FUEL COMPOSITIONS FROM LIGHT TIGHT OILS AND HIGH SULFUR FUEL OILS
First Claim
1. A process for conversion of hydrocarbonaceous feeds comprising sulfur and metals to form a fuel characterized in that feed comprises light tight oil and high sulfur fuel oil, said process comprising(a) feeding one or more high sulfur fuel oils (41) to a residue hydroconversion zone (401) and contacting such oil with hydrogen in presence of catalyst at residue hydroconversion conditions in an ebullated-bed reactor to form(1) reactor zone effluent which is separated into hydroconverted liquids (411) and purge gases (420) comprising hydrogen and sulfur,(2) unconverted oils (409) which are directed to solvent separation (301) to form (A) soluble deasphalted oil (311) which is recycled as feed to said hydroconversion zone (401), either separately or combined with added high sulfur fuel oil feed to said reactor and (B) insoluble pitch (351) which is directed to pitch treatment (501), and(b) combining all or one or more portions of a light tight oil (1) with said hydroconverted liquids (411) to form a fuel (600).
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Accused Products
Abstract
Methods are provided to prepare a low sulfur fuel from hydrocarbon sources, such as light tight oil and high sulfur fuel oil, often less desired by conventional refiners, who split crude into a wide range of differing products and may prefer presence of wide ranges (C3 or C5 to C20 or higher) of hydrocarbons. These fuels can be produced by separating feeds into untreated and treated streams, and then recombining them. Such fuels can also be formulated by combinations of light, middle and heavy range constituents in a selected manner as claimed. Not only low in sulfur, the fuels of this invention are also low in nitrogen and essentially metals free. Fuel use applications include on-board large marine transport vessels but also on-shore for large land based combustion gas turbines, boilers, fired heaters and transport vehicles and trains.
27 Citations
50 Claims
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1. A process for conversion of hydrocarbonaceous feeds comprising sulfur and metals to form a fuel characterized in that feed comprises light tight oil and high sulfur fuel oil, said process comprising
(a) feeding one or more high sulfur fuel oils (41) to a residue hydroconversion zone (401) and contacting such oil with hydrogen in presence of catalyst at residue hydroconversion conditions in an ebullated-bed reactor to form (1) reactor zone effluent which is separated into hydroconverted liquids (411) and purge gases (420) comprising hydrogen and sulfur, (2) unconverted oils (409) which are directed to solvent separation (301) to form (A) soluble deasphalted oil (311) which is recycled as feed to said hydroconversion zone (401), either separately or combined with added high sulfur fuel oil feed to said reactor and (B) insoluble pitch (351) which is directed to pitch treatment (501), and (b) combining all or one or more portions of a light tight oil (1) with said hydroconverted liquids (411) to form a fuel (600).
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16. A process for conversion of one or more hydrocarbonaceous feeds comprising sulfur and metals characterized in that said conversion is directed to a single liquid fuel product, said process comprising
(a) separating said feed (2, 3) by atmospheric (100) and vacuum distillation (200), into (i) light overhead still gases (6), (ii) liquid fractions at or below sulfur breakpoint (16), and (iii) fractions above sulfur breakpoint comprising (A) distillate range fractions comprising sulfur (24,26,28, 32) (B) vacuum gas oil range fractions comprising sulfur (36, 38) and (C) vacuum residue comprising sulfur (50), and associated purge gases comprising sulfur (b) directing the liquid fractions at or below the sulfur breakpoint (10), as untreated liquids, to a combination zone (600) (c) directing 16.(a)(iii)(A) distillate range fractions (20) to distillate hydrotreater (430) and 16.(a)(iii)(B) vacuum gas oil range fractions (39) to vacuum gas oil hydrotreater (460) for contact with addition of hydrogen in presence of catalyst at hydrotreating conditions to form (1) one or more treated liquids (65, 75) which are directed to a combination zone (600), and (2) purge gases comprising sulfur (428) (d) directing the 16.(a)(iii)(C) vacuum residue (50, 57) to ebullated residue hydroconversion (490) for contact with addition of hydrogen in presence of catalyst at ebullated hydroconversion conditions to form (1) one more treated liquids (85) which are directed to said combination zone (600) (2) purge gases comprising sulfur (428) (3) unconverted oils (409) which are directed to solvent separation (301) to form (A) soluble deasphalted oil (311) which is directed to said residue hydroconversion (490), either alone or combined with vacuum residue (50), and (B) insoluble pitch (351) which is directed to pitch treatment (501) (e) combining said untreated liquids (10) with said treated liquids (65, 75, 85) to form a fuel (600) having an actual sulfur content at or below a target sulfur content.
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30. A fuel derived from combining light tight oil and processed high sulfur fuel oil, wherein said high sulfur fuel oil is processed by residue hydroconversion, said fuel having an actual sulfur content of 0.5 wt. % or less comprising a range of crude oil derived hydrocarbons from about C5 to about C20 or higher, 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 portion of effluent from solvent separation which is subsequently treated, either by hydrotreating or hydroconversion, and forms a portion said fuel.
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31. A process for integration of atmospheric and vacuum distillation, solvent separation, hydrotreating, and hydroconversion to produce components of a fuel characterized in that the integration of this process separates feeds into streams, treats one or more portions of 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, where said process comprises
(a) feeding light tight oil (3) and crude oil (2) comprising sulfur and metal contaminants to an atmospheric distillation column (100) and separating the feed into light overhead gases (6) 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, 37) 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 (30) (c) feeding (b)(iv) vacuum residual (50, 57) to a residue hydroconversion zone (490) with addition of hydrogen in presence of catalyst at residue hydroconversion conditions in an ebullated-bed reactor system having liquids recovery comprising vacuum distillation within integrated zone (401) to form (i) hydroconverted liquids (85) comprising (A) naphtha (B) all or a portion of middle distillates product of hydroconversion and (C) all or a portion of vacuum gas oils product of hydroconversion within integrated zone (401), and associated purge gases comprising hydrogen and sulfur (ii) unconverted oils (409) which are directed to solvent separation (301) to form (A) soluble deasphalted oil (311) which is recycled as feed to said hydroconversion reactor (490), either separately or combined with added high sulfur fuel oil feed to said hydroconversion reactor and (B) substantially insoluble metals rich pitch (351) which is directed to pitch treatment (501), and (d) feeding to distillate hydrotreater (430) stream (20) comprising (a)(iii) light distillate, (a)(iv) medium distillate, (a)(v) first heavy distillate, and (b)(i) second heavy distillate stream and directing to distillate hydrotreater (430), as needed for sulfur content control, a portion of distillate range products of hydroconversion formed within integrated zone (401), for contact with addition of hydrogen in presence of catalyst at hydrotreating conditions to form a stream (65) comprising (i) wild naphtha (ii) ultra low sulfur diesel being a reduced sulfur stream formed from combination of treated distillate steams comprising (a)(iii) light distillate, (a)(iv) medium distillate, (a)(5) first heavy distillate and (b)(i) second heavy distillate and a portion of distillate range treated (c)(i)(B) middle distillate product of hydroconversion within integrated zone (401) and associated byproducts 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, (e) feeding to heavy oil hydrotreater (460) stream (39) comprising (b)(ii) light vacuum gas oil, (b)(iii) heavy vacuum gas oil, and directing to heavy oil hydrotreater (460) a portion of (c)(i)(C) vacuum gas oils product of hydroconversion within integrated zone (401) for contact with addition of hydrogen in presence of catalyst at hydrotreating conditions to form a stream (75) 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 a hydrotreated portion (c)(i)(C) derived from vacuum gas oils products of hydroconversion within integrated zone (401) and (iii) a second reduced sulfur stream formed from a second portion of the combination of treated distillate steams comprising (b)(ii) light vacuum gas oil (36), (b)(iii) heavy vacuum gas oil (38), and a hydrotreated portion derived from (c)(i)(C) vacuum gas oils product of hydro-conversion within integrated zone (401), and associated byproducts comprising (iv) sulfur containing gas stream comprising hydrogen sulfide (v) hydrogen rich off gas (428), at least a portion of which is treated for sulfur removal and is recycled as hydrogen addition, and (f) forming said fuel product (600) having an actual sulfur content at or below a target sulfur content limit level by combining (i) streams (a)(i) unstabilized wild straight run naphtha and (a)(ii) sulfur breakpoint cut without added treatment (10) with (ii) streams from distillate hydrotreater (65) comprising (d)(i) wild naphtha and (d)(ii) all or a portion of ultra low sulfur diesel, with (iii) streams from heavy oil hydrotreater (75) comprising (e)(i) wild naphtha, (e)(ii) ultra low sulfur diesel and (e)(iii) a second reduced sulfur stream, with (iv) streams from hydroconversion (85) comprising (c)(i) hydroconverted liquids, in a manner whereby actual sulfur content of said fuel (600) does not exceed target sulfur content limit. - View Dependent Claims (32, 33, 34, 35, 36, 37, 38, 39)
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40. A formulated combination useful as a fuel characterized in that said fuel is formed by combining a range of hydrocarbons constituents of (L)+(M)+(H) and the resulting combination is determined, based on 100 volume percent total, as follows:
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(a) (L) %+(M) %+(H) %=100% and (b) (L) %=(H) %=(100%−
(M) %)/2) and(c) if (M) % is zero or otherwise less than 100%, the remainder is (L) %/(H) % in ratio of 0.4/1 to 0.6/1, wherein such combination has fuel (1) density within 820 to 880 Kg/M3 at 15°
C., (2) sulfur content of 0.25 wt. % or less and (3) metals content of 40 ppmwt or less. - View Dependent Claims (41, 42, 43, 44)
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45. A formulated combination useful as a fuel characterized in that it is formed by combining a range of hydrocarbons of (L)+(M)+(H) and the resulting combination is from 30% to 70% by volume of (M) range constituents and the remainder is equal parts of (L) and (H) at (L)/(H) in ratio of 0.9/1 to 1/0.9, for 100 volume percent total, and fuel bulk density is within 820 to 880 Kg/M3 at 15°
- C., total sulfur is 0.25 wt. % or less and metals are 40 ppmwt or less.
- View Dependent Claims (46, 47)
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48. A formulated combination useful as a fuel characterized in that it is formed by combining a range of hydrocarbons of (L)+(M)+(H) and the resulting combination has the following properties:
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(a) sulfur from 0.05 wt. % (500 ppmwt) to 0.1 wt. % (1000 ppmwt), (b) density from 820 to 880 Kg/M3 at 15°
C.,(c) total metals of 25 ppmwt or less, (d) HHV from 43.81 to 45.15 MJ/kg, and (e) LHV from 41.06 to 42.33 MJ/kg. - View Dependent Claims (49)
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50. A formulated fuel comprising light tight oil and hydroconversion reaction effluent, said fuel having a range of hydrocarbons from an initial boiling of naphtha to end point of highest boiling oil insoluble in heptane solvent used in solvent separation preparation of feed to said hydroconversion reactor, a density within 820 to 880 Kg/M3 at 15°
- C., sulfur of 0.1 wt. % or less, and metals of 25 ppmwt or less.
Specification