Hydrocarbon hydroconversion process for the production of hydrogen, hydroprocessed hydrocarbons and electricity

• US 6,916,562 B1
• Filed: 05/09/2000
• Issued: 07/12/2005
• Est. Priority Date: 05/13/1999
• Status: Expired due to Fees

• Current Assignee: Shell Oil Company (Shell Plc)
• Original Assignee: Shell Oil Company (Shell Plc)
• Inventors: Roovers, Antonius Adrianus Maria, Groeneveld, Michiel Jan, Nowak, Andreas Karl, Gosselink, Johan Willem
• Primary Examiner(s): Ryan, Patrick Joseph
• Assistant Examiner(s): Parsons, Thomas H.
• Application Number:
  US10/030,932
• Time in Patent Office: 1,890 Days
• Field of Search: 429/17
• US Class Current: 429/415
• CPC Class Codes: C01B 2203/0261 containing a catalytic partial oxidation step [CPO]
• CPC Class Codes: C01B 2203/0283 containing a CO-shift step, i.e. a water gas shift step
• CPC Class Codes: C01B 2203/065 using hydrotreating, e.g. hydrogenation, hydrodesulfurisation
• CPC Class Codes: C01B 2203/066 with fuel cells
• CPC Class Codes: C01B 2203/1011 Packed bed of catalytic structures, e.g. particles, packing elements
• CPC Class Codes: C01B 2203/1047 Group VIII metal catalysts
• CPC Class Codes: C01B 2203/1064 Platinum group metal catalysts
• CPC Class Codes: C01B 2203/1082 Composition of support materials
• CPC Class Codes: C01B 2203/1235 Hydrocarbons
• CPC Class Codes: C01B 2203/1241 Natural gas or methane
• CPC Class Codes: C01B 2203/1258 Pre-treatment of the feed
• CPC Class Codes: C01B 2203/127 Catalytic desulfurisation
• CPC Class Codes: C01B 2203/148 involving a recycle stream to the feed of the process for making hydrogen or synthesis gas
• CPC Class Codes: C01B 2203/1647 Controlling the amount of the product
• CPC Class Codes: C01B 2203/1685 Control based on demand of downstream process
• CPC Class Codes: C01B 2203/82 Several process steps of C01B2203/02 - C01B2203/08 integrated into a single apparatus
• CPC Class Codes: C01B 2203/84 Energy production
• CPC Class Codes: C01B 3/386 Catalytic partial combustion
• CPC Class Codes: C01B 3/48 followed by reaction of water vapour with carbon monoxide
• CPC Class Codes: C10G 47/00 Cracking of hydrocarbon oils, in the presence of hydrogen or hydrogen- generating compounds, to obtain lower boiling fractions C10G15/00 takes precedence; destructive hydrogenation of non-melting solid carbonaceous or similar materials C10G1/06
• CPC Class Codes: H01M 8/0612 : from carbon-containing material
• CPC Class Codes: Y02E 60/50 : Fuel cells

Abstract

A method for treating hydrocarbonaceous feedstock to produce hydrogen, electricity, and one or more liquid hydrocarbon product, the method comprising: (a) subjecting hydrocarbonaceous feedstock to hydrotreating hydrogen in the presence of supported catalyst under hydrotreating conditions effective to produce hydrotreated product comprising one or more liquid hydrocarbon product; (b) subjecting hydrotreated product to hydrogen production conditions effective to produce hydrogen product and hydrogen production remainder; (c) subjecting a first part of the hydrogen product to electricity generating conditions effective to produce electricity; and (d) recycling a second part of the hydrogen product as hydrotreating hydrogen.

Claims

1. A method for treating hydrocarbonaceous feedstock to produce hydrogen, electricity, and one or more liquid hydrocarbon product, the method comprising:

a) subjecting hydrocarbonaceous feedstock to hydrotreating hydrogen in the presence of supported catalyst under hydrotreating conditions effective to produce hydrotreated product comprising one or more liquid hydrocarbon product;

b) subjecting hydrotreated product to hydrogen production conditions effective to produce hydrogen product;

c) subjecting a first part of the hydrogen product to electricity generating conditions effective to produce electricity; and

d) recycling a second part of the hydrogen product as hydrotreating hydrogen.

2. The method of claim 1 further comprising:

recovering one or more liquid hydrocarbon product from the hydrotreated product, leaving hydrotreated product remainder; and

subjecting hydrotreated product remainder to the hydrogen production conditions.

3. The method of claim 2 further comprising providing hydrocarbonaceous feedstock comprising a fraction having a boiling point range the same as or higher than the one or more liquid hydrocarbon product.

4. The method of claim 3 wherein the hydrotreated product has a boiling point range different from boiling point range of the hydrocarbonaceous feedstock.

5. The method of claim 4 further comprising providing hydrocarbonaceous feedstock having a boiling point range of from about ambient to about 650°

C. at standard conditions comprising 20°

C. 1 atmosphere.

6. The method of claim 4 further comprising providing hydrocarbonaceous feedstock having a 90% boiling point range of from about 400°

C. to 600°

C. at standard conditions.

7. The method of claim 6 further comprising providing hydrocarbonaceous feedstock comprising 5% wt. sulfur or less.

8. The method of claim 4 wherein the fraction is from about 5% wt to about 40% wt. of the hydrocarbonaceous feedstock.

9. The method of claim 8 wherein the fraction has a boiling point range higher than the one or more liquid hydrocarbon product.

10. The method of claim 9 wherein the one or more liquid hydrocarbon product is selected from the group consisting of kerosene and gas oil.

11. The method of claim 10 wherein the hydrogen production conditions comprise catalytic oxidation conditions effective to produce hydrogen product and carbon (di) oxide.

12. The method of claim 11 wherein the catalytic oxidation conditions comprise catalytic partial oxidation conditions.

13. The method of claim 11 wherein said electricity generating conditions comprise feeding at least some of the hydrogen product to a fuel cell under fuel cell conditions effective to produce electricity.

14. The method of claim 13 wherein the fuel cell conditions produce an amount of electricity in excess of a total amount of electricity needed the method.

15. The method of claim 13 wherein the fuel cell conditions produce fuel cell steam, the hydrogen production conditions comprising subjecting hydrotreating product to fuel cell steam.

16. The method of claim 13 wherein the catalytic oxidation conditions comprise watergas-shift conditions effective convert hydrocarbonaceous feedstock and watergas-shift water to one or more catalytic oxidation product selected from the group consisting of kerosene and gas oil.

17. The method of claim 16 wherein the hydrotreating conditions produce hydrogen sulfide, the method further comprising converting the hydrogen sulfide into elemental sulfur.

18. The method of claim 2 wherein the hydrogen production conditions comprise catalytic oxidation conditions effective to produce hydrogen product and carbon (di) oxide.

19. The method of claim 18 wherein the catalytic oxidation conditions comprise catalytic partial oxidation conditions.

20. The method of claim 1 further comprising providing hydrocarbonaceous feedstock comprising 5% wt. sulfur or less.

21. The method of claim 1 wherein the one or more liquid hydrocarbon product is selected from the group consisting of kerosene and gas oil.

22. The method of claim 1 wherein said electricity generating conditions comprise feeding at least some of the hydrogen product to a fuel cell under fuel cell conditions effective to produce electricity.

23. The method of claim 1 wherein the supported catalyst comprises zeolite beta.

24. The method of claim 1 wherein the supported catalyst is effective to convert at least 90% wt. per pass of hydrocarbonaceous feedstock to one more liquid hydrocarbon product.

25. The method of claim 16 wherein the supported catalyst comprises zeolite beta.

26. The method of claim 16 wherein the supported catalyst is effective to convert at least 90% wt. per pass of the hydrocarbonaceous feedstock to one or more liquid hydrocarbon product.

27. The method of claim 26 wherein the hydrotreating conditions comprise

a temperature of from about 100°

C. to about 550°

C.; and

,

a pressure of 400 atmospheres or less.

28. The method of claim 27 wherein the method requires a total amount of hydrogen and a total quantity of electricity, and the catalytic oxidation conditions and the fuel cell conditions generate the total amount of hydrogen or more and the total quantity of electricity or more.

29. The method of claim 27 wherein the hydrotreated product further comprises lower boiling hydrocarbons containing at most 4 carbon atoms.

30. The method of claim 29 further comprising separating remaining hydrotreating hydrogen from the hydrotreated product prior to subjecting at least a portion of the hydrotreated product to hydrogen production conditions.

31. The method of claim 30 further comprising providing hydrocarbonaceous feedstock comprising about 3% wt. sulfur or less.

32. The method of claim 1 wherein the hydrotreating conditions comprise

a temperature of from about 100°

C. to about 550°

C.; and

a pressure of 400 atmosphere or less.

33. The method of claim 16 wherein the hydrotreating conditions comprise

a temperature of from about 100°

C. to about 550°

C.; and

,

a pressure of 400 atmosphere or less.

34. A method for treating hydrocarbonaceous feedstock to produce hydrogen, electricity, and one or more liquid hydrocarbon product, the method comprising:

a) subjecting hydrocarbonaceous feedstock to hydrotreating hydrogen in the presence of supported catalyst under hydrotreating conditions effective to produce hydrotreated product comprising one or more liquid hydrocarbon product;

b) subjecting hydrotreated product to catalytic partial oxidation conditions effective to produce catalytic partial oxidation product;

c) subjecting catalytic partial oxidation product to watergas-shift water under watergas-shift conditions effective to produce hydrogen product and carbon dioxide;

d) recycling a first part of the hydrogen product as the hydrotreating hydrogen, the hydrotreating hydrogen being produced from no feedstocks other than the hydrocarbonaceous feedstock and watergas-shift water; and

,

e) subjecting a second part of the hydrogen product to electricity generating conditions effective to produce electricity.

35. The method of claim 34 wherein the carbon dioxide is produced from no feedstocks other than the hydrocarbonaceous feedstock and the watergas-shift water.

36. The method of claim 35 wherein the electricity is produced from no feedstocks other than the hydrocarbonaceous feedstock and the watergas-shift water.

37. The method of claim 36 wherein the supported catalyst converts at least about 65% wt. per pass of a fraction of the hydrocarbonaceous feedstock having a boiling point range the same as or above the one or more liquid hydrocarbon.

38. The method of claim 37 wherein the hydrotreating conditions comprise a temperature of from about 250°

C. to about 450°

C.; and

a pressure of from about 10 to about 200 atmospheres.

40. The method of claim 34 wherein the supported catalyst converts at least 90% wt. per pass of hydrocarbonaceous feedstock to the one or more liquid hydrocarbon product.

41. The method of claim 40 wherein the hydrotreating conditions are effective to produce hydrogen sulfide, the method further comprising converting the hydrogen sulfide into elemental sulfur.

42. The method of claim 41 further comprising providing hydrocarbonaceous feedstock having a 90% boiling point range of from about 400°

C. to about 600°

C. at standard conditions.

43. The method of claim 42 wherein the fuel cell conditions produce fuel cell steam, the watergas-shift water comprising fuel cell steam.

44. The method of claim 43 wherein the hydrotreating conditions comprise a temperature of from about 100°

C. to about 550°

C. and a pressure of 400 atmospheres or less.

45. The method of claim 44 wherein the method requires a total amount of hydrogen and a total quantity of electricity, and the watergas-shift conditions and the fuel cell conditions generate the total amount of hydrogen or more and the total quantity of electricity or more.

46. The method of claim 45 wherein the hydrotreated product comprises hydrocarbons containing at most 4 carbon atoms.

47. The method of claim 46 further comprising separating remaining hydrotreating hydrogen from the hydrotreated product before subjecting at least a portion of hydrotreated product to the hydrogen production conditions.

48. The method of claim 47 wherein the hydrocarbonaceous feedstock comprises about 3% wt sulfur or less.

50. The method of claim 41 further comprising:

recovering one or more liquid hydrocarbon product from the hydrotreated product, leaving hydrotreated product remainder; and

subjecting the hydrotreated product remainder to the hydrogen production conditions.

51. The method of claim 50 wherein the hydroprocessed product is selected from the group consisting of kerosene and gas oil.

52. The method of claim 51 wherein the hydrogen production conditions comprise catalytic oxidation conditions effective to produce hydrogen product and carbon (di) oxide.

53. The method of claim 52 wherein the catalytic oxidation conditions comprise catalytic partial oxidation conditions.

54. The method of claim 52 wherein said electricity generating conditions comprise feeding at least some of the hydrogen product to a fuel cell under fuel cell conditions effective to produce electricity.

55. The method of claim 54 wherein the fuel cell conditions produce fuel cell steam, the hydrogen production conditions comprising subjecting hydrotreated product to fuel cell steam.

56. The method of claim 55 wherein the hydrotreating conditions comprise

a temperature of from about 100°

C. to about 550°

C.; and

,

a pressure of 400 atmospheres or less.

57. The method of claim 56 wherein the method requires a total amount of hydrogen and a total quantity of electricity, and the catalytic oxidation conditions and the fuel cell conditions generate the total amount of hydrogen or more the total quantity of electricity or more.

58. The method of claim 55 further comprising separating remaining hydrotreating hydrogen from the hydrotreated product prior to subjecting at least a portion of the hydrotreated product to hydrogen production conditions.

39. A method for treating hydrocarbonaceous feedstock to produce hydrogen, electricity, and one or more liquid hydrocarbon product, the method comprising:

a) providing hydrocarbonaceous feedstock comprising about 5% wt. sulfur or less, said hydrocarbonaceous feedstock having a boiling point of from about ambient to about 650°

C. at standard conditions comprising 20°

C. and 1 atmosphere;

b) subjecting the hydrocarbonaceous feedstock to hydrotreating hydrogen in the presence of supported catalyst comprising zeolite beta under hydrotreating conditions effective to produce hydrotreated product comprising one or more liquid hydrocarbon product selected from the group consisting of kerosene and gas oil, the hydrotreated product having a first boiling point range different from the hydrocarbonaceous feedstock, the hydrocarbonaceous feedstock comprising a fraction of from about 5% wt. to about 40% wt. having a second boiling point range the same as or higher than the one or more liquid hydrocarbon product;

c) recovering at least some of the one or more liquid hydrocarbon product, leaving hydrotreated product remainder;

d) subjecting at least some of the hydrotreated product remainder to catalytic partial oxidation conditions effective to produce catalytic partial oxidation product;

e) subjecting catalytic partial oxidation product to watergas-shift water under watergas-shift conditions effective to convert the hydrotreated product remainder to hydrogen product and to a watergas-shift product selected from the group consisting of kerosene and gas oil;

f) feeding a first part of the hydrogen product to a fuel cell under electricity generating conditions effective to produce electricity; and

,

g) recycling a second part of the hydrogen product as hydrotreating hydrogen.

49. A method for treating hydrocarbonaceous feedstock to produce hydrogen, electricity, and one or more liquid hydrocarbon product, the method comprising

a) subjecting hydrocarbonaceous feedstock to hydrotreating hydrogen under hydrotreating conditions comprising supported zeolite catalyst effective to produce hydrotreated product comprising one or more liquid hydrocarbon product;

b) subjecting at least a portion of the hydrotreated product to hydrogen production conditions effective to produce hydrogen product;

c) subjecting a first part of the hydrogen product to electricity generating conditions effective to produce electricity; and

,

d) recycling a second part of the hydrogen product as hydrotreating hydrogen.

59. The method of claim 49 wherein the hydroprocessed product is selected from the group consisting of kerosene and gas oil.

60. The method of claim 49 wherein the hydrogen production conditions comprise catalytic oxidation conditions effective to produce hydrogen product and carbon (di) oxide.

61. The method of claim 60 wherein the catalytic oxidation conditions comprise catalytic partial oxidation conditions.

62. The method of claim 49 wherein said electricity generating conditions comprise feeding at least some of the hydrogen product to a fuel cell under fuel cell conditions effective to produce electricity.

63. The method of claim 49 wherein the hydrotreating conditions comprise

a temperature of from about 100°

C. to about 550°

C.; and

,

a pressure of 400 atmospheres or less.

64. The method of claim 49 further comprising separating remaining hydrotreating hydrogen from the hydrotreated product prior to subjecting at least a portion of the hydrotreated product to hydrogen production conditions.

65. The method of claim 49 wherein the supported zeolite catalyst is zeolite beta.