater than a critical pressure of water,

where the downflow supercritical upgrading reactor comprises

a first catalyst layer disposed in a central region of the reactor,

a second catalyst layer disposed vertically below the first catalyst layer in the downflow supercritical upgrading reactor,

an insert coaxially disposed inside a metal tubular wall of the reactor, and a plurality of purging fluid inlets disposed proximate to the first catalyst layer, the second catalyst layer, or both, where

the purging fluid inlets comprise one or more linear pipes extending horizontally within the reactor, and

the purging fluid inlets penetrate the insert;

passing the combined feed stream through the first catalyst layer, the second catalyst layer, or both to at least partially convert the combined feed stream to an upgraded product comprising light hydrocarbons;

injecting purging fluid through the purging fluid inlets to contact the first catalyst layer, the second catalyst layer, or both to reduce plugging; and

passing upgraded product out of the downflow supercritical upgrading reactor.

8. The process of claim 7, where the purging fluid inlets are vertically disposed above the catalyst layers.

9. The process of claim 7, wherein the purging fluid inlets are vertically disposed between the first catalyst layer and the second catalyst layer.

10. The process of claim 7, where the purging fluid inlets further comprise one or more angled linear pipes, the angle being relative to a horizontal plane defined by the first catalyst layer, the second catalyst layer, or both.

11. The process of claim 7, where the purging fluid inlets further comprise one or more non-linear pipes, the non-linear pipes including at least one bend or curvature relative to a straight section of the non-linear pipe.

12. The process of claim 11, in which the bend is oriented at an angle θ

relative to a plane defined by a straight section of the non-linear pipe.

13. The process of claim 7, where at least one of the purging fluid inlets further comprises an annular ring having one or more openings.

14. The process of claim 7, where the purging fluid inlets further comprise multiple pipes spaced apart or interconnected with one or more openings.

15. The process of claim 7, where the purging fluid comprises aromatic hydrocarbons selected from the group consisting of benzene, toluene, xylene, and combinations thereof.

16. The process of claim 7, further comprising one or more pressure sensors upstream, downstream, or both upstream and downstream of the downflow supercritical upgrading reactor.

17. The process of claim 16, where the pressure sensors trigger one or more of the purging fluid inlets to deliver purging fluid when the pressure of the downflow supercritical upgrading reactor deviates from 1% to 10% of operating pressure.