U.S. patent application number 13/889905 was filed with the patent office on 2013-11-14 for methods and systems for upgrading hydrocarbon.
The applicant listed for this patent is MARATHON OIL CANADA CORPORATION. Invention is credited to Mahendra L. Joshi, Jose Armando Salazar.
Application Number | 20130299387 13/889905 |
Document ID | / |
Family ID | 49547821 |
Filed Date | 2013-11-14 |
United States Patent
Application |
20130299387 |
Kind Code |
A1 |
Salazar; Jose Armando ; et
al. |
November 14, 2013 |
METHODS AND SYSTEMS FOR UPGRADING HYDROCARBON
Abstract
Methods and systems for upgrading hydrocarbon material,
including bituminous material such as tar sands. A hydrocarbon
material and a cracking material can be injected into separate
injection ports of a nozzle reactor to produce a hydrocarbon
product. The hydrocarbon product can be injected directly into a
coker so that heavy hydrocarbon compounds can be upgraded into
lighter hydrocarbon compounds, or the hydrocarbon product can first
be injected into a separation vessel to separate hydrocarbons
having higher boiling point temperature from hydrocarbons having
lower boiling point temperature. The hydrocarbons having higher
boiling point temperature can then be injected into a coker.
Inventors: |
Salazar; Jose Armando;
(Ashland, KY) ; Joshi; Mahendra L.; (Katy,
TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
MARATHON OIL CANADA CORPORATION |
Calgary |
|
CA |
|
|
Family ID: |
49547821 |
Appl. No.: |
13/889905 |
Filed: |
May 8, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61646641 |
May 14, 2012 |
|
|
|
Current U.S.
Class: |
208/76 ;
422/187 |
Current CPC
Class: |
C10G 9/005 20130101;
C10G 51/023 20130101; C10G 9/36 20130101 |
Class at
Publication: |
208/76 ;
422/187 |
International
Class: |
C10G 9/00 20060101
C10G009/00; C10G 9/36 20060101 C10G009/36 |
Claims
1. A hydrocarbon upgrading system comprising: a nozzle reactor
having an hydrocarbon product outlet; a separation vessel having a
hydrocarbon product inlet and a residual hydrocarbon outlet,
wherein the hydrocarbon product outlet of the nozzle reactor is in
fluid communication with the hydrocarbon product inlet of the
separation vessel; and a coker having a residual hydrocarbon inlet
and a cracked hydrocarbon outlet, wherein the residual hydrocarbon
outlet of the separation vessel is in fluid communication with the
residual hydrocarbon inlet of the coker.
2. The hydrocarbon upgrading system as recited in claim 1, wherein
the separation vessel comprises a vacuum distillation tower; an
atmospheric distillation tower; or a separator cyclone.
3. The hydrocarbon upgrading system as recited in claim 1, wherein
the coker is a delayed coker, a fluid coker, or a flexicoker.
4. A hydrocarbon upgrading system comprising: a nozzle reactor
having an hydrocarbon product outlet; and a coker having a
hydrocarbon product inlet and a cracked hydrocarbon outlet, wherein
the hydrocarbon product outlet of the nozzle reactor is in fluid
communication with the hydrocarbon inlet of the coker.
5. The hydrocarbon upgrading system as recited in claim 4, wherein
the coker is a delayed coker, a fluid coker, or a flexicoker.
6. A method of upgrading hydrocarbon comprising: injecting
hydrocarbon material into a feed injection port of a nozzle
reactor; injecting a cracking material into a cracking material
injection port of a nozzle reactor; collecting a hydrocarbon
product exiting the nozzle reactor; injecting the hydrocarbon
product into a separation vessel and separating a portion of the
hydrocarbon product from a residual hydrocarbon stream; and
injecting the residual hydrocarbon stream into a coker.
7. The method of 6, wherein the hydrocarbon material comprises
bituminous material.
8. The method of claim 6, wherein the cracking material is injected
into the nozzle reactor at a direction transverse to the direction
in which hydrocarbon material is injected into the nozzle
reactor.
9. The method of claim 6, wherein the cracking material is
accelerated to supersonic speed inside the nozzle reactor and prior
to interacting with the hydrocarbon material.
10. The method of claim 6, wherein the cracking material is
steam.
11. The method of claim 6, wherein the separation vessel is an
atmospheric distillation tower, a vacuum distillation tower, or a
cyclone separator.
12. The method of claim 6, wherein the coker is a delayed coker, a
fluid coker, or a flexicoker.
13. The method of claim 6, wherein the residual hydrocarbon stream
comprises predominantly hydrocarbons having a boiling point
temperature above about 1,050.degree. F.
14. A method of upgrading hydrocarbon comprising: injecting
hydrocarbon material into a feed injection port of a nozzle
reactor; injecting a cracking material into a cracking material
injection port of a nozzle reactor; collecting hydrocarbon product
exiting the nozzle reactor; and injecting the hydrocarbon product
into a coker.
15. The method of claim 14, wherein the hydrocarbon material
comprises bituminous material.
16. The method of claim 14, wherein the cracking material is
injected into the nozzle reactor at a direction transverse to the
direction in which hydrocarbon material is injected into the nozzle
reactor.
17. The method of claim 14, wherein the cracking material is
accelerated to supersonic speed inside the nozzle reactor and prior
to interacting with the hydrocarbon material.
18. The method of claim 14, wherein the cracking material is
steam.
19. The method of claim 14, wherein the coker is a delayed coker, a
fluid coker, or a flexicoker.
20. The method of claim 14, further comprising the step of
collecting an upgraded hydrocarbon material from the coker, wherein
the upgraded hydrocarbon material comprises predominantly
hydrocarbons having a boiling point temperature less than
1,050.degree. F.
Description
BACKGROUND OF THE INVENTION
[0001] Nozzle reactors can be used to upgrade hydrocarbon material,
including bituminous material such as tar sands. Some embodiments
of the nozzle reactors described in the aforementioned patent
applications and issued patents generally include a cracking
material injection port and a feed material injection port. The
cracking material injection port is designed to accelerate cracking
material to a supersonic speed. Additionally, the cracking material
injection port is configured so as to be aligned transverse to the
feed material injection port. When the cracking material (e.g.,
steam) and the feed material are injected into the reaction chamber
of the nozzle reactor, the two materials interact in such a way as
to cause the cracking and upgrading of the hydrocarbon
material.
[0002] However, some embodiments of the nozzle reactors described
above do not crack all of the feed material injected into the
nozzle reactor. As a result, some of the hydrocarbon material
leaving the nozzle reactor has a boiling point temperature of
greater than 1,050.degree. F. and is considered pitch. This pitch
material is difficult to process and less valuable then the cracked
hydrocarbon material. Accordingly, the some embodiments of the
above described nozzle reactors have a shortcoming of not cracking
all hydrocarbon material injected into the nozzle reactor and
outputting pitch material that is not a desirable end product of
the nozzle reactor process.
BRIEF SUMMARY OF THE INVENTION
[0003] Disclosed below are representative embodiments that are not
intended to be limiting in any way. Instead, the present disclosure
is directed toward features, aspects, and equivalents of the
embodiments of the nozzle reactor and method of use described
below. The disclosed features and aspects of the embodiments can be
used alone or in various combinations and sub-combinations with one
another.
[0004] In some embodiments, a hydrocarbon upgrading system is
described. The hydrocarbon upgrading system includes a nozzle
reactor and a coker. The hydrocarbon product outlet of the nozzle
reactor can be in fluid communication with the hydrocarbon product
inlet of the coker so that hydrocarbon material exiting the nozzle
reactor can be transported directly to the coker. The coker works
to crack and upgrade the heaviest hydrocarbons included in the
hydrocarbon product leaving the nozzle reactor, including the pitch
material. The nozzle reactor included in the system can include
nozzle reactors similar or identical to nozzle reactors described
in U.S. Pat. No. 7,618,597; U.S. Pat. No. 7,927,565; U.S. patent
application Ser. No. 12/579,193; U.S. patent application Ser. No.
12/816,844; and U.S. patent application Ser. No. 13/227,470.
[0005] In some embodiments, the system also includes a separation
vessel located intermediate the nozzle reactor and the coker. In
such embodiments, the hydrocarbon product leaving the nozzle
reactor can be introduced into the separation vessel to separate
light hydrocarbons from heavy hydrocarbons. The heavy hydrocarbons
are subsequently sent to the coke for upgrading. In some
embodiments, the separation vessel is part of the multiple pieces
of equipment that make up the coker, such a delayed coker system
which can include a fractionator.
[0006] In some embodiments, a method for upgrading hydrocarbon
material is described. The method generally includes the steps of
injecting hydrocarbon material into a feed injection port of a
nozzle reactor, injecting a cracking material into a cracking
material injection port of a nozzle reactor, collecting hydrocarbon
product exiting the nozzle reactor, and injecting the hydrocarbon
product into a coker. The nozzle reactor used in the method can
include nozzle reactors similar or identical to nozzle reactors
described in U.S. Pat. No. 7,618,597; U.S. Pat. No. 7,927,565; U.S.
patent application Ser. No. 12/579,193; U.S. patent application
Ser. No. 12/816,844; and U.S. patent application Ser. No.
13/227,470.
[0007] In some embodiments, the hydrocarbon upgrading method
includes one or more separation steps performed after collecting
the hydrocarbon product but before injecting the hydrocarbon
product into a coker. The separation steps can include injecting
the hydrocarbon product from the nozzle reactor into a separation
vessel, separating residual hydrocarbon from the hydrocarbon
product, and injecting the residual hydrocarbon stream into the
coker.
[0008] The foregoing and other features and advantages of the
present application will become apparent from the following
detailed description, which proceeds with reference to the
accompanying figures. It is thus to be understood that the scope of
the invention is to be determined by the claims as issued and not
by whether a claim includes any or all features or advantages
recited in this Brief Summary of the Invention or addresses any
issue identified in the Background of the Invention.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0009] The preferred and other embodiments are disclosed in
association with the accompanying drawings in which:
[0010] FIG. 1 is a flow chart illustrating the steps of some
embodiments of a hydrocarbon upgrading method described herein;
[0011] FIG. 2 shows a cross-sectional view of some embodiments of a
nozzle reactor described herein;
[0012] FIG. 3 shows a cross-sectional view of the top portion of
the nozzle reactor shown in FIG. 2;
[0013] FIG. 4 shows a cross-sectional perspective view of the
mixing chamber in the nozzle reactor shown in FIG. 2;
[0014] FIG. 5 shows a cross-sectional perspective view of the
distributor from the nozzle reactor shown in FIG. 2;
[0015] FIG. 6 shows a cross-sectional view of some embodiments of a
nozzle reactor described herein;
[0016] FIG. 7 shows a cross-sectional view of the top portion of
the nozzle reactor shown in FIG. 6;
[0017] FIG. 8a illustrates embodiments of a system suitable for use
in carrying out embodiments of the hydrocarbon upgrading method
described herein;
[0018] FIG. 8b illustrates embodiments of a system suitable for use
in carrying out embodiments of the hydrocarbon upgrading method
described herein; and
[0019] FIG. 9 illustrates embodiments of a system suitable for use
in carrying out embodiments of the hydrocarbon upgrading method
described herein.
DETAILED DESCRIPTION OF THE INVENTION
[0020] With reference to FIG. 1, some embodiments of a method for
upgrading hydrocarbon material generally include a step 1000 of
injecting hydrocarbon material into a feed injection port of a
nozzle reactor, a step 1100 of injecting a cracking material into a
cracking material injection port of the nozzle reactor, a step 1200
of collecting hydrocarbon product exiting the nozzle reactor, a
step 1300 of injecting the hydrocarbon product into a separation
vessel and separating a residual hydrocarbon stream from the
hydrocarbon product, and a step 1400 of injecting the residual
hydrocarbon stream into a coker. This method provides a manner for
upgrading the heavy hydrocarbon that passes through the nozzle
reactor uncracked and would otherwise be a commercially undesirable
product of the nozzle reactor. By providing a manner to crack this
material, the efficiency and profitability of the system is
increased and the overall cost and complexity of the system may be
decreased by doing away with additional processing equipment needed
for handling pitch material produced by the nozzle reactor,
including requiring a recycle stream for injecting the pitch
material back into the nozzle reactor.
[0021] In steps 1000 and 1100, the feed material and cracking
material may be injected into the nozzle reactor via their
respective injection ports. The aim of injecting the two materials
into the nozzle reactor is to cause the two materials to interact
in the reaction chamber of the nozzle reactor and result in the
cracking of the feed material.
[0022] In some embodiments, the feed material injected in step 1000
may be a hydrocarbon material, such as a hydrocarbon material
including hydrocarbons in need of cracking to produce lower boiling
point hydrocarbons that are generally more commercially valuable
than higher boiling hydrocarbons. While the hydrocarbon material
can include non-hydrocarbon material, such material is generally
less than 10 wt % of the overall material. In some embodiments, the
hydrocarbon material may be tar sands or material extracted from
tar sands. For example, in some embodiments, the hydrocarbon
material may be bitumen material obtained from processing tar
sands. The tar sands processing used to extract bitumen can include
solvent extraction techniques, such as solvent extraction technique
described in U.S. Pat. No. 7,909,989. In some embodiments, the
injected hydrocarbon material is the residue obtained from
subjecting heavy crude to separation processing, such as in an
atmospheric or vacuum tower. Accordingly, in some embodiments, an
atmospheric or vacuum tower may be located upstream of the nozzle
reactor and may be used to provide the residue that will serve as
the hydrocarbon material injected into the nozzle reactor.
[0023] Generally speaking, any material capable of being injected
into a nozzle reactor for the purpose of cracking feed material can
be used in step 1100. In some embodiments, the cracking material is
steam. Other suitable cracking materials include natural gas,
methanol, ethanol, ethane, propane, biodiesel, carbon monoxide,
nitrogen, or combinations thereof.
[0024] Any nozzle reactor suitable for use in upgrading hydrocarbon
material can be used to carry out the method described herein. In
some embodiments, the nozzle reactor includes a feed material
injection port that is aligned transverse to the cracking material
injection port so that the two materials enter the reaction chamber
of the nozzle reactor in perpendicular directions. The nozzle
reactor can also include a cracking material injection port capable
of accelerating the cracking material to supersonic speed prior to
entering the reaction chamber. Nozzle reactors fitting this
description are described in U.S. Pat. No. 7,618,597; U.S. Pat. No.
7,927,565; U.S. patent application Ser. No. 12/579,193; U.S. patent
application Ser. No. 12/816,844; and U.S. patent application Ser.
No. 13/227,470.
[0025] FIGS. 2 and 3 show cross-sectional views of one embodiment
of a nozzle reactor 100 suitable for use in the methods described
herein. The nozzle reactor 100 includes a head portion 102 coupled
to a body portion 104. A main passage 106 extends through both the
head portion 102 and the body portion 104. The head and body
portions 102, 104 are coupled together so that the central axes of
the main passage 106 in each portion 102, 104 are coaxial so that
the main passage 106 extends straight through the nozzle reactor
100.
[0026] It should be noted that for purposes of this disclosure, the
term "coupled" means the joining of two members directly or
indirectly to one another. Such joining may be stationary in nature
or movable in nature. Such joining may be achieved with the two
members or the two members and any additional intermediate members
being integrally formed as a single unitary body with one another
or with the two members or the two members and any additional
intermediate member being attached to one another. Such joining may
be permanent in nature or alternatively may be removable or
releasable in nature.
[0027] The nozzle reactor 100 includes a feed passage 108 that is
in fluid communication with the main passage 106. The feed passage
108 intersects the main passage 106 at a location between the
portions 102, 104. The main passage 106 includes an entry opening
110 at the top of the head portion 102 and an exit opening 112 at
the bottom of the body portion 104. The feed passage 108 also
includes an entry opening 114 on the side of the body portion 104
and an exit opening 116 that is located where the feed passage 108
meets the main passage 106.
[0028] During operation, the nozzle reactor 100 includes a reacting
fluid that flows through the main passage 106. The reacting fluid
enters through the entry opening 110, travels the length of the
main passage 106, and exits the nozzle reactor 100 out of the exit
opening 112. A feed material flows through the feed passage 108.
The feed material enters through the entry opening 114, travels
through the feed passage 106, and exits into the main passage 108
at exit opening 116.
[0029] The main passage 106 is shaped to accelerate the reacting
fluid. The main passage 106 may have any suitable geometry that is
capable of doing this. As shown in FIGS. 2 and 3, the main passage
106 includes a first region having a convergent section 120 (also
referred to herein as a contraction section), a throat 122, and a
divergent section 124 (also referred to herein as an expansion
section). The first region is in the head portion 102 of the nozzle
reactor 100.
[0030] The convergent section 120 is where the main passage 106
narrows from a wide diameter to a smaller diameter, and the
divergent section 124 is where the main passage 106 expands from a
smaller diameter to a larger diameter. The throat 122 is the
narrowest point of the main passage 106 between the convergent
section 120 and the divergent section 124. When viewed from the
side, the main passage 106 appears to be pinched in the middle,
making a carefully balanced, asymmetric hourglass-like shape. This
configuration is commonly referred to as a convergent-divergent
nozzle or "con-di nozzle".
[0031] The convergent section of the main passage 106 accelerates
subsonic fluids since the mass flow rate is constant and the
material must accelerate to pass through the smaller opening. The
flow will reach sonic velocity or Mach 1 at the throat 122 provided
that the pressure ratio is high enough. In this situation, the main
passage 106 is said to be in a choked flow condition.
[0032] Increasing the pressure ratio further does not increase the
Mach number at the throat 122 beyond unity. However, the flow
downstream from the throat 122 is free to expand and can reach
supersonic velocities. It should be noted that Mach 1 can be a very
high speed for a hot fluid since the speed of sound varies as the
square root of absolute temperature. Thus the speed reached at the
throat 122 can be far higher than the speed of sound at sea
level.
[0033] The divergent section 124 of the main passage 106 slows
subsonic fluids, but accelerates sonic or supersonic fluids. A
convergent-divergent geometry can therefore accelerate fluids in a
choked flow condition to supersonic speeds. The
convergent-divergent geometry can be used to accelerate the hot,
pressurized reacting fluid to supersonic speeds, and upon
expansion, to shape the exhaust flow so that the heat energy
propelling the flow is maximally converted into kinetic energy.
[0034] The flow rate of the reacting fluid through the
convergent-divergent nozzle is isentropic (fluid entropy is nearly
constant). At subsonic flow the fluid is compressible so that
sound, a small pressure wave, can propagate through it. At the
throat 122, where the cross sectional area is a minimum, the fluid
velocity locally becomes sonic (Mach number=1.0). As the cross
sectional area increases the gas begins to expand and the gas flow
increases to supersonic velocities where a sound wave cannot
propagate backwards through the fluid as viewed in the frame of
reference of the nozzle (Mach number>1.0).
[0035] The main passage 106 only reaches a choked flow condition at
the throat 122 if the pressure and mass flow rate is sufficient to
reach sonic speeds, otherwise supersonic flow is not achieved and
the main passage will act as a venturi tube. In order to achieve
supersonic flow, the entry pressure to the nozzle reactor 100
should be significantly above ambient pressure.
[0036] The pressure of the fluid at the exit of the divergent
section 124 of the main passage 106 can be low, but should not be
too low. The exit pressure can be significantly below ambient
pressure since pressure cannot travel upstream through the
supersonic flow. However, if the pressure is too far below ambient,
then the flow will cease to be supersonic or the flow will separate
within the divergent section 124 of the main passage 106 forming an
unstable jet that "flops" around and damages the main passage 106.
In one embodiment, the ambient pressure is no higher than
approximately 2-3 times the pressure in the supersonic gas at the
exit.
[0037] The supersonic reacting fluid collides and mixes with the
feed material in the nozzle reactor 100 to produce the desired
reaction. The high speeds involved and the resulting collision
produces a significant amount of kinetic energy that helps
facilitate the desired reaction. The reacting fluid and/or the feed
material may also be pre-heated to provide additional thermal
energy to react the materials.
[0038] The nozzle reactor 100 may be configured to accelerate the
reacting fluid to at least approximately Mach 1, at least
approximately Mach 1.5, or, desirably, at least approximately Mach
2. The nozzle reactor may also be configured to accelerate the
reacting fluid to approximately Mach 1 to approximately Mach 7,
approximately Mach 1.5 to approximately Mach 6, or, desirably,
approximately Mach 2 to approximately Mach 5.
[0039] As shown in FIG. 3, the main passage 106 has a circular
cross-section and opposing converging side walls 126, 128. The side
walls 126, 128 curve inwardly toward the central axis of the main
passage 106. The side walls 126, 128 form the convergent section
120 of the main passage 106 and accelerate the reacting fluid as
described above.
[0040] The main passage 106 also includes opposing diverging side
walls 130, 132. The side walls 130, 132 curve outwardly (when
viewed in the direction of flow) away from the central axis of the
main passage 106. The side walls 130, 132 form the divergent
section 124 of the main passage 106 that allows the sonic fluid to
expand and reach supersonic velocities.
[0041] The side walls 126, 128, 130, 132 of the main passage 106
provide uniform axial acceleration of the reacting fluid with
minimal radial acceleration. The side walls 126, 128, 130, 132 may
also have a smooth surface or finish with an absence of sharp edges
that may disrupt the flow. The configuration of the side walls 126,
128, 130, 132 renders the main passage 106 substantially
isentropic.
[0042] The feed passage 108 extends from the exterior of the body
portion 104 to an annular chamber 134 formed by head and body
portions 102, 104. The portions 102, 104 each have an opposing
cavity so that when they are coupled together the cavities combine
to form the annular chamber 134. A seal 136 is positioned along the
outer circumference of the annular chamber 134 to prevent the feed
material from leaking through the space between the head and body
portions 102, 104.
[0043] It should be appreciated that the head and body portions
102, 104 may be coupled together in any suitable manner. Regardless
of the method or devices used, the head and body portions 102, 104
should be coupled together in a way that prevents the feed material
from leaking and withstands the forces generated in the interior.
In one embodiment, the portions 102, 104 are coupled together using
bolts that extend through holes in the outer flanges of the
portions 102, 104.
[0044] The nozzle reactor 100 includes a distributor 140 positioned
between the head and body portions 102, 104. The distributor 140
prevents the feed material from flowing directly from the opening
141 of the feed passage 108 to the main passage 106. Instead, the
distributor 140 annularly and uniformly distributes the feed
material into contact with the reacting fluid flowing in the main
passage 106.
[0045] As shown in FIG. 5, the distributor 140 includes an outer
circular wall 148 that extends between the head and body portions
102, 104 and forms the inner boundary of the annular chamber 134. A
seal or gasket may be provided at the interface between the
distributor 140 and the head and body portions 102, 104 to prevent
feed material from leaking around the edges.
[0046] The distributor 140 includes a plurality of holes 144 that
extend through the outer wall 148 and into an interior chamber 146.
The holes 144 are evenly spaced around the outside of the
distributor 140 to provide even flow into the interior chamber 146.
The interior chamber 146 is where the main passage 106 and the feed
passage 108 meet and the feed material comes into contact with the
supersonic reacting fluid.
[0047] The distributor 140 is thus configured to inject the feed
material at about a 90.degree. angle to the axis of travel of the
reacting fluid in the main passage 106 around the entire
circumference of the reacting fluid. The feed material thus forms
an annulus of flow that extends toward the main passage 106. The
number and size of the holes 144 are selected to provide a pressure
drop across the distributor 140 that ensures that the flow through
each hole 144 is approximately the same. In one embodiment, the
pressure drop across the distributor is at least approximately 2000
pascals, at least approximately 3000 pascals, or at least
approximately 5000 pascals.
[0048] Referring back to FIG. 4, holes 144 are shown having a
circular cross-section. Circular holes 144 are suitable for
effective nozzle reactor operation when the nozzle reactor is
relatively small and handling production capacities less than,
e.g., 1,000 bbl/day. At such production capacities, the feed
material passing through the circular holes will break up into the
smaller droplet size necessary for efficient mixing or shearing
with the reacting fluid.
[0049] As the size and production capacity of the nozzle reactor is
increased, the diameter of the circular holes 144 also increases.
As the diameter of the circular holes 144 increases with scale up
of the nozzle reactor, the circular holes 144 eventually become too
large for feed material traveling therethrough to exert sufficient
inertial or shear forces on the circular holes 144. As a result,
the feed material traveling through the holes 144 does not break up
into the smaller droplets necessary for efficient mixing or
shearing with the reacting fluid, and uniform distribution of the
feed material is not achieved. Instead, the feed material passing
through the circular holes 144 maintains a cone-like structure for
a longer radial travel distance and impacts the reactive fluid in
large droplets not conducive for intimate mixing with the reacting
fluid. Non-uniform kinetic energy transfer from the reacting fluid
to the large droplets of feed material results and the overall
conversion efficiency of the reactor nozzle is reduced.
[0050] Accordingly, in some embodiments where larger nozzle
reactors are used to handle higher production capacities (e.g.,
greater than 1,000 bbl/day), the injection holes 144 can have a
non-circular cross-sectional shape. FIGS. 10-13 illustrate several
non-circular shapes that can be used for injection holes 144. In
FIG. 10, a cross-shaped injection hole is shown. In FIG. 11, a
star-shaped injection hole is shown. In FIG. 12, a lobed-shaped
injection hole is shown. In FIG. 13, a slotted-shaped injection
hole is shown. Other non-circular shapes, such as rectangular,
triangular, elliptical, trapezoidal, fish-eye, etc., not shown in
the Figures can also be used.
[0051] In some embodiments, the cross-shaped injection hole is a
preferred cross-sectional shape. The cross-shaped injection holes
can extend the maximum oil flow capacity at a given conversion rate
by at least 20 to 30% over circular injection holes having similar
cross-sectional areas. With reference to FIG. 14, various
dimensions of the cross-shaped injection hole are labeled,
including r.sub.0, r.sub.1, r.sub.2, and H. In some embodiments,
the cross-shaped injection hole has dimensions according to the
following ratios: r.sub.0/r.sub.1=1.2 to 2.0, preferably 1.5;
H/r.sub.0=3 to 4, preferably 3.5; and r.sub.2/r.sub.1=0.25 to 0.75,
preferably 0.5.
[0052] Changing the aspect ratio of the non-circular injection
holes along the major and/or minor axis can varying the level of
shear or turbulence generated by the reacting fluid. Generally,
elongated thin slots, or shapes having thinner cross sections and
at the same time changing orientation of slots along the
circumferential direction (such as cross or lobe shape) offer the
highest level of shear along the axial and circumferential jet
directions. This is generally due to generation of Helmholtz
vortices along various axes. The individual vortices develop in
pairs with counter rotating directions. The counter rotating
vortices contribute to increased shearing of jet and entrainment of
surrounding fluids.
[0053] The cross-sectional area of the non-circular injection holes
is generally not limited. In some embodiments, the cross-sectional
area of the non-circular injection holes is designed for required
oil flow capacity for optimum conversion at a given oil supply
pressure (e.g., 100 to 150 psig).
[0054] Any suitable manner for manufacturing the non-circular
injection holes can be used. In some embodiments, the non-circular
injection holes are cut using a water jet cutting process or
Electro Discharge Machining (EDM). In some embodiments, the
internal surfaces of the non-circular injection holes are smooth.
The internal surfaces can be made smooth using any suitable
techniques, including grinding, polishing, and lapping. Smooth
internal surfaces can be preferred because they produce smaller
droplets of feed material than when the internal surface of the
injection hole is rough.
[0055] Other parameters that have been found to impact the size of
the feed material droplets include the feed material pressure on
the injection hole (increased pressure result in smaller droplet
size), the viscosity of the feed material (lower viscosity feed
material has smaller droplets), and the spray angle (smaller spray
angles provide smaller droplets). Accordingly, one or more of these
parameters can be adjusted in the nozzle reactor in order to
produce the smaller feed material droplets that lead to better
mixing with the reacting material.
[0056] One benefit of using non-circular injection holes 144 in
larger nozzle reactors handling larger production capacities is
that the non-circular injection holes can help to ensure that the
core of the feed material jet breaks up into smaller particles over
a relatively short radial travel distance.
[0057] The non-circular injection holes also help to generate
streamwise and spanwise vortices. The interaction of the spanwise
(Kelvin-Helmholtz) vortices with the streamwise vortices produce
the high levels of mixing. These vortices form, intensify, and then
break down, and the high turbulence resulting from the vortex
breakdown improves the overall mixing process. Large-scale
turbulence is generated along the sides of the injection holes,
while small-scale turbulence is generated at the vortices.
[0058] Another benefit of using non-circular injection holes 144 is
the improvement in entrainment efficiency. The entrainment of feed
material in the reacting material at the area near the non-circular
injection hole 144 can be four times higher than in a circular
injection hole. Higher entrainment efficiency would allow more
uniform and earlier mixing of feed material droplets with the
reacting material. This would enable thermal and kinetic
interaction between streams and result in breakup of larger
molecules into smaller molecules.
[0059] Still another benefit of using the non-circular injection
holes described above is the incremental increase in conversion of
heavy residue hydrocarbons, such as 1050.degree. F.+ hydrocarbon
fractions. Other benefits include increasing the production
capacity of a given nozzle reactor, providing a smaller foot print
for installation, and reducing recycle volumes of unconverted
residue.
[0060] Adjusting the cross-section shape of holes 144 in order to
allow for scale up of the nozzle reactor without negatively
impacting the performance of the nozzle reactor can be preferable
to using multiple smaller nozzle reactors arranged in parallel. In
the parallel nozzle reactors configuration, each nozzle reactor
handles a small portion of overall production capacity and allows
for the continued use of circular holes 144. However, while this
method will maintain adequate mixing and conversion per nozzle
reactor, it will also result in higher capital costs associated
with nozzle reactors and the piping needed for feed distribution
and collecting converted products.
[0061] In some embodiments, throat 122 and divergent section 124 of
main passage 106 can also have a non-circular cross section, such
as the cross shape, lobe shape, or slotted shape described in
greater detail above with respect to injection holes 144. Cracking
material is typically injected into the nozzle reactor through this
portion of the main passage 106, and by providing a non-circular
cross-sectional shape, similar benefits to those described above
with respect to the non-circular injection holes 144 can be
achieved for the cracking material. For example, increased
turbulence of the cracking material and entrainment efficiency
between the cracking material and the feed material can be achieved
when throat 122 and divergent section 124 have a non-circular
shape. As discussed in greater detail previous, increases in
turbulence and entrainment efficiency can increase the conversion
of large hydrocarbon molecules into smaller hydrocarbon
molecules.
[0062] In some embodiments, the non-circular shape begins at the
narrowest portion of the throat 122 and the non-circular shape
continues the length of the divergent section 124 such that the
ejection end of the divergent section 124 has the non-circular
cross-section shape. The cross-sectional area in the divergent
section become larger as the ejection end is approached, but the
same cross-sectional shape can be maintained throughout the length
of the divergent section 124. As with the injection holes 144, the
interior surfaces of the throat 122 and divergent section 124 can
have a smooth surface.
[0063] In some embodiments, a combination of circular and
non-circular injection holes can be used within the same nozzle
reactor. Any combination of circular and non-circular injection
holes can be used. In some embodiments, the plurality of injection
holes provided for the reacting fluid can include both circular and
non-circular injection holes. In some embodiments, non-circular
injection holes can be used for the reacting material while
circular injection holes are used for the cracking fluid. In some
embodiments, circular injection holes can be used for the reacting
material while non-circular injection holes can be used for the
cracking fluid.
[0064] The distributor 140 includes a wear ring 150 positioned
immediately adjacent to and downstream of the location where the
feed passage 108 meets the main passage 106. The collision of the
reacting fluid and the feed material causes a lot of wear in this
area. The wear ring is a physically separate component that is
capable of being periodically removed and replaced.
[0065] As shown in FIG. 5, the distributor 140 includes an annular
recess 152 that is sized to receive and support the wear ring 150.
The wear ring 150 is coupled to the distributor 140 to prevent it
from moving during operation. The wear ring 150 may be coupled to
the distributor in any suitable manner. For example, the wear ring
150 may be welded or bolted to the distributor 140. If the wear
ring 150 is welded to the distributor 140, as shown in FIG. 4, the
wear ring 150 can be removed by grinding the weld off. In some
embodiments, the weld or bolt need not protrude upward into the
interior chamber 146 to a significant degree.
[0066] The wear ring 150 can be removed by separating the head
portion 102 from the body portion 104. With the head portion 102
removed, the distributor 140 and/or the wear ring 150 are readily
accessible. The user can remove and/or replace the wear ring 150 or
the entire distributor 140, if necessary.
[0067] As shown in FIGS. 2 and 3, the main passage 106 expands
after passing through the wear ring 150. This can be referred to as
expansion area 160 (also referred to herein as an expansion
chamber). The expansion area 160 is formed largely by the
distributor 140, but can also be formed by the body portion
104.
[0068] Following the expansion area 160, the main passage 106
includes a second region having a converging-diverging shape. The
second region is in the body portion 104 of the nozzle reactor 100.
In this region, the main passage includes a convergent section 170
(also referred to herein as a contraction section), a throat 172,
and a divergent section 174 (also referred to herein as an
expansion section). The converging-diverging shape of the second
region differs from that of the first region in that it is much
larger. In one embodiment, the throat 172 is at least 2-5 times as
large as the throat 122.
[0069] The second region provides additional mixing and residence
time to react the reacting fluid and the feed material. The main
passage 106 is configured to allow a portion of the reaction
mixture to flow backward from the exit opening 112 along the outer
wall 176 to the expansion area 160. The backflow then mixes with
the stream of material exiting the distributor 140. This mixing
action also helps drive the reaction to completion.
[0070] The dimensions of the nozzle reactor 100 can vary based on
the amount of material that is fed through it. For example, at a
flow rate of approximately 590 kg/hr, the distributor 140 can
include sixteen holes 144 that are 3 mm in diameter. The dimensions
of the various components of the nozzle reactor shown in FIGS. 2
and 3 are not limited, and may generally be adjusted based on the
amount of feed flow rate if desired. Table 1 provides exemplary
dimensions for the various components of the nozzle reactor 100
based on a hydrocarbon feed input measured in barrels per day
(BPD).
TABLE-US-00001 TABLE 1 Exemplary nozzle reactor specifications Feed
Input (BPD) Nozzle Reactor Component (mm) 5,000 10,000 20,000 Main
passage, converging region, entry 254 359 508 opening diameter Main
passage, converging region, throat 75 106 150 diameter Main
passage, converging region, exit opening 101 143 202 diameter Main
passage, converging region, length 1129 1290 1612 Wear ring
internal diameter 414 585 828 Main passage, diverging region, entry
opening 308 436 616 diameter Main passage, diverging region, throat
diameter 475 672 950 Main passage, diverging region, exit opening
949 1336 1898 diameter Nozzle reactor, body portion, outside
diameter 1300 1830 2600 Nozzle reactor, overall length 7000 8000
10000
[0071] It should be appreciated that the nozzle reactor 100 can be
configured in a variety of ways that are different than the
specific design shown in the Figures. For example, the location of
the openings 110, 112, 114, 116 may be placed in any of a number of
different locations. Also, the nozzle reactor 100 may be made as an
integral unit instead of comprising two or more portions 102, 104.
Numerous other changes may be made to the nozzle reactor 100.
[0072] Turning to FIGS. 6 and 7, another embodiment of a nozzle
reactor 200 is shown. This embodiment is similar in many ways to
the nozzle reactor 100. Similar components are designated using the
same reference number used to illustrate the nozzle reactor 100.
The previous discussion of these components applies equally to the
similar or same components includes as part of the nozzle reactor
200.
[0073] The nozzle reactor 200 differs a few ways from the nozzle
reactor 100. The nozzle reactor 200 includes a distributor 240 that
is formed as an integral part of the body portion 204. However, the
wear ring 150 is still a physically separate component that can be
removed and replaced. Also, the wear ring 150 depicted in FIG. 8 is
coupled to the distributor 240 using bolts instead of by welding.
It should be noted that the bolts are recessed in the top surface
of the wear ring 150 to prevent them from interfering with the flow
of the feed material.
[0074] In FIGS. 6 and 7, the head portion 102 and the body portion
104 are coupled together with a clamp 280. The seal, which can be
metal or plastic, resembles a "T" shaped cross-section. The leg 282
of the "T" forms a rib that is held by the opposing faces of the
head and body portions 102, 104. The two arms or lips 284 form
seals that create an area of sealing surface with the inner
surfaces 276 of the portions 102, 104. Internal pressure works to
reinforce the seal.
[0075] The clamp 280 fits over outer flanges 286 of the head and
body portions 102, 104. As the portions 102, 104 are drawn together
by the clamp, the seal lips deflect against the inner surfaces 276
of the portions 102, 104. This deflection elastically loads the
lips 284 against the inner surfaces 276 forming a self-energized
seal. In one embodiment, the clamp is made by Grayloc Products,
located in Houston, Tex.
[0076] When a nozzle reactor as shown in FIGS. 2 through 7 is used
in the embodiments described herein, the hydrocarbon material can
be introduced into the nozzle reactor via entry opening 114 of feed
passage 108. The cracking material can be introduced into the
nozzle reactor via entry opening 110 of main passage 106, at which
point the cracking material is accelerated to supersonic speed so
that it can interact with the injected hydrocarbon material and
crack the hydrocarbon material.
[0077] In step 1200, the hydrocarbon product leaving the nozzle
reactor can be collected. The hydrocarbon product collected will
generally include hydrocarbon compounds having a wide range of
boiling point temperatures. In some embodiments, hydrocarbons
having a boiling point temperature in the range of from 100 to
above 1,050.degree. F. can be included in the hydrocarbon product.
The low boiling point temperature hydrocarbons are the result of
successful hydrocarbon cracking and/or the presence of low boiling
point temperature hydrocarbons in the feed material. The high
boiling point temperature hydrocarbons are the result of some
hydrocarbons passing through the nozzle reactor uncracked or only
minimally cracked. In some embodiments, the hydrocarbon product
will include hydrocarbons having a boiling temperature of greater
than 1,050.degree. F. Such hydrocarbons can be referred to as
hydrocarbon pitch and/or hydrocarbon residue. In some embodiments,
the pitch represents from 4 to 25 wt % of the hydrocarbon product.
Such material is generally less commercially useful than lower
boiling point temperature hydrocarbons.
[0078] In step 1300, the hydrocarbon product collected from the
nozzle reactor can be injected into a separation vessel so that the
light hydrocarbons can be separated from the heavy hydrocarbons.
Any suitable separation vessel can be used. In some embodiments,
the separation vessel can be a cyclone separator. In some
embodiments, the separation vessel can be an atmospheric
distillation tower or a vacuum distillation tower. Additionally,
the separation vessel can include one or more separation vessels
used in conjunction to effectively separate the heavy hydrocarbons
from the light hydrocarbons. In some embodiments, the separation
vessel can be part of the coker system used in step 1400, such as
in a set up for a delayed coker, which includes a main fractionator
to ensure that primarily heavy hydrocarbons enter the coker
drums.
[0079] The separation vessel is generally used to separate
hydrocarbons having a higher boiling point temperature from
hydrocarbons having a lower boiling point temperature. Any boiling
point temperature can be selected as the cut off for separating
light hydrocarbon from heavy hydrocarbons, and the separation
vessels used can be tailored to perform separations at the selected
temperature. In some embodiments, the selected temperature is
850.degree. F., or more preferably 1,050.degree. F. When the cut
off temperature is 1,050.degree. F., the separation vessel works to
separate most or all of the hydrocarbons having a boiling point
above 1,050.degree. F. from hydrocarbons having a boiling point
temperature lower than 1,050.degree. F. The stream of hydrocarbons
having a boiling point temperature higher than 1,050.degree. F.
produced as a result of the separation step(s) can be referred to
as pitch or residual hydrocarbons.
[0080] In some alternate embodiments, step 1300 can be eliminated
from the hydrocarbon upgrading method, such that the entire stream
of hydrocarbon product produced by the nozzle reactor can be sent
into the coker, including both light and heavy hydrocarbons. Such
embodiments can be useful for reducing the complexity and cost of
the overall system, as these embodiments eliminate the need for
some separation vessels. However, such embodiments may be less
desirable, as the presence of light hydrocarbons in the coker
system may reduce the effectiveness of the coker to crack the heavy
hydrocarbons.
[0081] In some embodiments, the separation vessel receives both the
products from the nozzle reactor and a separate hydrocarbon
material feed. The separate hydrocarbon material can include, for
example, heavy crude that has yet to be subjected to separation
processing to separate light distillate products from the heavier
residue hydrocarbon components. In such embodiments, the separation
vessel separates the combination of the nozzle reactor product and
the separate hydrocarbon material feed into a heavy hydrocarbon
stream and a light hydrocarbon stream. Subsequently, the heavy
hydrocarbon leaving the separation vessel (i.e., the pitch or
residual hydrocarbon) can be split into two streams. The first
stream of the residual hydrocarbons can be recycled back to the
nozzle reactor and serves as a feed stream for the nozzle reactor
(possibly in conjunction with other hydrocarbon feed material being
injected into the nozzle reactor). The second stream of the
residual hydrocarbons can be sent to the coker and is processed as
described in greater detail below. Such configurations can be
beneficial because they can eliminate the need for a separation
vessel located upstream of the nozzle reactor that is used to
separate, for example, heavy crude and provide a residue stream for
injecting into the nozzle reactor. Instead, the separation vessel
located downstream of the nozzle reactor can be used to separate
both the nozzle reactor product and the heavy crude material that
is the source of the residue injected into the nozzle reactor.
[0082] In step 1400, the hydrocarbon product or the residual
hydrocarbon is injected into a coker so that the heavy hydrocarbons
can be upgraded into lighter hydrocarbon compounds. The coker can
generally receive the hydrocarbon stream including heavy
hydrocarbon compounds and convert the heavy hydrocarbon compounds
into lower molecular weight hydrocarbon. Cokers also generally
produce petroleum coke as a byproduct of the upgrading process. Any
coke produced by the coker can undergo further processing, such as
by calcining in a rotary kiln. Any type of coker suitable for use
in upgrading the hydrocarbon material can be used. In some
embodiments, the coker is a delayed coker, a fluid coker, or a
flexicoker.
[0083] In some embodiments, a process heater, such as a fired
furnace, is provided upstream of the coker and is used to heat the
heavy hydrocarbon to a desired temperature prior to being
introduced into the coker.
[0084] Typical product that will be produced by processing the
heavy hydrocarbon in the coker includes but is not limited to,
heavy gas oil, light gas oil, naptha, and low molecular weight
hydrocarbon gas (in addition to the coke mentioned above). These
distillates can be blended with the distillates from the nozzle
reactor or kept separate for further downstream processing.
[0085] FIG. 8a illustrates a system that can be used to carry out
the method described in greater detail above. The system generally
includes a nozzle reactor 800, a separation vessel 810, and a coker
820. A stream of hydrocarbon material 801, which can include
bitumen or a composition including bitumen, can be injected into
the nozzle reactor 800. A cracking material 802, which can include
steam, can also injected into the nozzle reactor 800. The two
injected materials interact inside the reaction chamber of the
nozzle reactor 800 and result in cracking a portion of hydrocarbons
in the feed material. A hydrocarbon product 803 leaves the nozzle
reactor 800 and can be passed to the separation vessel 810. The
separation vessel 810 works to separate heavy hydrocarbons and
light hydrocarbons, and can ultimately produce a heavy hydrocarbon
stream 811 and a light hydrocarbon stream 812. The heavy
hydrocarbon stream 811 will be sent to the coker 820 for further
cracking of the heavy hydrocarbon compounds in the heavy
hydrocarbon stream 811. In an alternative configuration (shown by
the dashed line), the separation vessel can be bypassed and the
hydrocarbon product 803 can be sent directly to the coker 820 for
upgrading. The coker 820 produces a distillate products stream 821
and a petroleum coke stream 822.
[0086] With reference to FIG. 8b, an alternate configuration for
carrying out methods described herein. FIG. 8b is similar to FIG.
8a, with the exception that a second hydrocarbon material stream
801a can be sent directly to the separator 810. The second
hydrocarbon material stream 801a can be, for example, heavy crude,
and the separator 810 can be used to separate both the hydrocarbon
product 803 and the second hydrocarbon material stream 801a. FIG.
8b also shows that the heavy hydrocarbon stream 811 leaving the
separation vessel 810 can be split, so that a portion 811a of the
heavy hydrocarbon stream is recycled back to the nozzle reactor 800
for injection into the nozzle reactor 800 and an additional attempt
at cracking the heavy hydrocarbon material in the nozzle reactor
800.
[0087] With reference to FIG. 9, embodiments of the method
described herein can be carried out using a system including two or
more nozzle reactors aligned in series. A stream of hydrocarbon
material 801 can be injected into first nozzle reactor 800a. A
cracking material 802a, which can include steam or natural gas, can
also injected into the first nozzle reactor 800a. A hydrocarbon
product 803a leaves the first nozzle reactor 800a and can be passed
to the separation vessel 810. The separation vessel 810 produces a
heavy hydrocarbon stream 811 and a light hydrocarbon stream 812.
The heavy hydrocarbon stream 811 can be split, so that a portion of
the stream goes to the coker 820 and another portion 811a of the
heavy hydrocarbon stream goes to a second nozzle reactor 800b.
Alternatively, the portion 811a may be further split and introduced
into both the second reactor nozzle reactor 800b and the first
nozzle reactor 800a. The heavy hydrocarbon injected into the second
nozzle reactor 800b interacts with cracking material 802b injected
into the second nozzle reactor 800b, and hydrocarbon product 803b
is produced. The cracking material 802b injected into the second
nozzle reactor 800b can be substantially identical in composition
to the cracking material 802a injected into the first nozzle
reactor 800a. The hydrocarbon product 803b can be sent to the coker
820, where it combines with the heavy hydrocarbon stream 811 from
the separation vessel 810 and may be treated in the coker 820 to
produce a distillate products stream 821 and a petroleum coke
stream 822.
[0088] While not shown in the Figures, embodiments of the method
described herein can also be carried out using multiple nozzle
reactors aligned in parallel. Each nozzle reactor operates as
described above and as shown in FIG. 8a or 8b, with nozzle reactor
product from each nozzle reactor being transported to a common
separation vessel. The common separation vessel separates the
combined nozzle reactor product into a light hydrocarbon stream and
a residue stream, and the residue stream is transported to a common
coker. If the residue leaving the common separation vessel is split
into a recycle stream and a stream to be transported to the coker
as shown in FIG. 8b, the recycle stream can be split into a stream
for each nozzle reactor in the parallel system. Alternatively, a
separation vessel is provided for each nozzle reactor, and the
residue from each separation vessel is combined and transported to
a common coker. Any number of nozzle reactors aligned in parallel
can be used in such a system, and the number of nozzle reactors in
the system can be selected based on the capacity of each nozzle
reactor and the amount of material to be treated.
* * * * *