ENVIRONMENT-FRIENDLY MARINE FUEL
First Claim
1. A process for conversion of crude oil comprising sulfur and metals characterized in that this process separates such feed into streams based on sulfur content, treats one or more liquid portions of such separate streams for sulfur removal while leaving other portions untreated, and then recombines a majority of the volumes of all treated and untreated liquid streams to form a liquid fuel having an actual sulfur content at or below a target sulfur content, said process comprising(a) separating said crude (2) by one or more distillation (100, 200) and solvent separation (300) steps, into light overhead still gases (4), metals enriched residue (90) insoluble in one or more solvents used for said solvent separation, gases comprising sulfur (420), and liquid fractions above sulfur breakpoint (20, 40) and liquid fractions at or below breakpoint (10),(b) treating, by one or more hydrotreating steps, liquid fractions of over sulfur breakpoint (20, 40), but not liquid fractions at or below sulfur breakpoint (10) or insoluble residue (90), to form one or more hydrotreated streams (60, 70) having reduced sulfur content, and(c) combining said hydrotreated streams (60, 70) with liquid fractions at or below sulfur breakpoint (10) to form said fuel (600).
1 Assignment
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Accused Products
Abstract
For the shipping industry, these fuels provide solutions to long outstanding technical problems that heretofore hindered supply of low sulfur marine fuels in quantities needed to meet worldwide sulfur reduction goals. Marine shipping use of high sulfur bunker oils is reported as largest source of world-wide transportation SOx emissions. When ships on the open seas burn cheap low grade heavy bunker oils high in sulfur, nitrogen and metals, the SOx, NOx, and metal oxides go to the environment. This invention converts essentially all of each barrel of crude feed to a single ultraclean fuel versus conventional refining where crude feed is cut into many pieces, and each piece is sent down a separate market path meeting various different product specifications. When in port, ships can use these fuels to generate and sell electricity to land based electrical grids to offset fuel cost in an environment-friendly manner.
46 Citations
44 Claims
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1. A process for conversion of crude oil comprising sulfur and metals characterized in that this process separates such feed into streams based on sulfur content, treats one or more liquid portions of such separate streams for sulfur removal while leaving other portions untreated, and then recombines a majority of the volumes of all treated and untreated liquid streams to form a liquid fuel having an actual sulfur content at or below a target sulfur content, said process comprising
(a) separating said crude (2) by one or more distillation (100, 200) and solvent separation (300) steps, into light overhead still gases (4), metals enriched residue (90) insoluble in one or more solvents used for said solvent separation, gases comprising sulfur (420), and liquid fractions above sulfur breakpoint (20, 40) and liquid fractions at or below breakpoint (10), (b) treating, by one or more hydrotreating steps, liquid fractions of over sulfur breakpoint (20, 40), but not liquid fractions at or below sulfur breakpoint (10) or insoluble residue (90), to form one or more hydrotreated streams (60, 70) having reduced sulfur content, and (c) combining said hydrotreated streams (60, 70) with liquid fractions at or below sulfur breakpoint (10) to form said fuel (600).
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15. A fuel derived from processing crude oil characterized in that said fuel has an actual sulfur content of 0.50% m/m (wt. %) or less and comprises a range of crude oil derived hydrocarbons from C3 or C5 to greater than C20, said hydrocarbons having an initial boiling point being the lowest boiling point of any fraction within untreated streams combined in said fuel and highest boiling point being the highest boiling point of a hydrotreated stream combined in said fuel.
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16. A process for integration of atmospheric and vacuum distillation, solvent separation, and hydrotreating to produce components of a fuel characterized in that the integration of this process separates feeds into streams, treats one or more portions of such separate streams, and then recombines treated and untreated streams to form a fuel having an initial boiling point being the lowest boiling point of any fraction within untreated streams combined in said fuel and highest boiling point being the highest boiling portion of effluent from solvent separation which is subsequently treated and forms a portion said fuel, said fuel having an actual sulfur content at or below a target sulfur content limit level, which process comprises
(a) feeding crude (2) comprising sulfur and metal contaminants to an atmospheric distillation column (100) and separating the feed into light overhead gases (4) and multiple cuts comprising: -
(i) unstabilized wild straight run naphtha (16) (ii) sulfur breakpoint cut (18) (iii) light distillate over breakpoint (24) (iv) medium distillate (26) (v) a first heavy distillate (28) (vi) atmospheric residual (30) (b) feeding (a)(vi) atmospheric residual (30) to a vacuum distillation tower (200) to produce (i) a second heavy distillate (32) (ii) light vacuum gas oil (36) (iii) heavy vacuum gas oil (38) (iv) vacuum residual (50) (c) feeding (b)(iv) vacuum residual (50) to solvent separation (300) to produce (i) deasphalted oil (80) and (ii) metals rich pitch (90), (d) feeding (a)(iii) light distillate (24), (a)(iv) medium distillate (26), (a)(v) first heavy distillate (28) and (b)(i) second heavy distillate (32) to a distillate hydrotreater (430) with addition of hydrogen in presence of catalyst at hydrotreating conditions to form a stream (60) comprising (i) wild naphtha (ii) ultra low sulfur diesel being a reduced sulfur stream formed from combination of treated distillate steam (60) comprising (a)(iii) light distillate (24), (a)(iv) medium distillate (26), (a)(v) first heavy distillate (28) and (b)(i) second heavy distillate (32),
with associated byproducts (420) comprising(iii) sulfur containing gas stream comprising hydrogen sulfide (iv) hydrogen rich off gas, at least a portion of which is treated for sulfur removal and is recycled as hydrogen addition (502) to either distillate hydrotreater of (d)(430) or heavy oil hydrotreater of (e) (460) (e) feeding (b)(ii) light vacuum gas oil (36), (b)(iii) heavy vacuum gas oil (38) and (c)(i) deasphalted oil (80) to a heavy oil hydrotreater (460) with addition of hydrogen in presence of catalyst at hydrotreating conditions to form a stream (70) comprising (i) wild naphtha (ii) ultra low sulfur diesel being a first reduced sulfur stream formed from a first portion of the combination of treated distillate steams comprising (b)(ii) light vacuum gas oil (36), (b)(iii) heavy vacuum gas oil (38) and (c)(i) deasphalted oil (80) (iii) a second reduced sulfur stream (70) formed from a second portion of the combination of treated distillate steams (40) comprising (b)(ii) light vacuum gas oil (36), (b)(iii) heavy vacuum gas oil (38) and (c)(i) deasphalted oil (80) with associated byproducts (420) comprising (iv) sulfur containing gas stream comprising hydrogen sulfide (v) hydrogen rich off gas, at least a portion of which is treated for sulfur removal and is recycled as hydrogen addition (502) to either distillate hydrotreater of (d)(430) or heavy oil hydrotreater of (e)(460), and (f) forming said fuel product having an actual sulfur content at or below a target sulfur content limit level by combining (i) streams without added treatment (10) of (a)(i) unstabilized wild straight run naphtha (16) and (a)(i) sulfur breakpoint cut (18) with (ii) streams from distillate hydrotreater (60) comprising (d)(i) wild naphtha and (d)(ii) all or a portion of ultra low sulfur diesel, with (iii) streams from heavy oil hydrotreater (70) comprising (e) (i) wild naphtha, (e)(ii) ultra low sulfur diesel and (e)(iii) a second reduced sulfur stream in a manner whereby actual sulfur content of said fuel does not exceed target sulfur content limit. - View Dependent Claims (17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 38, 43)
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31. A fuel meeting or exceeding all ISO RMA 10 (ISO 2817-10) specifications except flashpoint, characterized in that such fuel comprises a range of hydrocarbons having an initial boiling point of naphtha and highest boiling point being that of the highest boiling point component thereof soluble in a solvent suitable for solvent separation, said fuel having:
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(a) sulfur at 0.50% m/m (wt. %) or below, preferably in the range of 0.05 to 0.20 m/m (wt. %), (b) metals at 5.0 mg/Kg (ppmwt) or below, preferably 1.0 mg/Kg (1.0 ppmwt) or below, and (c) flashpoint less than 60°
C. without flashpoint treatment. - View Dependent Claims (32, 33, 34, 35, 36, 39, 44)
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40. A technical method for reducing emissions at or near locations of ports comprising:
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(a) technical analysis of per KWH amount of sulfur or metals emissions resulting from on-shore generation facilities that generate electricity normally supplied to grid at or near location of port including emissions of such facilities directly associated with use by ship of local electrical supply when ship is in port and connected to grid supplying on-shore generated electricity, (b) technical analysis per KWH amount of sulfur or metals emissions resulting from on-board ship electricity generation by a ship in port at the location of (a), then (c) if (b) is less than (a), tender all or portion of on-board electricity generation to grid.
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41. (canceled)
Specification