Patent EA-001938-B1 (EA)
Title: Process and apparatus for upgrading hydrocarbon feeds containing sulfur, metals and asphaltenes
Inventor: FRIDAY J ROBERT
IPC: C10G67/04
Filed: 1999-09-02
Abstract: 1. A process for upgrading a hydrocarbon feed containing sulfur, metals, and asphaltenes, said process comprising: a) applying said feed to a distillation column for producing a substantially asphaltene-free, and metal- free distillate fraction and a non-distilled fraction containing sulfur, asphaltenes and metals; b) converting at least some of said substantially asphaltene-free, and metal-free distillate fraction to a hydrogen donor diluent; c) processing said non-distilled fraction in a solvent deasphalting unit for producing a deasphalted oil stream and an asphaltene stream; d) combining said hydrogen donor diluent with said deasphalted oil stream to form a combined stream; e) thermal cracking said combined stream for forming a thermally cracked stream; and f) applying said thermally cracked stream to said distillation column. 2. A process according to claim 1 wherein said hydrogen donor diluent is combined with said deasphalted oil stream in the ratio of about 0.25 to 4 parts of hydrogen donor diluent to 1 part of deasphalted oil. 3. A process according to claim 2 wherein converting at least some of said substantially asphaltene-free, and metal-free distillate fraction to a hydrogen donor diluent includes: a) catalytically hydrogenating at least a portion of said substantially asphaltene-free, and metal-free distillate fraction for forming a hydrotreated stream; b) fractionating said hydrotreated stream for forming substantially asphaltene-free, and metal-free distillate, and said hydrogen donor diluent. 4. Apparatus for upgrading a hydrocarbon feed containing sulfur, metals, and asphaltenes, said apparatus comprising: a) a distillation column for receiving said feed and producing a substantially asphaltene-free, and metal-free distillate fraction and a non-distilled fraction containing sulfur, asphaltenes, and metals; b) means for converting at least some of said substantially asphaltene-free, and metal-free distillate fraction to a hydrogen donor diluent; c) a solvent deasphalting unit for processing said non-distilled fraction and producing a deasphalted oil stream and an asphaltene stream; d) means for combining said hydrogen donor diluent with said deasphalted oil stream to form a combined stream; e) a thermal cracker for thermally cracking said combined stream and forming a thermally cracked stream; and f) means for applying said thermally cracked stream to said distillation column. 5. Apparatus according to claim 4 including: a) a catalytic hydrotreater for treating at least a portion of said substantially asphaltene-free, and metal-free distillate fraction and forming a hydrotreated stream; b) a distillation column for fractionating said hydrotreated stream and forming substantially asphaltene-free, and metal-free distillate, and said hydrogen donor diluent. 6. A process for producing a distillate stream from a heavy hydrocarbon feed stream comprising: a) solvent deasphalting said feed for producing a deasphalted oil fraction and an asphaltene fraction; b) forming a hydrogen donor diluent; c) heating and thermal cracking said deasphalted oil fraction in the presence of said hydrogen diluent in a thermal cracking zone for forming a thermally cracked stream; d) fractionating said thermally cracked stream in a fractionating zone to produce a distilled fraction which constitutes said distillate stream, and a non-distilled fraction which constitutes said feed stream. 7. A process according to claim 6 wherein said hydrogen donor diluent is combined with said deasphalted oil fraction in the ratio of about 0.25 to 4 parts of hydrogen donor diluent to 1 part of deasphalted oil. 8. A process according to claim 6 wherein said hydrogen donor diluent is produced by hydrotreating a portion of said distillate stream. 9. A process according to claim 8 wherein the step of fractionating said thermally cracked stream includes fractionating a hydrocarbon feed containing sulfur, metals, and asphaltenes. 10. A process according to claim 8 including thermal cracking a hydrocarbon feed containing sulfur, metals, and asphaltenes in said thermal cracking zone. 11. A process according to claim 6 including burning at least a portion of said distillate stream for producing power. 12. A process according to claim 6 including burning at least some of the asphaltene fraction to provide at least some of the process heating requirements. 13. A process according to claim 6 wherein at least some of the hydrogen in said hydrogen donor diluent is formed by gasifying at least a portion of said asphaltene fraction. 14. A process for upgrading a hydrocarbon feed stream containing sulfur, metals, and asphaltenes, said process comprising: a) cracking said hydrocarbon feed stream to form a cracked hydrocarbon feed stream; b) applying said cracked hydrocarbon feed stream to a distillation column for producing a substantially asphaltene-free, and metal- free distillate fraction and a non-distilled fraction containing sulfur, asphaltenes, and metals; c) converting at least some of said substantially asphaltene-free, and metal-free distillate fraction to a hydrogen donor diluent; d) processing said non-distilled fraction in a solvent deasphalting unit for producing a deasphalted oil stream and an asphaltene stream; e) combining said hydrogen donor diluent with said deasphalted oil stream to form a combined stream; f) thermal cracking said combined stream for forming a thermally cracked stream; and g) applying said thermally cracked stream to said distillation column. 15. A process according to claim 1 wherein the thermal cracking of said combined stream is practiced in the presence of a catalyst. 16. A process according to claim 15 wherein the catalyst promotes cracking of said combined stream. 17. A process according to claim 15 wherein the catalyst suppresses the formation of asphaltenes. 18. A process according to claim 15 wherein the catalyst suppresses the formation of asphaltenes, and wherein the catalyst promotes cracking of said combined stream. 19. A process according to claim 15 wherein the catalyst is a metal selected from the group consisting of a Groups IVB, VB, VIB, VIIB, and VIII of the Periodic Table of Elements, and mixtures thereof. 20. A process according to claim 15 wherein the catalyst is a molybdenum. 21. A process of claim 1 wherein the thermal cracking is practiced in the presence of a hydrogen donor. 22. A process of claim 21 wherein the hydrogen donor is hydrogen gas. 23. A process of claim 21 wherein the hydrogen donor is a hydrogen donor diluent stream. 24. Apparatus for upgrading a hydrocarbon feed stream containing sulfur, metals, and asphaltenes, said apparatus comprising: a) a thermal cracker for cracking said hydrocarbon feed stream thereby producing a cracked hydrocarbon feed stream; b) a distillation column for receiving said cracked hydrocarbon feed stream and producing a substantially asphaltene-free, and metal- free distillate fraction and a non-distilled fraction containing sulfur, asphaltenes and metals; c) means for converting at least some of said substantially asphaltene-free, and metal-free distillate fraction to a hydrogen donor diluent; d) a solvent deasphalting unit for processing said non-distilled fraction and producing a deasphalted oil stream and an asphaltene stream; e) means for combining said hydrogen donor diluent with said deasphalted oil stream to form a combined stream; f) a thermal cracker for thermally cracking said combined stream and forming a thermally cracked stream; and g) means for applying said thermally cracked stream to said distillation column. 25. An apparatus according to claim 4 wherein the thermal cracker contains a catalyst. 26. An apparatus according to claim 24 wherein the catalyst promotes cracking of said combined stream. 27. An apparatus according to claim 24 wherein the catalyst suppresses the formation of asphaltenes. 28. An apparatus according to claim 24 wherein the catalyst both suppresses the formation of asphaltenes, and promotes the cracking of said combined stream. 29. An apparatus according to claim 24 wherein the catalyst is a metal selected from the group consisting of metals of Groups IVB, VB, VIB, VIIB, and VIII of the Periodic Table of Elements, and mixtures thereof. 30. An apparatus according to claim 24 wherein the catalyst is molybdenum. 31. An apparatus according to claim 6 wherein the thermal cracker contains a catalyst.