[0001] The present invention relates to a process for the thermal cracking of a residual
hydrocarbon oil. More specifically, the present invention relates to a process for
the thermal cracking of a residual hydrocarbon oil, wherein the thermal cracking is
integrated with a gasification treatment of an asphaltene-rich bottom product derived
from said thermal cracking.
[0002] Residual hydrocarbon oils may be obtained as the bottom product of the distillation
of crude oil at atmospheric pressure ("atmospheric" or "long" residue) or at reduced
pressure ("vacuum" or "short" residue).
[0003] Converting residual hydrocarbon oils by means of thermal cracking is already known
for a long time. Basically, thermal cracking is an endothermic, non-catalytic process
in which larger hydrocarbon molecules of residual oil fractions are broken into smaller
molecules. The energy required for breaking the larger molecules into smaller ones
is supplied by heating the residual hydrocarbon oil feed to a sufficiently high temperature.
However, a generally recognised problem in thermal cracking operations is the formation
of coke, particularly at more severe cracking conditions. There are several ways known
in the art to suppress this coke formation. For instance, if the conversion level
of the heavy hydrocarbons, i.e. those hydrocarbons having a boiling point of 520 °C
and higher (520 °C+ hydrocarbons), is kept sufficiently low then the formation of
coke may be largely prevented. Depending on the type of feedstock and severity of
the thermal cracking, said conversion level (further referred to as 520 °C+ conversion,
i.e. the weight percentage of the hydrocarbons having a boiling point of 520 °C and
higher present in the feed which are converted into lower boiling components) should
be kept below about 30% by weight. Another way to substantially prevent coke formation
is to deasphalt the residual hydrocarbon oil prior to thermal cracking, in which case
520 °C+ conversions of 30% by weight or higher are attainable. A drawback, however,
is that the asphaltenes removed can no longer contribute to the production of distillates
without further upgrading separately from the deasphalted oil.
[0004] The furnace-soaker configuration is well known in the field of thermal cracking.
Within the furnace, heating of the residual hydrocarbon oil feed takes place and a
substantial part of the hydrocarbon oil feed is already cracked into lower boiling
components. The heated oil is then fed into the soaker or "reaction chamber". In this
soaker the cracking reactions continue. Since cracking in the furnace is relatively
cheap and easy, the usual aim is to convert as much as possible high boiling material
in the furnace and to use the soaker for further increasing the conversion level.
However, the attainable conversion level in the furnace is restricted by the formation
of coke. In the conventional furnace-soaker configuration, wherein a final 520 °C+
conversion of about 30% by weight can be attained, about half of the final conversion
(i.e. about 15% by weight) therefore takes place in the furnace and the other half
in the soaker. If the conversion level in the furnace would be higher, which implies
that cracking conditions are more severe, then coke will be rapidly formed and will
deposit onto the internals of the furnace, thus causing a rapid decrease in heating
efficiency of the furnace and hence a decrease in the final conversion.
[0005] On the other hand, coke formation and consequent deposition of coke on metal parts
in the soaker is also a commonly recognised problem in conventional thermal cracking
processes. For this reason, the 520 °C+ conversion in the soaker is also bound to
a maximum. It will be understood that too rapid a coke formation in the soaker also
negatively influences the runtime of the process after each cleaning operation of
the equipment.
[0006] In addition, since normally no heat is provided to the soaker, the temperature of
the heated and partially converted oil decreases by about 15-30 °C during passage
through the soaker. This decrease in temperature is mainly caused by the endothermic
character of the cracking reactions, the evaporation of light distillates and the
heat loss to the environment via the soaker walls. As a result of this temperature
drop across the soaker, there is a decrease in cracking reactions in the direction
of the oil flow. Accordingly, the cracking efficiency within the soaker is not at
an optimum level.
[0007] In EP-A-0,328,216 a process for the thermal cracking of residual hydrocarbon oils
is disclosed wherein a furnace is dispensed with and wherein the residual hydrocarbon
oil feed is directly fed into a soaker together with hot synthesis gas. This synthesis
gas originates from gasification of an asphaltene-rich heavy hydrocarbon oil derived
from the cracked residue of thermal cracking. Accordingly, the heating of the residual
hydrocarbon oil feed is attained by direct heat exchange with the hot synthesis gas.
Although this process performs well and provides a very high level of integration
between thermal cracking and gasification, it cannot be easily implemented in an existing
refinery having thermal cracking and gasification capacity, because that would require
radical changes in both refinery line-up and particularly in the thermal cracking
equipment. Such implementation would consequently be very expensive making the economic
feasibility questionable.
[0008] The present invention aims to improve the final 520 °C+ conversion of thermal cracking
processes conducted in furnace-soaker configurations to a level of at least 35% by
weight. Furthermore, the present invention aims to provide a thermal cracking process
which can be relatively easy and at relatively low expenses be implemented in an existing
refinery having at least thermal cracking capacity and optionally gasification capacity.
More specifically, the present invention aims to suppress coke formation and deposition
in both furnace and soaker, while at the same time improving the cracking efficiency
within the soaker, thus increasing both 520 °C+ conversion and runtime, which self
evidently is beneficial from an economic point of view.
[0009] All the before mentioned objects have been met by the present invention which relates
to a process for the thermal cracking of a residual hydrocarbon oil wherein a final
520 °C+ conversion of at least 35% by weight is attained, i.e. wherein at least 35%
by weight of the hydrocarbons having a boiling point of 520 °C and higher present
in the residual hydrocarbon oil are converted into lower boiling components, said
process comprising the steps of:
(a) heating the residual hydrocarbon oil feed in a furnace to a temperature in the
range of from 400 to 510 °C for sufficient time to achieve 30 to 45% of the final
520 °C+ conversion;
(b) feeding the partially converted, hot hydrocarbon oil produced in step (a) and
a hot hydrogen-containing gas into a soaker, said hydrogen-containing gas having a
sufficiently high temperature to maintain the temperature of the hydrocarbon oil in
the soaker by means of direct heat exchange at a value in the range of from 420 to
650 °C, in which soaker the remainder up to 100% of the final 520 °C+ conversion takes
place; and
(c) recovering a gaseous fraction containing the hydrogen-containing gas and a cracked
residue from the soaker.
[0010] Suitable residual hydrocarbon oil feeds which may be used in step (a) are heavy hydrocarbonaceous
feedstocks comprising at least 25% by weight of 520 °C+ hydrocarbons, preferably more
than 37.5% by weight 520 °C+ hydrocarbons and even more preferably more than 75% by
weight of 520 °C+ hydrocarbons. Feedstocks comprising more than 90% by weight of 520
°C+ hydrocarbons are most advantageously used. Suitable feedstocks thus include atmospheric
residues and vacuum residues. If desired, the residual hydrocarbon oil may be blended
with a heavy distillate fraction, such as e.g. a cycle oil obtained by catalytic cracking
of a hydrocarbon oil fraction, or with a heavy hydrocarbon oil obtained by extraction
from a residual hydrocarbon oil.
[0011] In step (a) of the process according to the present invention the residual hydrocarbon
is heated in the furnace to a temperature in the range of from 400 to 510 °C for sufficient
time to achieve 30 to 45% of the final 520 °C+ conversion. The precise combination
of temperature and residence time in the furnace must in any event be such that 30-45%
of the final 520 °C+ conversion takes place in this furnace. Since in normal thermal
cracking operations involving a furnace and a subsequent soaker about 50% of the final
conversion takes place in the furnace, this implies that relatively mild thermal cracking
conditions are applied in the furnace, for instance those conditions usually applied
in visbreaking operations. The result of applying relatively mild conditions in the
furnace is that less coking occurs in this furnace, thus enabling longer runtimes.
It will be understood that this is economically highly attractive.
[0012] In order to compensate for the relatively low conversion level in the furnace, the
conversion level in the soaker must be higher than usual, i.e. higher than 50% of
the final 520 °C+ conversion. In the process of the present invention this is attained
by introducing hot hydrogen-containing gas into the soaker. In this manner the earlier
mentioned temperature drop across the soaker in the direction of the oil flow is avoided
and the thermal cracking reactions accordingly can proceed along the entire soaker
length at a similar rate. The hot hydrogen-containing gas can be introduced into the
soaker at one or more of its internals and/or at the bottom of the soaker. In the
event the heated hydrocarbon oil feed from the furnace is fed into the bottom of the
soaker, the hot gas is preferably introduced at one or more of the internals of the
soaker to warrant an efficient heating. If, on the other hand, said oil feed enters
the soaker at the top, the hot gas can be suitably introduced at the bottom of the
soaker, as in this mode of operation the hot gas and the oil flow move in a countercurrent
mode through the soaker which enables an efficient heat exchange between the hot gas
and the oil.
[0013] Beside its function as a heating medium, the hot gas also serves as a stripping medium
for removing the lighter fractions from the cracked oil, thus increasing the stability
of the remaining liquid, which in return results in decreased coke formation on the
metal parts inside the soaker which are in direct contact with the hot gas. In this
way longer runtimes and a deeper final 520 °C+ conversion can be attained. The use
of hydrogen-containing gas as a stripping medium in the thermal cracking process of
the present invention also forms a separate aspect of the present invention. The presence
of hydrogen during thermal cracking is also considered to be favourable for the stability
of the remaining liquid and thus for the suppression of coke formation. Thermal cracking
in the presence of hydrogen, namely, is known to reduce the formation of carbonaceous
products during thermal cracking of heavy hydrocarbon oils and to be advantageous
for the stability of the oils formed, such as for instance reported in JP-A-62-96589.
[0014] The hydrogen-containing gas used in step (b) in principle may be any gas which is
stable at elevated temperatures and which contains hydrogen. It may for instance be
pure hydrogen or a hydrogen-rich gas. Particularly in a refinery where hydrotreatment
units are present, the use of such gases may be beneficial. Hot synthesis gas may
also be applied as the hot hydrogen-containing gas. This is a very feasible option
if the refinery involved has a gasification unit where hot synthesis gas is produced
by gasification, i.e. partial oxidation, of heavy asphaltene-rich oil fractions. Furthermore,
synthesis gas from a gasification unit may also contain soot. Without wishing to be
bound by any particular theory, the presence of soot in the soaker may be beneficial,
since it offers a surface area to deposit coke and coke precursors, thus inhibiting
fouling of the metal parts in the soaker, and it may act catalytically in activating
the hydrogen present in the synthesis gas due to the metals present in the soot. In
this connection the presence of nickel (as nickel sulphide) is considered particularly
important. It will be understood that due to its aforementioned advantageous effects
in thermal cracking reactions, hydrogen may also be present in step (a) of the process
according to the present invention, i.e. in the furnace.
[0015] In any event, the hydrogen-containing gas must be stable at such high temperatures
which are necessary to maintain the temperature of the hydrocarbon oil in the soaker
at a value in the range of from 420 to 650 °C, preferably 450 to 600 °C, by means
of direct heat exchange. As already mentioned before, by introducing heat and hydrogen
into the soaker in the form of hot hydrogen-containing gas, a temperature drop across
the soaker is at least significantly reduced and coke formation on the metal parts
inside the soaker being in direct contact with the hydrogen-containing gas is suppressed,
as a result of which 55% or more of the final conversion can be realised in the soaker
without excessive coking. Because coking is also significantly reduced in the furnace
due to the milder cracking conditions, the overall result is less coke deposition
on the internals of the furnace and soaker and hence longer run times can be achieved.
In other words, by shifting the conversion to a certain extent and under certain conditions
from the furnace to the soaker, coke formation is reduced and longer run times are
attained.
[0016] The total pressure in the soaker may vary from 2 to 100 bar. For economic reasons
it is, however, preferred to apply total pressures in the range of from 2 to 65 bar.
At pressures above 65 bar and especially at pressures above 100 bar, the high pressure
equipment needed will become so expensive that economically feasible operation of
the process will become increasingly difficult.
[0017] After the thermal cracking has taken place a gaseous fraction containing the hydrogen-containing
gas and a cracked residue are recovered from the soaker in step (c). The said gaseous
fraction can subsequently be further separated in a fractionator into a top fraction
containing methane, ethane and the hydrogen-containing gas, one or more gaseous lower
hydrocarbons, i.e. propane, butane and the like, and a bottom fraction. If desired,
the hydrogen-containing gas can then be separated from the said top-fraction, for
instance by pressure swing adsorption. The cracked residue can have different destinations.
It can for instance be partially or totally recycled and blended with the furnace
and/or soaker feedstock in order to be once again subjected to thermal cracking conditions.
It is however preferred that the cracked residue is further separated in a subsequent
step (d) into one or more asphaltene-poor fractions and an asphaltene-rich bottom
fraction. This separation can suitably be performed by means of vacuum flashing or
vacuum distillation. In this mode of operation the bottom fraction obtained from fractionating
the gaseous fraction recovered from the soaker may optionally be vacuum flashed together
with said cracked residue.
[0018] The asphaltene-rich bottom fraction can subsequently be used in several ways. It
can for instance be applied in bitumen for road and roofing purposes, in emulsion
fuels or in solid fuels by means of pelletizing. In a preferred embodiment of the
present invention, however, the asphaltene-rich bottom fraction is partially oxidised
(gasified) in an additional step (e) in the presence of oxygen and steam, usually
high pressure steam, thereby producing hot synthesis gas. This synthesis gas, in return,
can be applied as clean fuel gas in the refinery or for the cogeneration of power
and steam, hydrogen manufacture and hydrocarbon synthesis processes. For the purpose
of the present invention it is however preferred that at least a part of the hot synthesis
gas produced in step (e) is introduced into the soaker in accordance with step (b)
of the process according to the present invention.
[0019] In figure 1 an example of a refinery line-up is depicted involving a preferred embodiment
of the thermal cracking process according to the present invention, i.e. a furnace-soaker
configuration integrated with a gasification unit.
[0020] Residual hydrocarbon oil feed (6) is fed into furnace (2) where it is heated to a
temperature of from 400 to 510 °C and where 30-45% of the final conversion takes place.
The hot, partially converted hydrocarbon oil (7) leaves the furnace and is fed into
soaker (3) together with hot synthesis gas (9) produced in gasification unit (1) via
partial oxidation of asphaltene-rich bottom fraction (19) in the presence of oxygen/steam
(8). Gaseous fraction (10) and cracked residue (15) are recovered from the soaker
(3). Gaseous fraction (10) is separated in fractionator (4) into top fraction (11)
-containing methane, ethane and synthesis gas-, light hydrocarbon fractions (12) and
(13) and bottom fraction (14). This bottom fraction (14) is fed into vacuum flasher
(5) together with cracked residue (15), where separation into the asphaltene-poor
fractions (16), (17) and (18) and the asphaltene-rich bottom fraction (19) takes place.
Part of the bottom fraction (19) is subsequently used as feedstock for gasification
unit (1).
[0021] The invention is further illustrated by the following examples.
Example 1 and Comparative Example 1
[0022] When subjecting a Middle East short residue, having the properties as indicated in
Table I, to thermal cracking, a final 520 °C+ conversion of 40% by weight can be attained
when applying the process according to the present invention as illustrated by figure
1 (example 1). Under similar conditions, a conventional thermal cracking process only
yields a final 520 °C+ conversion of 31% by weight (comparative example 1). Pressure
in the soaker in example 1 is about 10 bar. The other conditions under which both
thermal cracking processes take place as well as the conversion levels in furnace
and soaker and the yields of the product streams are indicated in Table II. The numbers
in the column "Stream/Unit No." refers to the reference numbers used in figure 1.
[0023] From the results given in Table II it can be concluded that in comparison with the
conventional furnace-soaker thermal cracking process the process of the present invention
enables a higher final 520 °C+ conversion, thus resulting in higher yields of the
useful product streams boiling below 520 °C and in less residual hydrocarbons.
Table I
| Feedstock properties |
| 350-520 °C fraction (% wt) |
5.0 |
| 520 °C+ fraction (% wt) |
95.0 |
| Sulphur (% wt) |
5.4 |
| Conradson Carbon No. (% wt) |
20.3 |
| C7-asphaltenes (% wt) |
10.2 |
| Viscosity at 100 °C (mm2/s) |
2350 |
| Density 70/4 |
0.998 |
Table II
| Thermal cracking experiments |
| |
Stream/ Unit No. |
Example 1 |
Comp. Example 1 |
| Feed (t/d) |
6 |
1000 |
1000 |
| Feed gas (t/d) |
9 |
255 |
- |
| Tgas (°C) |
9 |
650 |
- |
| FOT (°C) |
2 |
460 |
460 |
| SOT (°C) |
3 |
460 |
432 |
| Product streams (t/d) |
|
|
|
| Gas |
11 |
288.6 |
25.2 |
| 0-165 °C |
12 |
74.4 |
54.0 |
| 165-350 °C |
13 |
140.7 |
104.1 |
| 350-520 °C |
16, 17, 18 |
182.5 |
166.7 |
| 520 °C+ |
19 |
568.8 |
650.0 |
| 520 °C+ conv. (% wt) |
|
|
|
| Furnace |
|
15 (37.5% |
15 (48.4%) |
| Final |
|
40 |
31 |
The abbreviations and expressions used in Table II have the following meaning:
| t/d |
tons/day |
| % wt |
% by weight |
| Feed gas |
synthesis gas from gasification unit |
| Tgas |
temperature of the feed gas |
| FOT |
Furnace Outlet Temperature |
| SOT |
Soaker Outlet Temperature. |
[0024] The product streams are indicated via their boiling point range and of the 520 °C+
conversion it is indicated what the final conversion is ("Final") and what part of
it is attained in the furnace. The percentage between brackets indicates the percentage
of the final 520 °C+ conversion taking place in the furnace.
Example 2
[0025] A stirred autoclave of 100 ml capacity was charged with about 25 g of the same Middle
East short residue used in Example 1. The filled autoclave was pressurized with synthesis
gas to 50 bar. The reactor and its contents were then rapidly heated to 450 °C (within
2 minutes starting at 350 °C) and maintained at that temperature for 20 minutes to
allow thermal cracking reactions to occur. Thereafter the reactor was rapidly cooled
to room temperature. The autoclave was subsequently depressurized and the gas and
liquid were collected and sampled for analysis. The amount of coke was determined
by extraction with tetrahydrofuran. It was found that only 4.7% by weight of the total
of gas and liquid recovered was coke. In addition, the surfaces of the autoclave and
the stirrer parts in contact with the synthesis gas remained uncoked.
Comparative Example 2
[0026] The procedure of Example 2 was repeated only this time nitrogen was used to pressurize
the filled autoclave to 50 bar instead of synthesis gas. It was found that coke constituted
7.8% by weight of the total of gas and liquid recovered and that coke was formed on
the surfaces of the autoclave and on the stirrer parts in contact with the nitrogen.
[0027] Comparing the results of Example 2, wherein the conditions in a soaker operated in
accordance with the process of the present invention are imitated, with those of Comparative
Example 2, shows that at thermal cracking conditions in the presence of a hot hydrogen-containing
gas coke formation is significantly reduced and deposition of coke onto the metal
parts inside the soaker which are in direct contact with said hot gas is even completely
avoided.
Example 3
[0028] A stirred autoclave of 100 ml capacity was charged with about 25 g of the same Middle
East short residue as used in Example 1. The filled autoclave was pressurized with
pure hydrogen gas to 10 bar. The autoclave was operated at constant pressure using
a pressure controller in the outlet line of the autoclave and a continuous gas supply
through the liquid residue via a hollow stirrer. Gas flow was kept constant at 200
Nl/kg.h. The residue was then preheated to a temperature of 340 °C under stirring
and was held there for 15 minutes. Thereafter, it was heated at a rate of 45 °C/min
to the desired reaction temperature (450 °C) and was maintained there for 15 minutes
to allow thermal cracking reactions to occur. Subsequently, the autoclave was cooled
to room temperature at a rate of 90 °C/min. The autoclave was subsequently depressurized
and the gas and liquid were collected and sampled for analysis. The amount of coke
was determined by extraction with tetrahydrofuran. It was found that only 3.5% by
weight of the total of gas and liquid recovered was coke. In addition, the inner surfaces
of the autoclave and the stirrer parts in contact with the hydrogen had remained uncoked.
[0029] The results of this example show that under thermal cracking conditions in the presence
of hydrogen, even at such low pressure of 10 bar, coke formation is significantly
reduced whilst deposition of coke onto the metal parts inside the soaker which are
in direct contact with the hydrogen is completely avoided.
1. Verfahren zum thermischen Cracken eines Kohlenwasserstoffrückstandsöls, in welchem
eine 520°C
+-Gesamtumwandlung von zumindestens 35 Gew.-% erreicht wird, welches Verfahren die
folgenden Stufen umfaßt:
(a) Erhitzen des Kohlenwasserstoffrückstandsöl-Einsatzmaterials in einem Ofen auf
eine Temperatur im Bereich von 400 bis 510°C für eine ausreichende Zeit, um 30 bis
45 % der 520°C+-Gesamtumwandlung zu erzielen;
(b) Einspeisen des in Stufe (a) gebildeten partiell umgewandelten heißen Kohlenwasserstoffrückstandsöls
und eines heißen wasserstoffhältigen Gases in einen Soaker, wobei dieses Wasserstoffhältige
Gas eine genügend hohe Temperatur besitzt, um die Temperatur des Kohlenwasserstofföls
im Soaker durch direkten Wärmeaustausch auf einem Wert im Bereich von 420 bis 650°C
zu halten, in welchem Soaker der Rest auf 100 % der 520°C+-Gesamtumwandlung stattfindet; und
(c) Gewinnen einer gasförmigen Fraktion mit einem Gehalt an dem wasserstoffhältigen
Gas und eines gecrackten Rückstandes aus dem Soaker.
2. Verfahren nach Anspruch 1, welches außerdem die Stufen
(d) Auftrennen des in Stufe (c) gewonnenen gecrackten Rückstands in eine oder mehrere
asphaltenarme Fraktionen und in eine asphaltenreiche Sumpffraktion umfaßt.
3. Verfahren nach Anspruch 2, welches zusätzlich die Stufe
(e) partielles Oxidieren der in Stufe (d) gebildeten asphaltenreichen Sumpffraktion
in Gegenwart von Sauerstoff und Dampf umfaßt, wodurch heißes Synthesegas gebildet
wird.
4. Verfahren nach Anspruch 3, worin wenigstens ein Teil des in Stufe (e) gebildeten heißen
Synthesegases als das heiße wasserstoffhältige Gas in Stufe (b) verwendet wird.
5. Verwendung eines wasserstoffhältigen Gases als Strippmedium in einem Verfahren nach
einem der Ansprüche 1 bis 4.
1. Procédé de craquage thermique d'une huile hydrocarbonée résiduelle, où l'on atteint
une conversion de 520°C+ finale d'au moins 35% en poids, lequel procédé qui comprend
les étapes consistant à :
(a) chauffer la charge d'huile hydrocarbonée résiduelle dans un four à une température
qui varie de 400 à 510°C pendant une durée qui suffit à atteindre 30 à 45% de la conversion
de 520°C+ finale,
(b) introduire l'huile hydrocarbonée chaude et partiellement convertie, produite au
cours de l'étape (a) et un gaz contenant de l'hydrogène chaud dans un maturateur,
ledit gaz contenant de l'hydrogène se trouvant à une température suffisamment élevée
pour maintenir la température de l'huile hydrocarbonée dans le maturateur, par l'intermédiaire
d'un échange de chaleur direct à une valeur qui varie de 420 à 650°C, maturateur dans
lequel le reste, jusqu'à 100%, de la conversion de 520°C+ finale se produit et
(c) récupérer une fraction gazeuse contenant le gaz contenant de l'hydrogène et un
résidu craqué du maturateur.
2. Procédé suivant la revendication 1, caractérisé en ce qu'il comprend également l'étape
consistant à
(d) séparer le résidu craqué récupéré au cours de l'étape (c) en une ou plusieurs
fractions pauvres en asphalténes et en une fraction de fond ou de queue riche en asphalténes.
3. Procédé suivant la revendication 2, caractérisé en ce qu'il comprend également l'étape
consistant à
(e) partiellement oxyder la fraction de queue ou de fond riche en asphalténes obtenue
à l'étape (d), en présence d'oxygène et de vapeur d'eau, de manière à produire du
gaz de synthèse chaud.
4. Procédé suivant la revendication 3, caractérisé en ce que l'on utilise au moins une
partie du gaz de synthèse chaud produit dans l'étape (a), à titre de gaz contenant
de l'hydrogène chaud dans l'étape (b).
5. Utilisation d'un gaz contenant de l'hydrogène à titre de milieu de lavage dans un
procédé suivant l'une quelconque des revendications 1 à 4.