Refinery process for heavy oil and bitumen
First Claim
1. A process for upgrading crude oil or heavy oil or bitumen to formulate refined hydrocarbon products, comprising:
- (a) providing a source of crude oil or bitumen or heavy oil feedstock and treating said feedstock to form at least one distilled fraction and a non-distilled bottom fraction;
(b) optionally treating said non-distilled bottom fraction to a hydrocarbon treatment operation to form a treated fraction and a treated bottom fraction;
(c) processing said at least one distilled fraction and/or said treated fraction in a hydrocarbon cracking operation to form a processed stream;
(d) feeding the non-distilled bottom fraction or the treated bottom fraction to a syngas generating circuit for formulating a hydrogen lean syngas stream via a partial oxidation reaction;
(e) treating at least a portion of said hydrogen lean syngas stream to a water gas shift (WGS) reaction to generate an optimum Fischer-Tropsch syngas;
(f) treating said optimum Fischer-Tropsch syngas stream in a Fischer-Tropsch unit to formulate synthesized hydrocarbons; and
(g) blending a portion of said synthesized hydrocarbons with a portion of said processed stream to form said refined hydrocarbon products comprise naphtha, gasoline, diesel, kerosene, jet fuel or a combination thereof.
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Abstract
A bitumen and heavy oil upgrading process and system is disclosed for the synthesis of hydrocarbons, an example of which is synthetic crude oil (SCO). The process advantageously avoids the waste attributed to residuum and/or petcoke formation which has a dramatic effect on the yield of hydrocarbon material generated. The process integrates Fischer-Tropsch technology with gasification and hydrogen rich gas stream generation. The hydrogen rich gas generation is conveniently effected using singly or in combination a hydrogen source, a hydrogen rich vapor from hydroprocessing and the Fischer-Tropsch process, a steam methane reformer (SMR) and autothermal reformer (ATR) or a combination of SMR/ATR. The feedstock for upgrading is distilled and the bottoms fraction is gasified and converted in a Fischer-Tropsch reactor. A resultant hydrogen lean syngas is then exposed to the hydrogen rich gas stream to optimize the formation of, for example, the synthetic crude oil.
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Citations
28 Claims
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1. A process for upgrading crude oil or heavy oil or bitumen to formulate refined hydrocarbon products, comprising:
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(a) providing a source of crude oil or bitumen or heavy oil feedstock and treating said feedstock to form at least one distilled fraction and a non-distilled bottom fraction; (b) optionally treating said non-distilled bottom fraction to a hydrocarbon treatment operation to form a treated fraction and a treated bottom fraction; (c) processing said at least one distilled fraction and/or said treated fraction in a hydrocarbon cracking operation to form a processed stream; (d) feeding the non-distilled bottom fraction or the treated bottom fraction to a syngas generating circuit for formulating a hydrogen lean syngas stream via a partial oxidation reaction; (e) treating at least a portion of said hydrogen lean syngas stream to a water gas shift (WGS) reaction to generate an optimum Fischer-Tropsch syngas; (f) treating said optimum Fischer-Tropsch syngas stream in a Fischer-Tropsch unit to formulate synthesized hydrocarbons; and (g) blending a portion of said synthesized hydrocarbons with a portion of said processed stream to form said refined hydrocarbon products comprise naphtha, gasoline, diesel, kerosene, jet fuel or a combination thereof. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28)
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Specification