Process and device for treating high sulfur heavy marine fuel oil for use as feedstock in a subsequent refinery unit

• US 10,533,141 B2
• Filed: 08/14/2018
• Issued: 01/14/2020
• Est. Priority Date: 02/12/2017
• Status: Active Grant

• Current Assignee: Magema Technology, LLC
• Original Assignee: Mag{Tilde Over}Ma Technology LLC
• Inventors: Moore, Michael Joseph, Klussmann, Bertrand Ray, White, Carter James
• Primary Examiner(s): Boyer, Randy
• Assistant Examiner(s): Valencia, Juan C
• Application Number:
  US16/103,897
• Publication Number:
  US 20190016974A1
• Time in Patent Office: 518 Days
• CPC Class Codes: B01D 3/343 the substance being a gas
• CPC Class Codes: B01D 53/1481 Removing sulfur dioxide or sulfur trioxide
• CPC Class Codes: B01J 21/04 Alumina
• CPC Class Codes: B01J 2208/00557 controlling the residence time inside the reactor vessel
• CPC Class Codes: B01J 2208/02 with stationary particles
• CPC Class Codes: B01J 2208/025 Two or more types of catalyst
• CPC Class Codes: B01J 23/24 Chromium, molybdenum or tungsten
• CPC Class Codes: B01J 23/40 of the platinum group metals
• CPC Class Codes: B01J 23/74 Iron group metals
• CPC Class Codes: B01J 8/008 Details of the reactor or of the particulate material; Processes to increase or to retard the rate of reaction B01J8/0285, B01J8/067, B01J8/087, B01J8/1836 take precedence
• CPC Class Codes: B01J 8/0278 Feeding reactive fluids for solid material B01J8/0015
• CPC Class Codes: B01J 8/0292 with stationary packing material in the bed, e.g. bricks, wire rings, baffles
• CPC Class Codes: B01J 8/0457 the beds being placed in separate reactors
• CPC Class Codes: B01J 8/0492 Feeding reactive fluids for solid material, see B01J8/0015
• CPC Class Codes: C10G 2300/1037 Hydrocarbon fractions
• CPC Class Codes: C10G 2300/1044 Heavy gasoline or naphtha having a boiling range of about 100 - 180 °C
• CPC Class Codes: C10G 2300/1048 Middle distillates
• CPC Class Codes: C10G 2300/1059 Gasoil having a boiling range of about 330 - 427 °C
• CPC Class Codes: C10G 2300/107 Atmospheric residues having a boiling point of at least about 538 °C
• CPC Class Codes: C10G 2300/1077 Vacuum residues
• CPC Class Codes: C10G 2300/201 : Impurities
• CPC Class Codes: C10G 2300/202 : Heteroatoms content, i.e. S, N, O, P
• CPC Class Codes: C10G 2300/205 : Metal content
• CPC Class Codes: C10G 2300/206 : Asphaltenes
• CPC Class Codes: C10G 2300/207 : Acid gases, e.g. H2S, COS, SO2, HCN
• CPC Class Codes: C10G 2300/208 : Sediments, e.g. bottom sediment and water or BSW
• CPC Class Codes: C10G 2300/30 : Physical properties of feedstocks or products
• CPC Class Codes: C10G 2300/302 : Viscosity
• CPC Class Codes: C10G 2300/308 : Gravity, density, e.g. API
• CPC Class Codes: C10G 2300/4012 : Pressure
• CPC Class Codes: C10G 2300/4018 : Spatial velocity, e.g. LHSV, WHSV
• CPC Class Codes: C10G 2300/4062 : Geographical aspects, e.g. different process units form a combination process at different geographical locations
• CPC Class Codes: C10G 2300/70 : Catalyst aspects
• CPC Class Codes: C10G 2300/80 : Additives
• CPC Class Codes: C10G 2400/04 : Diesel oil
• CPC Class Codes: C10G 2400/06 : Gasoil
• CPC Class Codes: C10G 25/003 : Specific sorbent material, not covered by C10G25/02 or C10G25/03
• CPC Class Codes: C10G 25/02 : with ion-exchange material
• CPC Class Codes: C10G 45/00 : Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds
• CPC Class Codes: C10G 45/02 : to eliminate hetero atoms without changing the skeleton of the hydrocarbon involved and without cracking into lower boiling hydrocarbons; Hydrofinishing
• CPC Class Codes: C10G 45/04 : characterised by the catalyst used
• CPC Class Codes: C10G 45/06 : containing nickel or cobalt metal, or compounds thereof
• CPC Class Codes: C10G 45/08 : in combination with chromium, molybdenum, or tungsten metals, or compounds thereof
• CPC Class Codes: C10G 45/22 : with hydrogen dissolved or suspended in the oil
• CPC Class Codes: C10G 47/02 : characterised by the catalyst used
• CPC Class Codes: C10G 65/04 : including only refining steps
• CPC Class Codes: C10G 65/16 : including only refining steps
• CPC Class Codes: C10G 67/02 : plural serial stages only
• CPC Class Codes: C10G 67/06 : including a sorption process as the refining step in the absence of hydrogen
• CPC Class Codes: C10G 69/02 : plural serial stages only
• CPC Class Codes: C10G 7/00 : Distillation of hydrocarbon oils
• CPC Class Codes: C10L 1/04 : essentially based on blends of hydrocarbons
• CPC Class Codes: C10L 1/12 : Inorganic compounds
• CPC Class Codes: C10L 1/14 : Organic compounds
• CPC Class Codes: C10L 1/1608 : Well defined compounds, e.g. hexane, benzene
• CPC Class Codes: C10L 2200/0263 : Sulphur containing compounds
• CPC Class Codes: C10L 2200/0438 : Middle or heavy distillates, heating oil, gasoil, marine fuels, residua
• CPC Class Codes: C10L 2270/02 : for internal combustion engines
• CPC Class Codes: C10L 2270/026 : for diesel engines, e.g. automobiles, stationary, marine

Abstract

A multi-stage process for transforming a high sulfur ISO 8217 compliant Feedstock Heavy Marine Fuel Oil involving a core desulfurizing process that produces a Product Heavy Marine Fuel Oil that can be used as a feedstock for subsequent refinery process such as anode grade coking, needle coking and fluid catalytic cracking. The Product Heavy Marine Fuel Oil exhibits multiple properties desirable as a feedstock for those processes including a sulfur level has a maximum sulfur content (ISO 14596 or ISO 8754) between the range of 0.05 mass % to 1.0 mass. A process plant for conducting the process is also disclosed.

Claims

1. A process for treating high sulfur Heavy Marine Fuel Oil for use as feedstock in a subsequent refinery unit, the process comprising:

mixing a quantity of Feedstock Heavy Marine Fuel Oil with a quantity of Activating Gas mixture to give a Feedstock Mixture;

contacting the Feedstock Mixture with one or more catalysts under reactive conditions to form a Process Mixture from said Feedstock Mixture;

receiving said Process Mixture and separating hydrocarbon liquid components of the Process Mixture from any bulk gaseous components of the Process Mixture;

subsequently separating any residual gaseous components and any by-product hydrocarbon components from the hydrocarbon liquid components to give a Product Heavy Marine Fuel Oil; and

, discharging the Product Heavy Marine Fuel Oil, wherein the Feedstock Heavy Marine Fuel Oil complies with ISO 8217 (2017) and has a sulfur content (ISO 14596 or ISO

     8754) between the range of 5.0 mass % to 1.0 mass %, and wherein said Feedstock Heavy Marine Fuel Oil has;

a maximum of kinematic viscosity at 50°

C. (ISO

     3104) between the range from 180 mm²/s to 700 mm²/s;

a maximum of density at 15°

C. (ISO

     3675) between the range of 991.0 kg/m³ to 1010.0 kg/m³;

a CCAI in the range of 780 to 870;

a flash point (ISO

     2719) no lower than 60°

C.;

a total sediment—

aged (ISO 10307-2) of less than 0.10 mass %;

a carbon residue—

micro method (ISO

     10370) less than 20.00 mass % and wherein the Product Heavy Marine Fuel Oil has a sulfur content (ISO 14596 or ISO

     8754) between the range of 0.50 mass % to 0.05 mass % and wherein said Product Heavy Marine Fuel Oil has;

a maximum of kinematic viscosity at 50°

C. (ISO

     3104) between the range from 180 mm²/s to 700 mm²/s;

a maximum of density at 15°

C. (ISO

     3675) between the range of 991.0 kg/m³ to 1010.0 kg/m³;

a CCAI in the range of 780 to 870;

a flash point (ISO

     2719) no lower than 60°

C.;

a total sediment—

aged (ISO 10307-2) of less than 0.10 mass %;

a carbon residue—

micro method (ISO

     10370) less than 20.00 mass %.

2. The process of claim 1, further comprising fractionating the Product Heavy Marine Fuel Oil to remove a light to middle distillate fraction, said light to middle distillate fraction have a maximum boiling point less than 650°

F.

3. The process of claim 1 wherein the one or more catalysts comprises:

a porous inorganic oxide catalyst carrier and a transition metal catalyst, wherein the porous inorganic oxide catalyst carrier is at least one carrier selected from the group consisting of alumina, alumina/boria carrier, a carrier containing metal-containing aluminosilicate, alumina/phosphorus carrier, alumina/alkaline earth metal compound carrier, alumina/titania carrier and alumina/zirconia carrier, and wherein the transition metal catalyst is one or more metals selected from the group consisting of group 6, 8, 9 and 10 of the Periodic Table; and

wherein the Activating Gas is selected from mixtures of nitrogen, hydrogen, carbon dioxide, gaseous water, and methane, such that Activating Gas has an ideal gas partial pressure of hydrogen (p_H2) greater than 80% of the total pressure of the Activating Gas mixture (P).

4. The process of claim 1 wherein the reactive conditions comprise;

a ratio of the quantity of the Activating Gas to the quantity of Feedstock Heavy Marine Fuel Oil is in the range of 250 scf gas/bbl of Feedstock Heavy Marine Fuel Oil to 10,000 scf gas/bbl of Feedstock Heavy Marine Fuel Oil; and

, a total pressure is between of 250 psig and 3000 psig; and

, an indicated temperature is between of 500°

F. to 900°

F., and, a liquid hourly space velocity is between 0.05 oil/hour/m³ catalyst and 1.0 oil/hour/m³ catalyst.

5. The process of claim 1 wherein said Product Heavy Marine Fuel Oil is a feedstock in subsequent refinery process selected from the group consisting of anode grade coking process unit;

needle grade coking process unit and fluid catalytic cracking process unit.

6. The process of claim 1 wherein said Product Heavy Marine Fuel Oil is a suitable feedstock for anode grade coking having a vanadium content less than about 100 ppmw and nickel content less than about 100 ppmw.

7. The process of claim 1 wherein said Product Heavy Marine Fuel Oil is a suitable feedstock for needle grade coking having a vanadium content less than about 50 ppmw;

Nickel content less than about 50 ppmw;

a aromatic content in the range from about 50-80 wt %;

an asphaltene content less than about 8 wt %;

a nitrogen content in the range from about 0.0-0.7 wt; and

an ash value less than about 100 ppmw.

8. The process of claim 1 wherein said Product Heavy Marine Fuel Oil is a suitable feedstock for a fluid catalytic cracking unit and has a sulfur content in the range of 0.1 to 0.05 wt % sulfur;

a vanadium content less than about 50 ppmw;

a nickel content less than about 50 ppmw;

an asphaltene content less than 10 wt %;

a micro carbon residue (MCR) content of in the range of 5-20% wt and a nitrogen content less than 0.7 wt.