Catalytic multi-stage process for hydroconversion and refining hydrocarbon feeds

Patent · Mon Jan 01 04:00:00 EST 2001

OSTI ID:873565

Comolli, Alfred G ^[1]; Lee, Lap-Keung ^[2]

---

1. Yardley, PA
2. Cranbury, NJ

A multi-stage catalytic hydrogenation and hydroconversion process for heavy hydrocarbon feed materials such as coal, heavy petroleum fractions, and plastic waste materials. In the process, the feedstock is reacted in a first-stage, back-mixed catalytic reactor with a highly dispersed iron-based catalyst having a powder, gel or liquid form. The reactor effluent is pressure-reduced, vapors and light distillate fractions are removed overhead, and the heavier liquid fraction is fed to a second stage back-mixed catalytic reactor. The first and second stage catalytic reactors are operated at 700-850.degree. F. temperature, 1000-3500 psig hydrogen partial pressure and 20-80 lb./hr per ft.sup.3 reactor space velocity. The vapor and light distillates liquid fractions removed from both the first and second stage reactor effluent streams are combined and passed to an in-line, fixed-bed catalytic hydrotreater for heteroatom removal and for producing high quality naphtha and mid-distillate or a full-range distillate product. The remaining separator bottoms liquid fractions are distilled at successive atmospheric and vacuum pressures, low and intermediate-boiling hydrocarbon liquid products are withdrawn, and heavier distillate fractions are recycled and further upgraded to provide additional low-boiling hydrocarbon liquid products. This catalytic multistage hydrogenation process provides improved flexibility for hydroprocessing the various carbonaceous feedstocks and adjusting to desired product structures and for improved economy of operations.

• Research Organization: HYDROCARBON RESEARCH INC
• DOE Contract Number: AC22-92PC92148
• Assignee: Hydrocarbon Technologies, Inc. (Lawrenceville, NJ)
• Patent Number(s): US 6190542
• OSTI ID: 873565
• Country of Publication: United States
• Language: English

Related Subjects

/208/
1000-3500
20-80
700-850
additional
adjusting
atmospheric
back-mixed
based catalyst
bed catalytic
bottoms
carbonaceous
carbonaceous feed
carbonaceous feedstock
carbonaceous feedstocks
catalyst
catalytic
catalytic hydrogenation
catalytic multi-stage
catalytic reactor
catalytic reactors
coal
combined
conversion process
degree
desired
desired product
dispersed
distillate
distillate fraction
distillate fractions
distillates
distilled
economy
effluent
effluent stream
fed
feed
feed material
feed materials
feeds
feedstock
feedstocks
first-stage
fixed-bed
flexibility
form
fraction
fractions
full-range
heavier
heavy
heavy hydrocarbon
heavy petroleum
heteroatom
highly
highly dispersed
hydrocarbon
hydrocarbon feed
hydrocarbon liquid
hydroconversion
hydroconversion process
hydrogen
hydrogen partial
hydrogenation
hydrogenation process
hydroprocessing
hydrotreater
improved
in-line
intermediate-boiling
iron-based
lb
light
light distillate
liquid
liquid form
liquid fraction
liquid fractions
liquid product
liquid products
low-boiling
low-boiling hydrocarbon
materials
mid-distillate
multi-stage
multistage
naphtha
operated
operations
overhead
partial
partial pressure
passed
petroleum
petroleum fraction
plastic
plastic waste
powder
pressure
pressure-reduced
pressures
process
process provides
producing
product
products
provide
provide additional
provides
provides improved
psig
psig hydrogen
quality
reacted
reactor
reactor effluent
reactor space
reactors
recycled
refining
remaining
removal
removed
separator
space
space velocity
stage
stage catalytic
stage hydrogenation
stage reactor
streams
structures
successive
temperature
upgraded
vacuum
vacuum pressure
vacuum pressures
vapor
vapors
various
velocity
waste
waste material
waste materials
withdrawn