Process for producing tailored synthetic crude oil that optimize crude slates in target refineries
First Claim
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1. An integrated process for upgrading a heavy oil feedstock, comprising:
- a) establishing a communication link between an upgrading facility and a target refinery;
b) acquiring a refining data set from the target refinery that characterizes a tailored synthetic crude having a 95% boiling point as determined by ASTM D1160 of less than 1000°
F. and API gravity of greater than 10;
c) generating a feedstock data set from the upgrading facility that characterizes a heavy oil feedstock having a 95% boiling point as determined by ASTM D1160 of greater than 1000°
F.;
d) using the refining data set from the target refinery and the feedstock data set from the upgrading facility to generate an upgrading dataset of select upgrading process conditions;
e) upgrading the heavy oil feedstock at the select upgrading process conditions within the upgrading facility and recovering a tailored synthetic crude, wherein the upgrading comprises contacting the heavy oil feedstock with hydrogen in the presence of an active unsupported slurry catalystwherein the active unsupported slurry catalyst in oil is a catalyst composition prepared by;
a) mixing a Group VI B metal oxide and aqueous ammonia to form a Group VI metal compound aqueous mixture;
b) sulfiding, in a first reaction zone, the aqueous mixture with a gas comprising hydrogen sulfide to a dosage greater than 8 SCF of hydrogen sulfide per pound of Group VIB metal to form a slurry;
c) promoting the slurry with a Group VIII metal;
d) mixing the promoted slurry with a first hydrocarbon oil having a viscosity of at least 2 cSt at 212°
F. to form a reaction mixture;
e) combining the reaction mixture with hydrogen gas and a second hydrocarbon oil in a second reaction zone to form an active catalyst composition, the second hydrocarbon oil having a boiling point in the range from 50°
F. to 300°
F. and further having a lower viscosity than the first hydrocarbon oil; and
f) transporting the tailored synthetic crude to the target refinery.
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Abstract
The instant invention is directed to a process wherein a heavy oil feedstock upgrader alters its mode of operation of its full conversion hydroprocessing unit to create a custom tailored synthetic crude feedstock based upon data communicated from a target refinery and data communicated from the heavy oil feedstock upgrader. The data from the target refinery is data that represents refining process data and linear program modeling along with analysis by a refining planner to calculate the optimum “synthetic trim crude” that will optimize the effective use of the target refinery'"'"'s capacity and equipment.
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Citations
21 Claims
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1. An integrated process for upgrading a heavy oil feedstock, comprising:
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a) establishing a communication link between an upgrading facility and a target refinery; b) acquiring a refining data set from the target refinery that characterizes a tailored synthetic crude having a 95% boiling point as determined by ASTM D1160 of less than 1000°
F. and API gravity of greater than 10;c) generating a feedstock data set from the upgrading facility that characterizes a heavy oil feedstock having a 95% boiling point as determined by ASTM D1160 of greater than 1000°
F.;d) using the refining data set from the target refinery and the feedstock data set from the upgrading facility to generate an upgrading dataset of select upgrading process conditions; e) upgrading the heavy oil feedstock at the select upgrading process conditions within the upgrading facility and recovering a tailored synthetic crude, wherein the upgrading comprises contacting the heavy oil feedstock with hydrogen in the presence of an active unsupported slurry catalyst wherein the active unsupported slurry catalyst in oil is a catalyst composition prepared by; a) mixing a Group VI B metal oxide and aqueous ammonia to form a Group VI metal compound aqueous mixture; b) sulfiding, in a first reaction zone, the aqueous mixture with a gas comprising hydrogen sulfide to a dosage greater than 8 SCF of hydrogen sulfide per pound of Group VIB metal to form a slurry; c) promoting the slurry with a Group VIII metal; d) mixing the promoted slurry with a first hydrocarbon oil having a viscosity of at least 2 cSt at 212°
F. to form a reaction mixture;e) combining the reaction mixture with hydrogen gas and a second hydrocarbon oil in a second reaction zone to form an active catalyst composition, the second hydrocarbon oil having a boiling point in the range from 50°
F. to 300°
F. and further having a lower viscosity than the first hydrocarbon oil; andf) transporting the tailored synthetic crude to the target refinery. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21)
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Specification