Fuel compositions from light tight oils and high sulfur fuel oils

• US 10,883,056 B2
• Filed: 10/18/2016
• Issued: 01/05/2021
• Est. Priority Date: 10/18/2016
• Status: Active Grant

• Current Assignee: Mawetal, LLC
• Original Assignee: Mawetal, LLC
• Inventors: Wohaibi, Mohammed, Pruitt, Tom F.
• Primary Examiner(s): Boyer, Randy
• Application Number:
  US16/089,932
• Publication Number:
  US 20190136144A1
• Time in Patent Office: 1,540 Days
• CPC Class Codes: C10C 3/002 by thermal means
• CPC Class Codes: C10G 2300/1033 Oil well production fluids
• CPC Class Codes: C10G 2300/202 Heteroatoms content, i.e. S, N, O, P
• CPC Class Codes: C10G 63/06 plural parallel stages only
• CPC Class Codes: C10G 65/02 plural serial stages only
• CPC Class Codes: C10G 67/0454 Solvent desasphalting
• CPC Class Codes: C10G 67/0463 The hydrotreatment being a hydrorefining
• CPC Class Codes: C10J 2300/165 integrated with a gas turbine or gas motor gas turbine plants provided with a gas producer F02C3/28; engines using solid fuels F02B43/08
• CPC Class Codes: C10J 2300/1675 making use of a steam turbine
• CPC Class Codes: C10J 2300/1807 Recycle loops, e.g. gas, solids, heating medium, water
• CPC Class Codes: C10J 3/84 with means for removing dust or tar from the gas
• CPC Class Codes: C10L 1/04 essentially based on blends of hydrocarbons
• CPC Class Codes: C10L 2200/0407 Specifically defined hydrocarbon fractions as obtained from, e.g. a distillation column
• 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
• CPC Class Codes: C10L 2270/04 for turbines, planes, power generation
• CPC Class Codes: C10L 2270/08 for small applications, such as tools, lamp oil, welding
• CPC Class Codes: C10L 2290/06 Heat exchange, direct or indirect
• CPC Class Codes: C10L 2290/10 Recycling of a stream within the process or apparatus to reuse elsewhere therein
• CPC Class Codes: C10L 2290/543 : Distillation, fractionation or rectification for separating fractions, components or impurities during preparation or upgrading of a fuel
• CPC Class Codes: C10L 2290/544 : Extraction for separating fractions, components or impurities during preparation or upgrading of a fuel
• CPC Class Codes: F04D 13/086 : the pump and drive motor are both submerged
• CPC Class Codes: F04D 29/0462 : Bearing cartridges
• CPC Class Codes: F04D 29/606 : Mounting in cavities
• CPC Class Codes: F05B 2240/52 : Axial thrust bearings
• CPC Class Codes: Y02E 20/16 : Combined cycle power plant [CCPP], or combined cycle gas turbine [CCGT]
• CPC Class Codes: Y02E 20/18 : Integrated gasification combined cycle [IGCC], e.g. combined with carbon capture and storage [CCS]

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.

Claims

1. 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:

(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,

(d) wherein such combination has final (1) combination density within 820 to 880 Kg/M3 at 15°

C., (2) sulfur content of 0.5 wt. % or less and (3) metals content of 40 ppmwt or less, except if (M) % is zero or otherwise less than 100% and the remainder is (L) %/(H) % in ratio of 0.4/1 to 0.6/1, then sulfur content is 0.25 wt. % or less,

(e) wherein (L) comprises components of naphtha and kerosene range materials, which are refined or partially refined, unrefined or extracted and used without being subject to any fractionation, hydrotreating or other treatment process, except optional separation of light gases or water, having an initial boiling point of 38°

C. (100°

F.) or less having a ninety percent (90%) plus final boiling point of 190°

C. (374°

F.) to about 205°

C. (401°

F.), where (L) range components contribute to (L) range bulk density and to final combination density even though individual constituents of (L) may fall outside said combination density range,

(f) wherein (M) comprises refined or partially refined petroleum fractions having initial boiling point of about 190°

C. (374°

F.) to about 205°

C. (401°

F.) and a 90% plus final boiling point of about 385°

C. (725°

F.) to 410°

C. (770°

F.), where (M) range components contribute to (M) range bulk density and to final combination density, even though individual constituents of (M) may fall outside said combination density range, and

(g) wherein (H) comprises refined or partially refined petroleum fractions having initial boiling point of about 385°

C. (725°

F.) to about 410°

C. (770°

F.) and a final boiling point of about 815°

C. (1499°

F.) or less, where final boiling point of (H) is highest boiling point of a component of a stream treated by solvent separation to reduce presence of asphaltenes and metals then recovered and subsequently treated by hydroconversion or hydrotreating to a level to enable addition of such stream to a combination of (L), (M) and (H) to meet final sulfur content for the combination fuel, and where (H) range components contribute to (H) range bulk density and to final combination density even though individual constituents of (H) may fall outside said combination density range.

2. A fuel in accordance with claim 1 wherein (M) is present from 10 to 90% and remainder is (L)/(H) in ratio of 0.4/1 to 0.6/1.

3. A fuel in accordance with claim 1 wherein (M) is present from 20 to 80% and remainder is (L)/(H) in equal parts 0.9/1 to 1/0.9 or in ratio of 0.4/1 to 0.6/1.

4. A fuel in accordance with claim 1 wherein (M) is present from 30 to 70% and remainder is (L)/(H) in equal parts 0.9/1 to 1/0.9 or in ratio of 0.4/1 to 0.6/1.

5. A fuel in accordance with claim 1 wherein sulfur is 0.1 wt. % or less metals content is 25 ppmwt or less.

6. A fuel in accordance with claim 1 characterized in that 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 total sulfur is 0.25 wt. %.

7. A fuel in accordance with claim 1 wherein (M) ranges from 40% to 60% by volume and the remainder is (L) and (H) at (L) %/(H) % in ratio of 0.9/1 to 1/0.9.

8. A fuel in accordance with claim 1 wherein total sulfur is 0.1 wt. % or less, metals are 25 ppmwt or less, said fuel comprising hydrocarbons derived from a combination of light tight oil and hydroconverted high sulfur fuel oil, said fuel having an initial boiling point being the lowest boiling point of any fraction of either said oils at atmospheric distillation conditions and highest boiling point being the highest boiling point of the residual portion of said high sulfur fuel oil which is soluble in a solvent suitable for solvent separation.

9. A fuel in accordance with claim 1 having the following properties:

(a) sulfur from 0.05 wt. % (500 ppmwt) to 0.1 wt. % (1000 ppmwt),

(b) total metals of 25 ppmwt or less,

(c) HHV from 43.81 to 45.15 MJ/kg, and

(d) LHV from 41.06 to 42.33 MJ/kg.

10. A fuel in accordance with claim 1 having one or more the following additional properties:

(a) kinematic viscosity at 50°

C. of less than 10 mm²/s where 1 mm²/s=1 cSt,

(b) carbon residue is the range of 0.32 to 1.5,

(c) existent gum is less than 5,

(d) oxidation stability is about 0.5, and

(e) acid number less than 0.05 mg KOH/g.