PROCESS FOR ELIMINATING REENTRY DISULFIDES IN A MERCAPTAN EXTRACTION PROCESS

Abstract: Reentry disulphides are eliminated in a continuous process for treating a sour hydrocarbon stream by extracting the mercaptans contained in the hydrocarbon stream 1 with a disulphide-free alkaline solution in an extraction zone 3, oxidizing the mercaptans to disulphides in the presence of an oxidation catalyst, in oxidation zone 6, separating a major portion of the disulphides from the alkaline solution at 9, reducing the residual disulphides in the alkaline solution to mercaptans and recycling the resulting substantially disulphide-free alkaline solution from the reduction zone 12 to the extraction zone 3. The reduction of the disulphides to mercaptans may be carried out by hydrogenation or by electrochemical reduction.

Description: This invention concerns a process for removing mercaptans from a hydrocarbon stream by means of alkali-extraction without contaminating the hydrocarbon stream with disulphides. Traditionally the removal of mercaptans from various process materials and/or streams has been a substantial problem. The reasons for desiring this removal are well-known in the art and include problems arising from: corrosion, combustion, catalyst poisoning, undesired side reactions and offensive odours, etc. The methods that have been proposed for the solution of this removal problem can be categorized into those that seek the absolute removal of mercaptan compounds, or any derivatives of these compounds, from the carrier stream or material, and those that seek only to convert the mercaptans into less harmful derivatives with no attendant attempt at removal of these less harmful derivatives. Solutions of the former type are generally labelled as "extraction" processes. Solutions of the latter type are generally labelled as "sweetening" processes. Prominent among the extraction processes is a process which depends for its effectiveness on the fact that mercaptans are slightly acidic in nature and in the presence of a strong base tend to form salts (called mercaptides) which have a remarkably high preferential solubility in a basic solution. In this type of process, an extraction step is coupled with a regeneration step and an alkaline stream is continuously recirculated therebetween. In the extraction step, the alkaline stream is used to extract mercaptans from the hydrocarbon stream, and the resulting mercaptide-rich alkaline stream is treated in the regeneration step to remove mercaptide compounds, with continuous cycling of the alkaline stream between the extraction step and the regeneration step. The regeneration step is typically operated to produce disulphide compounds which are immiscible with the alkaline stream, and the major portion of which is typically separated therefrom in a settling step. In many instances, however, it is desired to remove substantially all disulphide compounds from the alkaline streams, but complete separation of disulphide compounds from the alkaline stream in a settling step is not feasible because of the high dispersion of these compounds throughout the alkaline solution. Accordingly, the art has resorted to a number of techniques in order to coalesce the disulphide compounds and effect their removal from the regenerated alkaline solution. One technique that has been utilized involves the use of a coalescing agent, such as steel wool. This technique, however, leaves significant amounts of disulphides in the alkaline solution. Another technique which has been widely utilized involves the use of one or more stages of a naphtha wash (see, for example, US-A-3574093) in order to extract disulphide compounds from the alkaline solution. Although this technique has been widely utilized, it has several disadvantages, in that it requires: 1) the availability of naphtha; 2) the use of large volumes of naphtha because of its low efficiency; 3) a separate train of vessels and separators; and 4) disposal of the contaminated naphtha. As is well known to those skilled in the art, there are certain low boiling hydrocarbon streams for which is it absolutely critical that the amount of sulphur compounds contained therein be held to a very low level. In many instances, this requirement is expressed as a limitation on the total amount of sulphur that can be tolerated in the treated stream. Typically the requirement is for a sulphur content of less than 50 wt. ppm, calculated as elemental sulphur, and more frequently, the requirement is for less than 10 wt. ppm of sulphur. Accordingly, when a mercaptan-extraction process of the type described above is designed to meet these stringent sulphur limitations, it is essential that the amount of disulphides contained in the regenerated alkaline solution be held to an extremely low level in order to avoid contamination of the extracted stream with disulphides. For example, in the sweetening of a hydrocarbon stream containing C₃ and C₄ hydrocarbons and about 750 wt. ppm of mercaptan sulphur, an extraction process can easily be designed that should in theory produce a treated hydrocarbon distillate having about 5 wt. ppm of mercaptan sulphur, but without special treatment of the regenerated alkaline solution, the total sulphur content of the treated hydrocarbon stream will in practice be about 50 wt. ppm, because of reentry disulphide compounds which are returned to the extraction step via the alkaline stream, from which they are transferred to the treated hydrocarbon stream. The present invention solves this problem by treating the disulphide containing alkaline solution in a reduction step whereby the disulphides are reduced back to mercaptans. Since the mercaptans are preferentially soluble in the alkaline phase, they are not transferred to the treated hydrocarbon stream. The reduction of disulphides to mercaptans is known in the art (see US-A-4072584) but has been carried out for other purposes than that presented herein. Reduction of the disulphide can be accomplished either by hydrogenation of the disulphide with hydrogen over a hydrogenation catalyst, or by electrochemical means wherein the disulphide is reduced at the cathode of an electrochemical cell. Some of the broad advantages associated with this solution to the sulphur-reentry problem are: 1) it eliminates the disposal problem and additional separation hardware required for naphtha washing; and 2) it minimizes the amount of disulphides in the alkaline recycle stream charged to the extraction zone. This invention therefore relates to a process for continuously treating a sour hydrocarbon stream containing mercaptans in order to generate a purified stream of reduced mercaptan content and of reduced total sulphur content. More precisely, the present invention relates to a process for the treatment of a sour hydrocarbon fraction for the purpose of physically removing mercaptans contained therein, which comprises extracting the mercaptans in an extraction zone with an alkaline solution, oxidizing the mercaptans to disulphides in the presence of an oxidation catalyst, separating disulphides from the alkaline solution, reducing residual disulphides in the alkaline solution to mercaptans, and recycling the alkaline solution to the extraction zone. Accordingly, one embodiment of this invention provides a continuous process for treating a sour hydrocarbon stream containing mercaptans to produce a substantially disulphide- and mercaptan-free product hydrocarbon stream which comprises: a) contacting the hydrocarbon stream with an aqueous substantially disulphide-free solution in an extraction zone to form a substantially disulphide- and mercaptan-free product hydrocarbon stream, and a mercaptide-rich aqueous alkaline solution; b) passing the mercaptide-rich aqueous alkaline solution to an oxidation zone, and therein treating it with an oxidizing agent in the presence of a metal phthalocyanine oxidation catalyst to oxidize the mercaptides to liquid disulphides; c) separating a major portion of the liquid disulphides from the treated aqueous alkaline solution in a separation zone, to form a treated aqueous alkaline solution containing residual disulphides; d) passing the treated aqueous alkaline solution to a reduction zone and therein reducing disulphides to mercaptans; and e) recycling the resulting substantially disulphide-free aqueous alkaline solution to the extraction zone. In a specific embodiment, the process comprises: a) contacting the hydrocarbon stream with an aqueous substantially disulphide-free sodium hydroxide solution in the extraction zone at a temperature of 10 to 100°C and a pressure from ambient to 300 psig (2069 kPa gauge) to form a purified hydrocarbon stream and a mercaptide-rich aqueous sodium hydroxide solution; b) passing the mercaptide-rich aqueous sodium hydroxide solution to an oxidation zone, and therein oxidizing mercaptides to disulphides with an excess of air in the presence of a cobalt phthalocyanine catalyst, which is contained in the mercaptide-rich sodium hydroxide solution, at a temperature of 30 to 70°C, and a pressure of 30 to 100 psig (207 to 690 kPa gauge); c) separating a major portion of the disulphides in a separation zone from the effluent stream from step (b) to form aqueous sodium hydroxide containing residual disulphides; d) passing the residual disulphide-containing aqueous sodium hydroxide solution to a reduction zone, and reducing the residual disulphides to mercaptans by means of hydrogen over a palladium on carbon hydrogenation catalyst; and e) recycling the resulting substantially disulphide-free aqueous sodium hydroxide solution to the extraction zone. Other objects and embodiments of the present invention encompass details about particular input hydrocarbon streams, catalysts for use in the oxidation and reduction steps thereof, mechanics associated with each of the essential steps thereof, and preferred operating conditions for each of the essential steps thereof. As heretofore stated, this invention relates to a process for treating a sour hydrocarbon stream. This stream can be exemplified by the following: liquefied petroleum gas (LPG), light naphtha, straight run naphtha, methane, ethane, ethylene, propane, propylene, butene-1, butene-2, isobutylene, butane, and pentanes. The alkaline solution utilized in the present invention may comprise any alkaline reagent known to have the capability to extract mercaptans from relatively low boiling hydrocarbon streams. A preferred alkaline solution generally comprises an aqueous solution of an alkali metal hydroxide, such as sodium hydroxide, potassium hydroxide, or lithium hydroxide. Similarly, aqueous solutions of alkaline earth metal hydroxides such as calcium hydroxide, barium hydroxide, and magnesium hydroxide, may be utilized if desired. A particularly preferred alkaline solution for use in the present invention is an aqueous solution of 1 to 50% by weight of sodium hydroxide, with particularly good results obtained with aqueous solutions having 4 to 25 wt. percent of sodium hydroxide. The catalyst which is used in the oxidation step is a metal phthalocyanine catalyst. Particularly preferred metal phthalocyanines comprise cobalt phthalocyanine and iron phthalocyanine. Other metal phthalocyanines include vanadium, copper, nickel, molybdenum, chromium, tungsten, magnesium, platinum, hafnium and palladium phthalocyanines. The metal phthalocyanine in general is not highly polar and, therefore, to improve operation, is preferably utilized as a polar derivative thereof. Particularly preferred polar derivatives are the sulphonated derivatives such as monosulpho, disulpho, trisulpho, and tetrasulpho derivatives. These sulpho derivatives may be obtained from any suitable source, or may be prepared by one of two general methods as described in US-A-3408287 or -3252890. Firstly, the metal phthalocyanine can be reacted with fuming sulphuric acid; or secondly, the sulphonated phthalocyanine compound can be synthesized from a sulpho-substituted phthalic anhydride or equivalent thereof. While the sulpho derivatives are preferred, it is understood that other suitable derivatives may be employed. Particularly, other derivatives include a carboxylated derivative which may be prepared, for example, by the action of trichloroacetic acid on the metal phthalocyanine, or by the action of phosgene and aluminium chloride. In the latter reaction, the acid chloride is formed and may be converted into the desired carboxylic derivative by conventional hydrolysis. Specific examples of these derivatives include: cobalt phthalocyanine monosulphonate, cobalt phthalocyanine disulphonate, cobalt phthalocyanine trisulphonate, cobalt phthalocyanine tetrasulphonate, vanadium phthalocyanine monosulphonate, iron phthalocyanine disulphonate, palladium phthalocyanine trisulphonate, platinum phthalocyanine tetrasulphonate, nickel phthalocyanine carboxylate, cobalt phthalocyanine carboxylate and iron phthalocyanine carboxylate. The preferred phthalocyanine catalyst can be used in the present invention in one of two modes. Firstly, it can be utilized in a water-soluble form or a form which is capable of forming a stable emulsion in water as disclosed in US-A-2853432. Secondly the phthalocyanine catalyst can be utilized as a combination of a phthalocyanine compound with a suitable carrier material, as disclosed in US-A-2988500. In the first mode, the catalyst is present as a dissolved or suspended solid in the alkaline stream which is charged to the regeneration step. In this mode, the preferred catalyst is cobalt or vanadium phthalocyanine disulphonate which is typically utilized in an amount of 5 to 1,000 wt. ppm of the alkaline stream. In the second mode of operation, the catalyst is preferably utilized as a fixed bed of particles of a composite of the phthalocyanine compound with a suitable carrier material. The carrier material should be insoluble, or substantially unaffected by the alkaline stream or hydrocarbon stream, under the conditions prevailing in the various steps of the process. Activated charcoals are particularly preferred because of their high adsorptivity under these conditions. The amount of the phthalocyanine compound combined with the carrier material is preferably 0.1 to 2.0 wt. percent of the final composite. Additional details as to alternative carrier materials, methods of preparation, and the preferred amount of catalytic components for the preferred phthalocyanine catalyst for use in this second mode are given in the teachings of US-A-3108081. The disulphide reduction step can be accomplished either by hydrogenation using a hydrogenation catalyst and hydrogen, or by electrochemically reducing the disulphide. Hydrogenation of the disulphide occurs via the following equation: RSSR + H₂ → 2 RSH In the preferred embodiment of the process, the catalyst for the hydrogenation reaction comprises a metal on a solid support. The support can be chosen from carbon, alumina, silica, aluminosilicates, zeolites, clays, etc. while the metal is preferably chosen from Group VIII of the Periodic Table, and more preferably from the group comprising nickel, platinum, palladium, etc. The preferred supports are carbon-based, due to their stability in strong caustic, and include activated carbons, synthetic carbons, and natural carbons as examples. Particularly preferred catalysts are: 0.01 to 5.0 wt. % of palladium on a carbon support, 0.1 to 8.0 wt. % of platinum on a carbon support, and 0.1 to 8.0 wt. % of nickel on an alumina support. In general, the palladium or platinum catalysts may be prepared by methods known in the art. For example, a soluble palladium salt can be contacted with a carbon support in order to deposit the desired amount of the palladium salt. Examples of soluble palladium salts which may be used are palladium chloride, palladium nitrate, palladium carboxylates, palladium sulphate, and amine complexes of palladium chloride. Finally, the finished palladium catalyst may be activated by reduction, if desired, by treatment with a reducing agent. Examples of reducing agents are gaseous hydrogen, hydrazine and formaldehyde. The preferred catalyst is used under the following hydrogenation conditions: a hydrogen to disulphide mole ratio of 1:1 to 100:1, and preferably 10:1 to 100:1, an LHSV from 3 to 18 h⁻¹, a temperature from 30 to 150°C, more preferably 40 to 100°C, and a pressure from 30 to 125 psig (207 to 862 kPa), more preferably 50 to 125 psig (345 to 862 kPa). Preferred reaction conditions are a hydrogen concentration of 50 to 100 times the stoichiometric amount required to reduce disulphides, a LHSV from 6 to 12 h⁻¹, and a temperature from 50 to 100°C. Alternatively the disulphide can be reduced by electrochemical means. The electrochemical cell which may be employed to effect the reduction step in the present process comprises a cathode and an anode, and an electrolyte. The cathode may be chosen from zinc, lead, platinum, graphite, glossy carbon, synthetic carbons, cadmium, palladium, iron, nickel, copper, etc., while the anode may be chosen from platinum, graphite, iron, zinc, and brass. The electrodes may also comprise a combination of the above metal systems, for example zinc-coated graphite, or platinum-coated graphite. The electrolyte is the disulphide-containing alkaline solution itself. When a voltage is applied across the two terminals, the following reaction occur at the electrodes: CATHODE: RSSR + 2e⁻ → 2 RS⁻ ANODE: H₂0 → ½ 0₂ + 2H⁺ + 2e⁻ NETT: RSSR + H₂0 → 2RSH + ½ 0₂ The anode reaction is not limited to the oxidation of water and, in principle, may be any suitable exidation which can be coupled with the disulphide reduction reaction to complete the electrochemical reaction. This electrochemical process can be either a batch process or a continuous process, with the continuous process being preferred. A voltage from 1.3 to 3.0v is applied, with the preferred voltage being from 1.5 to 2.5v. This invention will be further described with reference to the attached drawing which is a schematic outline of the process under discussion. The attached drawing is merely intended as a general representation of a preferred flow scheme with no intent to give details about vessels, heaters, condensers, pumps, compressors, valves, process control equipment, etc., except where a knowledge of these devices is essential to the understanding of this invention or would not be self-evident to one skilled in the art. Referring now to the attached drawing, a sour hydrocarbon stream enters the extraction zone 3 via line 1. The aqueous alkaline solution containing the phthalocyanine catalyst enters the extraction zone 3 via line 2. Extraction zone 3 is typically a vertical tower containing suitable contacting means such as baffle pans, trays, and the like, designed to effect intimate contact between the two liquid streams charged thereto. In extraction zone 3, the sour hydrocarbon stream is counter-currently contacted with an alkaline solution containing a phthalocyanine catalyst, which enters via line 2. When desired, fresh alkaline solution may be introduced into the system by an extension of line 2. The function of extraction zone 3 is to bring about intimate contact between the sour hydrocarbon stream and the alkaline stream, such that the mercaptans contained in the hydrocarbon stream are preferentially dissolved in the alkaline solution. The rates of flow of the sour hydrocarbon stream and the alkaline solution are adjusted so that the treated hydrocarbon stream leaving the extraction zone 3 via line 5 contains substantially less mercaptans than the sour hydrocarbon stream introduced via line 1. In this manner, zone 3 acts both to extract the mercaptans from the sour hydrocarbon stream into the alkaline solution and to separate the treated hydrocarbon stream from the alkaline solution. Extraction zone 3 is preferably operated at a temperature of 25 to 100°C, and more preferably at a temperature of 30 to 75°C. Likewise, the pressure within zone 3 is generally selected to maintain the hydrocarbon stream in liquid phase, and may range from ambient up to 300 psig (2069 kPa gauge). For an LPG stream the pressure is preferably 140 to 175 psig (965 to 1207 kPa gauge). The volume loading of the alkaline stream relative to the hydrocarbon stream is preferably 1 to 30 vol. percent of the hydrocarbon stream, with excellent results obtained for an LPG type stream when the alkaline stream is introduced into zone 3 in an amount of about 5% of the hydrocarbon stream. The mercaptide-rich alkaline stream is passed via line 4 to oxidation zone 6, where it is mixed with the oxidant which enters via line 7. The amount of oxidant, such as oxygen or air, mixed with the alkaline stream is ordinarily at least the stoichiometric amount necessary to oxidize mercaptides, contained in the alkaline stream, to disulphides. In general, it is a good practice to operate with sufficient oxidant to ensure that the reaction goes essentially to completion. The oxidant used for this step comprises an oxygen-containing gas, such as oxygen or air, with air usually being the oxidant of choice for economic and availability reasons. The function of zone 6 is to regenerate the alkaline solution by oxidizing the mercaptide compounds to disulphides. As pointed out above, this regeneration step is preferably performed in the presence of a Phthalocyanine catalyst which is present as a solution in the alkaline stream. In the preferred embodiment of the apparatus, a suitable packing material is utilized in order to effect intimate contact between the catalyst, the mercaptides and oxygen. Zone 6 is preferably operated at a temperature corresponding to the temperature of the entering mercaptide-rich alkaline solution, which is typically from 35 to 70°C. The pressure in zone 6 is generally substantially less than that in the extraction zone. For instance, in a typical embodiment, wherein extraction zone 3 is run at a pressure from 140 to 175 psig (965 to 1207 gauge), zone 6 is preferably operated at 30 to 70 psig (207 to 483 kPa gauge). An effluent stream containing nitrogen, disulphide compounds, alkaline solution and optionally phthalocyanine catalyst is withdrawn from zone 6 via line 8 and passed to a separating zone 9, which is preferably operated under the conditions used in zone 6. In zone 9, the effluent stream is allowed to separate into (a) a gas phase, which is withdrawn via line 10 and discharged from the process, (b) a disulphide phase, which is substantially immiscible with the alkaline phase, and is withdrawn from the process via line 11, and (c) an alkaline phase, which is withdrawn via line 12. In general, the complete coalescence of the disulphide compound into a separate phase is extremely difficult to achieve without the aid of suitable coalescing agents, such as a bed of steel wool, sand, glass, etc. In addition, a relatively high residence time of 0.5 to 2 hours is typically used within zone 9 in order further to facilitate this phase-separation. Despite these precautions, the regenerated alkaline stream which is withdrawn via line 12, inevitably contains minor amounts of disulphides and mercaptides. In fact, the amount of sulphur present in this regeneration alkaline stream is such that complete treatment of the sour hydrocarbon stream in extraction zone 3 is not possible. In accordance with the present invention, the regenerated alkaline solution is passed to zone 13 via line 12. The function of zone 13 is to reduce the disulphides entrapped in the alkaline solution. Zone 13 can be operated in one of two ways: as a catalytic hydrogenation or as an electrochemical reduction. In the catalytic hydrogenation configuration, zone 13 preferably contains a fixed catalyst bed of 10 to 30 mesh (nominal aperture of 0.59 to 2.0 mm) particles comprising palladium on carbon. Hydrogen is charged to zone 13 via line 15 and intermingled with the alkaline solution in contact with the hydrogenation catalyst, thereby reducing the disulphides to mercaptides. This zone is preferably operated at a temperature of 30 to 150°C, a pressure of 30 to 150 psig (207 to 1034 kPa gauge), an LHSV of 1 to 20 h⁻¹, and a hydrogen concentration of 1 to 100 times the stoichiometric amount necessary to reduce disulphides to mercaptans. In the preferred embodiment of the invention, the reduction conditions will include a temperature of 40 to 100°C, an LHSV of 3 to 15 h⁻¹, a pressure of 50 to 125 psig (345 to 862 kPa gauge) and a hydrogen concentration of 15 to 30 times the stoichiometric amount. Unreacted hydrogen gas phase is withdrawn from zone 13 via line 14 and discharged from the process, and a substantially disulphide-free alkaline aqueous phase is withdrawn via line 16, passed to line 2 and thereby cycled to extraction zone 3. Alternatively, the hydrogenation catalyst utilized in zone 13 can comprise a soluble hydrogenation catalyst, such as a Group VIII carboxylate, and be present in the alkaline solution throughout the entire process. In this instance, zone 13 is preferably operated at a temperature of 30 to 125°C, a pressure of 30 to 150 psig (207 to 1034 kPa gauge), a residence time of 3 to 30 min., and a hydrogen concentration of 1 to 100 times the stoichiometric amount. In the electrochemical configuration, zone 16 comprises an electrochemical cell comprising a cathode, an anode and an electrolyte solution. The electrolyte solution is the to-be-treated alkaline solution which is introduced into zone 13 via line 12. The cathod of the cell is preferably graphite. The anode is preferably platinum or graphite. This electrochemical reduction can be carried out either as a batch process or a continuous process. A voltage from 1.3 to 3.0 v is applied, with the preferred voltage being from 1.5 to 2.5 v. When operated as a batch process, the residence time is preferably 30 to 240 min, while when operated as a continuous process, a residence time of 3 min to 30 min is preferred. As in the catalytic hydrogenation, the effluent stream separates into a gas phase, primarily comprising oxygen which is withdrawn via line 14, and an alkaline aqueous phase, which is withdrawn via line 16, joined to line 2 and cycled to extraction zone 3. The following examples are given to illustrate further the process of the present invention, and indicate the benefits to be afforded by the utilization thereof. In particular the examples describe only the reduction part of the invention. EXAMPLE 1 A palladium on carbon hydrogenation catalyst was prepared in the following manner. To a beaker containing 500 ml of deionized water was added 7.5 grams of palladium nitrate, Pd (N0₃)₂ × H₂0. In a separate beaker, 200 grams (450 ml) of 10 to 30 (0.59 to 2.0 mm) mesh carbon was wetted with 450 ml of deionized water. The palladium nitrate solution and the wetted carbon were mixed in a rotary evaporator and rolled for 15 minutes. After this period, the evaporator was heated by introducing steam so that the aqueous phase was evaporated. Complete evaporation of the aqueous phase took about 3 hours. Next, the impregnated catalyst was dried in a forced air oven for 3 hours at 80°C. Finally, the dried catalyst was calcined under nitrogen at 400°C for 2 hours. The final catalyst composite contained 1.13% by weight of palladium. A commercial alkaline solution having a disulphide content of 298 wt. ppm was contacted with a fixed bed of the palladium on carbon catalyst described about at an LHSV of 10 hr⁻¹, a temperature of 75°C, a pressure of 100 psig (670 kPa gauge) and a hydrogen concentration of 80 times the stoichiometric amount (i.e., a hydrogen to disulphide mole ratio of 80:1). After 3 hours, the effluent was analyzed for disulphides and it was determined that 74% of the disulphides were being converted into mercaptans. The feed stream was continuously fed through the reaction vessel containing the catalyst at the conditions stated herein for 110 hours, at which point the conversion of disulphide to mercaptan was found to be 90%. EXAMPLE 2 A zinc cathode and a platinum anode were placed in a 500 ml beaker. 300 ml of a 6.0% sodium hydroxide solution containing 300 wt. ppm of disulphide were added to the beaker and a voltage of -1.8 V was applied across the 2 electrodes. After 4 hours, the solution was analyzed for disulphides and it was determined that 53% of the disulphides were converted into mercaptans. EXAMPLE 3 A lead cathode and a platinum anode were placed in a 500 ml beaker. 300 ml of a 6.0% sodium hydroxide solution containing 300 wt. ppm of disulphide were added to the beaker and a voltage of -1.8 v was applied across the 2 electrodes. After 4 hours the solution was analyzed for disulphides and it was determined that 39% of the disulphides were converted into mercaptans. EXAMPLE 4 A graphite rod cathode and a platinum anode were placed in a 500 ml beaker. To this beaker there was added 300 ml of a 6.0% sodium hydroxide solution containing 300 wt. ppm of disulphide, and a voltage of -1.8 v was applied across the 2 electrodes. After a 6 hour period, 25% of the disulphides were converted into mercaptans. In addition, carbon-based electrodes such as graphite show very high stability to strongly alkaline solutions, making carbon-based electrodes the preferred materials for the cathode.

Claims: A continuous process for treating a sour hydrocarbon stream containing mercaptans to produce a substantially disulphide- and mercaptan-free product hydrocarbon stream by contacting the hydrocarbon stream with an aqueous alkaline solution in an extraction zone to form a substantially disulphide- and mercaptide-rich aqueous alkaline solution; oxidizing the mercaptide-rich aqueous alkaline solution with an oxidizing agent in the presence of a metal phthalocyanine oxidation catalyst to convert mercaptides into liquid disulphides; separating a major portion of said liquid disulphides from the treated aqueous alkaline solution and recycling the resulting treated aqueous alkaline solution to the extraction zone; characterized in that the treated aqueous alkaline solution is subjected to reduction conditions to convert disulphides into mercaptans before it is recycled to the extraction zone. A process according to claim 1 characterized in that the reduction of disulphides is effected in the presence of hydrogen and a hydrogenation catalyst at a hydrogen to disulphide mole ratio of 1:1 to 100:1, a temperature from 40 to 100°C and a pressure from 50 to 125 psig (345 to 862 kPa gauge). A process according to claim 2 characterized in that the hydrogenation catalyst comprises from 0.01 to 5 wt. % of palladium supported on carbon, from 0.1 to 8 wt. % of platinum supported on carbon, or from 0.1 to 8 wt. % of nickel supported on alumina. A process according to claim 2 characterized in that the hydrogenation catalyst comprises a Group VIII metal carboxylate and is present in the alkaline solution. A process according to claim 4 characterized in that the metal carboxylate is a palladium or nickel carboxylate. A process according to claim 1 characterized in that the reduction of disulphides is effected in an electrochemical cell having an active electrode and a counter electrode. A process according to claim 6 characterized in that the active electrode comprises zinc, lead, platinum, graphite, glossy carbon, carbon, cadmium, palladium, iron, nickel or copper and the counter electrode comprises platinum or graphite.

Inventors: BRICKER, JEFFERY C., STAEHLE, BRUCE E.
Applicants: UOP
Application year: 1987
Main classification: C10G19
IPC codes: C07B61, B01D53, C10G19, C07C67, C10G11, C07C319, B01J31, B01J23, C07C313, C07C321, C10G53