U.S. patent application number 16/713987 was filed with the patent office on 2021-06-17 for production of linear alpha olefins from organic sulfides.
This patent application is currently assigned to SAUDI ARABIAN OIL COMPANY. The applicant listed for this patent is SAUDI ARABIAN OIL COMPANY. Invention is credited to Abdullah T. ALABDULHADI, Muneef F. ALQARZOUH, Maddala V. BHANUMURTHY, Ki-Hyouk CHOI.
Application Number | 20210179512 16/713987 |
Document ID | / |
Family ID | 1000004566374 |
Filed Date | 2021-06-17 |
United States Patent
Application |
20210179512 |
Kind Code |
A1 |
CHOI; Ki-Hyouk ; et
al. |
June 17, 2021 |
PRODUCTION OF LINEAR ALPHA OLEFINS FROM ORGANIC SULFIDES
Abstract
Embodiments of the disclosure provide a system and method for
producing a linear alpha olefin. A disulfide, a hydrogen donating
compound, and water are combined to produce a mixture. The mixture
is introduced to a reactor operated at a pressure equal to or
greater than 22.06 MPa and a temperature equal to or greater than
374 deg. C to produce an effluent stream. The effluent stream is
separated to produce a product stream including the linear alpha
olefin. The disulfide can be a compound of formula R--S--S--R'
where R is a first alkyl group having carbon atoms ranging from 1
to 12 and R' is a second alkyl group having carbon atoms ranging
from 5 to 12. The hydrogen donating compound can include a
partially hydrogenated multi-ring aromatic compound.
Inventors: |
CHOI; Ki-Hyouk; (Dhahran,
SA) ; ALQARZOUH; Muneef F.; (Dhahran, SA) ;
ALABDULHADI; Abdullah T.; (Dhahran, SA) ;
BHANUMURTHY; Maddala V.; (Yanbu, SA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SAUDI ARABIAN OIL COMPANY |
Dhahran |
|
SA |
|
|
Assignee: |
SAUDI ARABIAN OIL COMPANY
Dhahran
SA
|
Family ID: |
1000004566374 |
Appl. No.: |
16/713987 |
Filed: |
December 13, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B01J 19/0013 20130101;
C10G 49/007 20130101; B01D 11/0403 20130101; B01D 17/02 20130101;
C10G 45/26 20130101; C07C 1/322 20130101; C07C 7/04 20130101; B01J
2219/00087 20130101; C10G 2300/805 20130101; C10L 2290/146
20130101; C10G 49/26 20130101; C10G 47/22 20130101; B01J 14/00
20130101; B01D 19/00 20130101; B01D 3/143 20130101; C10G 49/22
20130101; C10G 31/08 20130101 |
International
Class: |
C07C 1/32 20060101
C07C001/32; C07C 7/04 20060101 C07C007/04; B01J 14/00 20060101
B01J014/00; B01J 19/00 20060101 B01J019/00; B01D 17/02 20060101
B01D017/02; B01D 19/00 20060101 B01D019/00; B01D 3/14 20060101
B01D003/14 |
Claims
1. A method for producing a linear alpha olefin (LAO), the method
comprising the steps of: combining a disulfide oil feed and a
hydrogen donor feed to produce a first mixed stream, the disulfide
oil feed comprising a disulfide, the hydrogen donor feed comprising
a hydrogen donating compound (HDC); combining the first mixed
stream and a water feed to produce a second mixed stream;
introducing the second mixed stream to a reactor, wherein the
reactor is operated at a pressure equal to or greater than 22.06
MPa and a temperature equal to or greater than 373.9 deg. C to
produce an effluent stream, the effluent stream comprising the LAO;
introducing the effluent stream to a first separator to produce a
gas stream and a liquid stream, the liquid stream comprising the
LAO; introducing the liquid stream to a second separator to produce
a hydrocarbon stream and a water stream, the hydrocarbon stream
comprising the LAO; and introducing the hydrocarbon stream to a
distillation unit to produce an LAO stream and a byproduct stream,
the LAO stream comprising the LAO.
2. The method of claim 1, further comprising the step of:
pressurizing the first mixed stream to a pressure equal to or
greater than 22.06 MPa.
3. The method of claim 1, further comprising the step of: heating
the first mixed stream to a temperature ranging between 80 deg. C
and 150 deg. C.
4. The method of claim 1, further comprising the step of:
pressurizing the water feed to a pressure equal to or greater than
22.06 MPa.
5. The method of claim 1, further comprising the step of: heating
the water feed to a temperature ranging between 374 deg. C and 500
deg. C.
6. The method of claim 1, further comprising the step of: cooling
the effluent stream to a temperature ranging between 50 deg. C and
about 110 deg. C.
7. The method of claim 1, further comprising the step of:
depressurizing the effluent stream to ambient pressure.
8. The method of claim 1, wherein the disulfide is a compound of
formula (I): R--S--S--R' (I) wherein R is a first alkyl group
having carbon atoms ranging from 1 to 12, wherein R' is a second
alkyl group having carbon atoms ranging from 5 to 12.
9. The method of claim 8, wherein the disulfide comprises
1-(pentyldisulfanyl)pentane.
10. The method of claim 1, wherein the HDC comprises a partially
hydrogenated multi-ring aromatic compound.
11. The method of claim 10, wherein the HDC is selected from the
group consisting of: 1,2,3,4-tetrahydronaphthalene,
6-butyl-1,2,3,4-tetrahydronaphthalene,
7-ethyl-1,2,3,4-tetrahydronaphthalene, 9,10-dihydroanthracene,
9,10-dihydrophenanthrene, and combinations of the same.
12. The method of claim 1, wherein the first mixed stream has an
HDC-to-disulfide mole ratio ranging between 0.1:1 and 0.5:1.
13. The method of claim 1, wherein the second mixed stream has an
oil-to-water volume ratio ranging between 0.5:1 and 0.2:1 at
standard temperature and pressure.
14. The method of claim 1, wherein the reactor is operated such
that components of the second mixed stream have a residence time
ranging between 0.5 minutes and 10 minutes.
15. The method of claim 1, wherein the byproduct stream comprises a
dehydrogenated form of the HDC selected from the group consisting
of: naphthalene, 1,2-dihydronaphthalene, anthracene, phenanthrene,
and combinations of the same.
16. The method of claim 15, further comprising the step of:
regenerating the dehydrogenated form of the HDC.
17. A method for producing a linear alpha olefin (LAO), the method
comprising the steps of: combining a disulfide, a hydrogen donating
compound (HDC), and water to produce a mixture; and pressurizing
the mixture to a pressure equal to or greater than 22.06 MPa and
heating the mixture to a temperature equal to or greater than 374
deg. C, wherein the disulfide is a compound of formula (I):
R--S--S--R' (I) wherein R is a first alkyl group having carbon
atoms ranging from 1 to 12, wherein R' is a second alkyl group
having carbon atoms ranging from 5 to 12, wherein the HDC comprises
a partially hydrogenated multi-ring aromatic compound.
18. The method of claim 17, wherein the disulfide comprises
1-(pentyldisulfanyl)pentane.
19. The method of claim 17, wherein the HDC is selected from the
group consisting of: 1,2,3,4-tetrahydronaphthalene,
6-butyl-1,2,3,4-tetrahydronaphthalene,
7-ethyl-1,2,3,4-tetrahydronaphthalene, 9,10-dihydroanthracene,
9,10-dihydrophenanthrene, and combinations of the same.
20. A system for producing a linear alpha olefin (LAO), the system
comprising: a first mixer, the first mixer configured to combine a
disulfide oil feed and a hydrogen donor feed to produce a first
mixed stream, wherein the disulfide oil feed comprises a disulfide,
the hydrogen donor feed comprises a hydrogen donating compound
(HDC); a first pump, the first pump fluidly connected downstream of
the first mixer, the first pump configured to pressurize the first
mixed stream to a pressure equal to or greater than 22.06 MPa; a
first heat exchanger, the first heat exchanger fluidly connected
downstream of the first mixer, the first heat exchanger configured
to heat the first mixed stream to a temperature ranging between 80
deg. C and 150 deg. C; a second pump, the second pump configured to
pressurize a water feed to a pressure equal to or greater than
22.06 MPa; a second heat exchanger, the second heat exchanger
configured to heat the water feed to a temperature ranging between
374 deg. C and 500 deg. C; a second mixer, the second mixer fluidly
connected downstream of the first pump and the first heat exchanger
and fluidly connected downstream of the second pump and the second
heat exchanger, the second mixer configured to combine the first
mixed stream and the water feed to produce a second mixed stream; a
reactor, the reactor fluidly connected downstream of the second
mixer, the reactor operated at a pressure equal to or greater than
22.06 MPa and a temperature equal to or greater than 373.9 deg. C
to produce an effluent stream, wherein the effluent stream
comprises the LAO; a third heat exchanger, the third heat exchanger
fluidly connected downstream of the reactor, the third heat
exchanger configured to cool the effluent stream to a temperature
ranging between 50 deg. C and about 110 deg. C; a pressure reducer,
the pressure reducer fluidly connected downstream of the reactor,
the pressure reducer configured to depressurize the effluent stream
to ambient pressure; a first separator, the first separator fluidly
connected downstream of the third heat exchanger and the pressure
reducer, the first separator configured to separate the effluent
stream into a gas stream and a liquid stream, wherein the liquid
stream comprises the LAO; a second separator, the second separator
fluidly connected downstream of the first separator, the second
separator configured to separate the liquid stream into a
hydrocarbon stream and a water stream, wherein the hydrocarbon
stream comprises the LAO; and a distillation unit, the distillation
unit fluidly connected downstream of the second separator, the
distillation unit configured to separate the hydrocarbon stream to
produce an LAO stream and a byproduct stream, wherein the LAO
stream comprises the LAO.
21. The system of claim 20, further comprising: a Merox unit, the
Merox unit fluidly connected upstream of the first mixer, the Merox
unit configured to produce the disulfide oil feed by removing
sulfur from naphtha and kerosene.
Description
BACKGROUND
Field of the Disclosure
[0001] Embodiments of the disclosure generally relate to producing
linear alpha olefins. More specifically, embodiments of the
disclosure relate to a method and system for producing linear alpha
olefins using organic sulfide compounds and supercritical
water.
Description of the Related Art
[0002] Linear alpha olefins (LAOs) are aliphatic hydrocarbons
having a carbon-carbon double bond in the terminal position. LAOs
are typically used as raw materials for products such as linear low
density polyethylene (LLDPE), surfactants, and synthetic lubricant
oils. In an industrial scale, LAOs are produced by methods such as
catalytic oligomerization of ethylene, catalytic dehydrogenation of
n-paraffins, and thermal cracking of n-paraffins.
[0003] In a Ziegler process, LAOs are produced by using ethylene as
a feed material in the presence of an organometallic catalyst. In a
Pacol process, olefins are produced by converting C6 to C19
n-paraffins in the presence of a heterogeneous catalyst. The
produced olefins are a mixture of internal olefins and LAOs. In a
thermal cracking process, C20 to C30 n-paraffins (generally in the
form of wax) are used as a feed material and are subjected to a
temperature ranging between 500 deg. C and 600 deg. C in the
presence of steam at ambient or marginally elevated pressure. The
residence time in the thermal cracking reactor ranges between 7 to
15 seconds, where the conversion rate is about 25%, in which 90% to
95% are LAOs.
[0004] Due to the complexities of separating internal olefins,
branched olefins, and LAOs from a produced mixture, it is necessary
for LAO production processes to be selective in producing LAOs as
opposed to internal olefins and branched olefins. Although there
are certain separation schemes proposed and implemented in
industrial scale, the purity of the LAO-containing product is still
a key consideration for successfully producing LAOs.
SUMMARY
[0005] Embodiments of the disclosure generally relate to producing
linear alpha olefins. More specifically, embodiments of the
disclosure relate to a method and system for producing linear alpha
olefins using organic sulfide compounds and supercritical
water.
[0006] Embodiments of the disclosure provide a method for producing
an LAO. The method includes the step of combining a disulfide oil
feed and a hydrogen donor feed to produce a first mixed stream. The
disulfide oil feed includes a disulfide. The hydrogen donor feed
includes a hydrogen donating compound (HDC). The method includes
the step of combining the first mixed stream and a water feed to
produce a second mixed stream. The method includes the step of
introducing the second mixed stream to a reactor. The reactor is
operated at a pressure equal to or greater than 22.06 MPa and a
temperature equal to or greater than 373.9 deg. C to produce an
effluent stream. The effluent stream includes the LAO. The method
includes the step of introducing the effluent stream to a first
separator to produce a gas stream and a liquid stream. The liquid
stream includes the LAO. The method includes the step of
introducing the liquid stream to a second separator to produce a
hydrocarbon stream and a water stream. The hydrocarbon stream
includes the LAO. The method includes the step of introducing the
hydrocarbon stream to a distillation unit to produce an LAO stream
and a byproduct stream. The LAO stream includes the LAO.
[0007] In some embodiments, the method further includes the step of
pressurizing the first mixed stream to a pressure equal to or
greater than 22.06 MPa. In some embodiments, the method further
includes the step of heating the first mixed stream to a
temperature ranging between 80 deg. C and 150 deg. C. In some
embodiments, the method further includes the step of pressurizing
the water feed to a pressure equal to or greater than 22.06 MPa. In
some embodiments, the method further includes the step of heating
the water feed to a temperature ranging between 374 deg. C and 500
deg. C. In some embodiments, the method further includes the step
of cooling the effluent stream to a temperature ranging between 50
deg. C and about 110 deg. C. In some embodiments, the method
further includes the step of depressurizing the effluent stream to
ambient pressure.
[0008] In some embodiments, the disulfide is a compound of formula
R--S--S--R' where R is a first alkyl group having carbon atoms
ranging from 1 to 12 and R' is a second alkyl group having carbon
atoms ranging from 5 to 12. In some embodiments, the disulfide
includes 1-(pentyldisulfanyl)pentane.
[0009] In some embodiments, The HDC includes a partially
hydrogenated multi-ring aromatic compound. In some embodiments, the
HDC includes 1,2,3,4-tetrahydronaphthalene,
6-butyl-1,2,3,4-tetrahydronaphthalene,
7-ethyl-1,2,3,4-tetrahydronaphthalene, 9,10-dihydroanthracene,
9,10-dihydrophenanthrene, and combinations of the same.
[0010] In some embodiments, the first mixed stream has an
HDC-to-disulfide mole ratio ranging between 0.1:1 and 0.5:1. In
some embodiments, the second mixed stream has an oil-to-water
volume ratio ranging between 0.5:1 and 0.2:1 at standard
temperature and pressure.
[0011] In some embodiments, the byproduct stream includes a
dehydrogenated form of the HDC including naphthalene,
1,2-dihydronaphthalene, anthracene, phenanthrene, and combinations
of the same. In some embodiments, the method further includes the
step of regenerating the dehydrogenated form of the HDC.
[0012] Embodiments of the disclosure also provide a method for
producing an LAO. The method includes the step of combining a
disulfide, an HDC, and water to produce a mixture. The method
includes the step of pressurizing the mixture to a pressure equal
to or greater than 22.06 MPa and heating the mixture to a
temperature equal to or greater than 374 deg. C. The disulfide is a
compound of formula R--S--S--R' where R is a first alkyl group
having carbon atoms ranging from 1 to 12 and R' is a second alkyl
group having carbon atoms ranging from 5 to 12. The HDC includes a
partially hydrogenated multi-ring aromatic compound.
[0013] In some embodiments, the disulfide includes
1-(pentyldisulfanyl)pentane. In some embodiments, the HDC includes
1,2,3,4-tetrahydronaphthalene,
6-butyl-1,2,3,4-tetrahydronaphthalene,
7-ethyl-1,2,3,4-tetrahydronaphthalene, 9,10-dihydroanthracene,
9,10-dihydrophenanthrene, and combinations of the same.
[0014] Embodiments of the disclosure also provide a system for
producing an LAO. The system includes a first mixer, a first pump,
a first heat exchanger, a second pump, a second heat exchanger, a
second mixer, a reactor, a third heat exchanger, a pressure
reducer, a first separator, a second separator, and a distillation
unit. The first mixer is configured to combine a disulfide oil feed
and a hydrogen donor feed to produce a first mixed stream. The
disulfide oil feed includes a disulfide. The hydrogen donor feed
includes an HDC. The first pump is fluidly connected downstream of
the first mixer. The first pump is configured to pressurize the
first mixed stream to a pressure equal to or greater than 22.06
MPa. The first heat exchanger is fluidly connected downstream of
the first mixer. The first heat exchanger is configured to heat the
first mixed stream to a temperature ranging between 80 deg. C and
150 deg. C. The second pump is configured to pressurize a water
feed to a pressure equal to or greater than 22.06 MPa. The second
heat exchanger is configured to heat the water feed to a
temperature ranging between 374 deg. C and 500 deg. C. The second
mixer is fluidly connected downstream of the first pump and the
first heat exchanger and fluidly connected downstream of the second
pump and the second heat exchanger. The second mixer is configured
to combine the first mixed stream and the water feed to produce a
second mixed stream. The reactor is fluidly connected downstream of
the second mixer. The reactor is operated at a pressure equal to or
greater than 22.06 MPa and a temperature equal to or greater than
373.9 deg. C to produce an effluent stream. The effluent stream
includes the LAO. The third heat exchanger is fluidly connected
downstream of the reactor. The third heat exchanger is configured
to cool the effluent stream to a temperature ranging between 50
deg. C and about 110 deg. C. The pressure reducer is fluidly
connected downstream of the reactor. The pressure reducer is
configured to depressurize the effluent stream to ambient pressure.
The first separator is fluidly connected downstream of the third
heat exchanger and the pressure reducer. The first separator is
configured to separate the effluent stream into a gas stream and a
liquid stream. The liquid stream includes the LAO. The second
separator is fluidly connected downstream of the first separator.
The second separator is configured to separate the liquid stream
into a hydrocarbon stream and a water stream. The hydrocarbon
stream includes the LAO. The distillation unit is fluidly connected
downstream of the second separator. The distillation unit is
configured to separate the hydrocarbon stream to produce an LAO
stream and a byproduct stream. The LAO stream includes the LAO.
[0015] In some embodiments, the system further includes a Merox
unit. The Merox unit is fluidly connected upstream of the first
mixer. The Merox unit is configured to produce the disulfide oil
feed by removing sulfur from naphtha and kerosene.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] So that the manner in which the previously-recited features,
aspects, and advantages of the embodiments of this disclosure as
well as others that will become apparent are attained and can be
understood in detail, a more particular description of the
disclosure briefly summarized previously may be had by reference to
the embodiments that are illustrated in the drawings that form a
part of this specification. However, it is to be noted that the
appended drawings illustrate only certain embodiments of the
disclosure and are not to be considered limiting of the
disclosure's scope as the disclosure may admit to other equally
effective embodiments.
[0017] FIG. 1 is a schematic diagram of a process for LAO
production according to an embodiment of the disclosure.
[0018] FIG. 2 is a schematic diagram of a Merox process.
[0019] FIG. 3 is a schematic diagram of a distillation unit for LAO
production according to an embodiment of the disclosure.
[0020] In the accompanying Figures, similar components or features,
or both, may have a similar reference label.
DETAILED DESCRIPTION
[0021] The disclosure refers to particular features, including
process or method steps and systems. Those of skill in the art
understand that the disclosure is not limited to or by the
description of embodiments given in the specification. The subject
matter of this disclosure is not restricted except only in the
spirit of the specification and appended claims.
[0022] Those of skill in the art also understand that the
terminology used for describing particular embodiments does not
limit the scope or breadth of the embodiments of the disclosure. In
interpreting the specification and appended claims, all terms
should be interpreted in the broadest possible manner consistent
with the context of each term. All technical and scientific terms
used in the specification and appended claims have the same meaning
as commonly understood by one of ordinary skill in the art to which
this disclosure belongs unless defined otherwise.
[0023] Although the disclosure has been described with respect to
certain features, it should be understood that the features and
embodiments of the features can be combined with other features and
embodiments of those features.
[0024] Although the disclosure has been described in detail, it
should be understood that various changes, substitutions, and
alternations can be made without departing from the principle and
scope of the disclosure. Accordingly, the scope of the present
disclosure should be determined by the following claims and their
appropriate legal equivalents.
[0025] As used throughout the disclosure, the singular forms "a,"
"an," and "the" include plural references unless the context
clearly indicates otherwise.
[0026] As used throughout the disclosure, the word "about" includes
+/-5% of the cited magnitude. The word "substantially" includes
+/-5% of the cited magnitude.
[0027] As used throughout the disclosure, the words "comprise,"
"has," "includes," and all other grammatical variations are each
intended to have an open, non-limiting meaning that does not
exclude additional elements, components or steps. Embodiments of
the present disclosure may suitably "comprise," "consist," or
"consist essentially of" the limiting features disclosed, and may
be practiced in the absence of a limiting feature not disclosed.
For example, it can be recognized by those skilled in the art that
certain steps can be combined into a single step.
[0028] As used throughout the disclosure, the words "optional" or
"optionally" means that the subsequently described event or
circumstances can or may not occur. The description includes
instances where the event or circumstance occurs and instances
where it does not occur.
[0029] Where a range of values is provided in the specification or
in the appended claims, it is understood that the interval
encompasses each intervening value between the upper limit and the
lower limit as well as the upper limit and the lower limit. The
disclosure encompasses and bounds smaller ranges of the interval
subject to any specific exclusion provided.
[0030] Where reference is made in the specification and appended
claims to a method comprising two or more defined steps, the
defined steps can be carried out in any order or simultaneously
except where the context excludes that possibility.
[0031] As used throughout the disclosure, terms such as "first" and
"second" are arbitrarily assigned and are merely intended to
differentiate between two or more components of an apparatus. It is
to be understood that the words "first" and "second" serve no other
purpose and are not part of the name or description of the
component, nor do they necessarily define a relative location or
position of the component. Furthermore, it is to be understood that
that the mere use of the term "first" and "second" does not require
that there be any "third" component, although that possibility is
contemplated under the scope of the present disclosure.
[0032] As used throughout the disclosure, spatial terms described
the relative position of an object or a group of objects relative
to another object or group of objects. The spatial relationships
apply along vertical and horizontal axes. Orientation and
relational words such are for descriptive convenience and are not
limiting unless otherwise indicated.
[0033] As used throughout the disclosure, the term "external supply
of hydrogen" refers to the addition of hydrogen to the feed to the
reactor or to the reactor itself. For example, a reactor in the
absence of an external supply of hydrogen means that the feed to
the reactor and the reactor are in the absence of added hydrogen
such that no hydrogen is a feed or a part of a feed to the
reactor.
[0034] As used throughout the disclosure, the term "external supply
of catalyst" refers to the addition of catalyst to the feed to the
reactor or the presence of a catalyst in the reactor, such as a
fixed bed catalyst in the reactor. For example, a reactor in the
absence of an external supply of catalyst means no catalyst has
been added to the feed to the reactor and the reactor does not
contain a catalyst bed in the reactor.
[0035] As used throughout the disclosure, the terms "mercaptan" or
"thiol" refer to a compound with a carbon-sulfur bond in the form
R--SH, where R can have a carbon number of 1 for a mercaptan (in
the form CH.sub.3SH) and R can have a carbon number between 2 and
12.
[0036] As used throughout the disclosure, the terms "disulfide" or
"disulfide compound" refer to aliphatic, organic, sulfur-containing
compounds taking the form R--S--S--R', where each of R and R' can
have a carbon number between 1 and 12.
[0037] Embodiments of the disclosure provide processes and systems
of an LAO producing process using aliphatic sulfur compounds such
as disulfides in the presence of supercritical water. Hydrogen
donating compounds are used to suppress and prevent secondary
reactions of LAOs.
[0038] It is known in the art that supercritical water has unique
properties making it suitable for use as a petroleum reaction
medium where the reaction objectives can include conversion
reactions, desulfurization reactions, denitrogenation reactions,
and demetallization reactions. Supercritical water is water at a
temperature at or greater than the critical temperature of water
and at a pressure at or greater than the critical pressure of
water. The critical temperature of water is 373.946 deg. C. The
critical pressure of water is 22.06 megapascals (MPa).
Advantageously, at supercritical conditions water acts as both a
hydrogen source and a solvent (diluent) in conversion reactions,
desulfurization reactions and demetallization reactions and a
catalyst is not needed. Hydrogen from the water molecules is
transferred to the hydrocarbons through direct transfer or through
indirect transfer, such as the water gas shift reaction.
[0039] Without being bound any theory, it is understood that the
basic reaction mechanism of supercritical water mediated petroleum
processes is similar to a free radical reaction mechanism. Radical
reactions include initiation, propagation, and termination steps.
With hydrocarbons, initiation is the most difficult step.
Initiation requires the breaking of chemical bonds. The bond energy
of carbon-carbon bonds (C--C) is about 350 kilojoules per mole
(kJ/mol), while the bond energy of carbon-hydrogen bonds (C--H) is
about 420 kJ/mol, both of which are considered high chemical bond
energies. Due to the high chemical bond energies, carbon-carbon
bonds and carbon-hydrogen bonds do not break easily at the
temperatures in a supercritical water process, 380 deg. C to 450
deg. C, without catalyst or radical initiators. In contrast,
carbon-sulfur bonds (C--S) have a bond energy of about 250 kJ/mol.
Aliphatic carbon-sulfur bonds, such as included in thiols,
sulfides, and disulfides, have a lower bond energy than the
aromatic carbon-sulfur bond. In addition, aliphatic sulfur-sulfur
bonds (S--S), such as included in disulfides, have a bond energy
lesser than that of carbon-sulfur bonds. For comparison, n-heptane
has a C1-C2 dissociation energy of about 368.2 kJ/mol.
Butane-1-thiol has a C--S dissociation energy of about 309 kJ/mol.
(Methyldisulfanyl)methane (or dimethyl disulfide) has a S--S
dissociation energy of about 272 kJ/mol. Although aliphatic sulfur
compounds generally have lesser bond dissociation energy than
aliphatic hydrocarbons, it is known that disulfides and thiol
compounds are not readily decomposed at a temperature lesser than
350 deg. C. For example, dimethyl disulfide has an induction period
of about 120 seconds at about 314 deg. C to be decomposed. At about
360 deg. C, the induction period is reduced to about 35 seconds.
The main decomposition product of dimethyl disulfide is
methanethiol (or methyl mercaptan). Another example includes
1-hexanethiol (or hexyl mercaptan), where the conversion rate is
about 10% at about 350 deg. C producing olefinic compounds.
[0040] Thermal energy creates radicals through chemical bond
breakage. Supercritical water creates a "cage effect" by
surrounding the radicals. The radicals surrounded by water
molecules cannot react easily with each other, and thus,
intermolecular reactions that contribute to coke formation are
suppressed. The cage effect suppresses coke formation by limiting
inter-radical reactions. Supercritical water, having low dielectric
constant, dissolves hydrocarbons and surrounds radicals to prevent
the inter-radical reaction, which is the termination reaction
resulting in condensation (dimerization or polymerization). Because
of the barrier set by the supercritical water cage, hydrocarbon
radical transfer is more difficult in supercritical water as
compared to conventional thermal cracking processes, such as
delayed coker, where radicals travel freely without such
barriers.
[0041] Sulfur compounds released from sulfur-containing molecules
can be converted to hydrogen sulfide, mercaptans, and elemental
sulfur. Without being bound to a particular theory, it is believed
that hydrogen sulfide is not "stopped" by the supercritical water
cage due its small size and chemical structure similar to water.
Hydrogen sulfide can travel freely through the supercritical water
cage to propagate radicals and distribute hydrogen. Hydrogen
sulfide can lose its hydrogen due to hydrogen abstraction reactions
with hydrocarbon radicals. The resulting hydrogen-sulfur radical
(HS.) is capable of abstracting hydrogen from hydrocarbons
(including disulfides and thiyl radicals) which will result in
formation of more radicals. Thus, hydrogen sulfide in radical
reactions acts as a transfer agent to transfer radicals and
abstract/donate hydrogen. However, without a diluent such as
supercritical water, hydrogen-sulfur radicals can lead to secondary
reactions of the produced LAO, such as isomerization. For example,
internal olefins are more stable than terminal olefins. The
carbon-carbon double bond position of terminal olefins can be
rearranged via isomerization to an internal position in the
presence of hydrogen-sulfur radicals resulting from hydrogen
sulfide reducing the LAO yield. The presence of a catalyst may also
lead to isomerization of LAOs to internal or branched olefins, even
in cases when the catalyst has marginal acidity.
[0042] As previously noted, aromatic sulfur compounds are more
stable in supercritical water compared to more active aliphatic
sulfur compounds. As a result, a feedstock having more aliphatic
sulfur can have a higher activity in supercritical water. Organic
disulfides, such as diethyl disulfide, has a similar bond
dissociation energy (S--S bond) as a C--S bond. Decomposition of
one mole of organic disulfide can generate two moles of thiyl
radicals, which means labile organic disulfide is a useful
precursor for terminal olefin production in supercritical
water.
[0043] Aliphatic sulfur compounds are generally found in naphtha,
kerosene, and vacuum residue. In vacuum residue, aliphatic
carbon-sulfur bonds are believed to be present in an asphalthenic
fraction. The amount of aliphatic sulfur compounds is less than
aromatic sulfur compounds in common crude oils. Thus, it is
required to find an aliphatic sulfur rich stream in refinery as a
reactant for producing LAOs.
[0044] FIG. 1 shows a schematic diagram of a process 100 for LAO
production, according to an embodiment of the disclosure. The
process 100 can include mixer 102, pump 104, pump 106, heat
exchanger 108, heat exchanger 110, mixer 112, supercritical water
reactor 114, heat exchanger 116, pressure reducer 118, separator
120, separator 122, and distillation unit 124.
[0045] Disulfide oil feed 202 is introduced to the process 100.
Disulfide oil feed 202 can be selected from a stream containing
aliphatic sulfur compounds including disulfides. Disulfide oil feed
202 can include natural gas, liquefied petroleum gas (LPG),
naphtha, or kerosene. The disulfide compounds included in disulfide
oil feed 202 can have boiling points ranging between about 200 deg.
C and about 400 deg. C, alternately between about 230 deg. C and
about 360 deg. C, or alternately between about 260 deg. C and about
320 deg. C. In at least one embodiment, the disulfide compounds
included in disulfide oil feed 202 have boiling points ranging
between 260 deg. C and about 320 deg. C. Disulfide oil feed 202 can
include greater than about 20 wt. % of disulfide compounds having
boiling points greater than about 260 deg. C, alternately greater
than about 30 wt. % of disulfide compounds having boiling points
greater than about 260 deg. C, or alternately greater than about 50
wt. % of disulfide compounds having boiling points greater than
about 260 deg. C. In at least one embodiment, disulfide oil feed
202 includes greater than about 50 wt. % of disulfide compounds
having boiling points greater than about 260 deg. C. Disulfide oil
feed 202 can include disulfide compounds containing C1 to C12
groups. Disulfide oil feed 202 can include disulfide compounds
containing C5 groups, C5 to C6 groups, C5 to C7 groups, C5 to C7
groups, C5 to C8 groups, C5 to C9 groups, C5 to C10 groups, C5 to
C11 groups, and C5 to C12 groups. Non-limiting example disulfide
compounds include 1-(pentyldisulfanyl)pentane (or dipentyl
disulfide, having a boiling point of about 264 deg. C),
1-(pentyldisulfanyl)hexane (or pentyl hexyl disulfide),
1-(hexyldisulfanyl)hexane (or dihexyl disulfide),
1-(hexyldisulfanyl)heptane (or hexyl heptyl disulfide), and
1-(heptyldisulfanyl)heptane (or diheptyl disulfide). In at least
one embodiment, the disulfide oil includes dipentyl disulfide. In
at least one embodiment, the disulfide oil includes a disulfide
compound having at least one C5 group. Disulfide oil feed 202 can
include greater than about 5 wt. % disulfide compounds, alternately
greater than about 10 wt. % disulfide compounds, alternately
greater than about 20 wt. % disulfide compounds. In at least one
embodiment, disulfide oil feed 202 includes greater than about 20
wt. % disulfide compounds. Disulfide oil feed 202 can have a total
sulfur content of greater than about 1 wt. %, alternately greater
than about 3 wt. %, or alternately greater than about 5 wt. %. In
at least one embodiment, disulfide oil feed 202 has a total sulfur
content of greater than about 5 wt. %. The sodium content in
disulfide oil feed 202 is less than about 50 parts-per-million by
weight (wt. ppm), alternately less than 40 wt. ppm, alternately
less than 30 wt. ppm, alternately less than 20 wt. ppm, or
alternately less than 10 wt. ppm. Maintaining a sodium content in
disulfide oil 12 of less than 50 wt. ppm reduces or eliminates
alkali precipitation in supercritical water reactor 114.
Advantageously, disulfides are more manageable to process than
hydrogen sulfide, because hydrogen sulfide is difficult to compress
to supercritical water conditions and can be difficult to handle.
In contrast, disulfides are safely handled and can mix within the
hydrocarbon stream at supercritical water conditions. In at least
one embodiment, disulfide oil feed 202 can contain disulfides,
trisulfides, mercaptans, alkanes, alkenes, and combinations of the
same. In at least one embodiment, disulfide oil feed 202 can
further contain other hydrocarbons.
[0046] In general, the most abundant form of sulfur compounds found
in petroleum crude oil is thiophenic sulfur. A lesser quantity of
aliphatic sulfur are concentrated in light fractions such as
naphtha and kerosene. The sulfur concentration of aliphatic sulfur
included in crude oil ranges between about 0.1 wt. % and about 1
wt. %.
[0047] To increase the aliphatic sulfur content for LAO production,
the disulfide oil can be produced by a caustic extraction process
such as a Merox process. A Merox process is a desulfurization
process. In general, a Merox process can remove sulfur from natural
gas, LPG, naphtha, and kerosene. Mercaptans present in a diesel
fraction or heavier fraction cannot be treated by Merox because
those fractions have low miscibility with caustic solutions, and
thus have phase transfer limitations. The following reactions occur
in a Merox unit:
2R--SH+2NaOH.fwdarw.2NaS--R+2H.sub.2O Reaction (1)
4NaS--R+O.sub.2+2H.sub.2O.fwdarw.2R--S--S--R+4NaOH Reaction (2)
where R--SH represents a mercaptan or thiol (where R represents an
alkyl group containing at least one carbon), NaOH is sodium
hydroxide, NaS--R is a sodium bonded to an (S--R).sup.- ion, where
the R is an alkyl group, H.sub.2O is water, O.sub.2 is oxygen, and
R--S--S--R represents a disulfide.
[0048] In a Merox process, a caustic solution containing sodium
hydroxide reacts with a thiol to form NaSR, which is extracted to a
water phase. The NaSR can then be reacted with oxygen to form a
water insoluble disulfide and sodium hydroxide. The sodium
hydroxide can be recycled to the front of the process. The
disulfide oil can be separated from the caustic solution and air by
a phase separator. An embodiment of a Merox process is shown in
FIG. 2.
[0049] Referring back to FIG. 1, hydrogen donor feed 204 is
introduced to the process 100. Hydrogen donor feed 204 includes an
HDC. The HDC is used to prevent secondary reactions of LAOs
therefore enhancing the yield of LAOs. Hydrogen donor feed 204 can
be selected from a residual fraction of distillate, hydrocracker,
coker, visbreaker, hydrotreater, and catalytic cracker. Hydrogen
donor feed 204 can also be selected from extracts of liquefied
coal, petroleum refinery distillates, cracked products from a
petroleum refinery product stream, and residue from a petroleum
refinery. The HDC included in hydrogen donor feed 204 can have a
boiling point ranging between about 100 deg. C and about 450 deg.
C, alternately between about 150 deg. C. and about 400 deg. C, or
alternately between about 200 deg. C and about 350 deg. C. In at
least one embodiment, the HDC included in hydrogen donor feed 204
has a boiling point ranging between about 200 deg. C and about 350
deg. C. Advantageously, the use of HDC having a boiling point equal
to or greater than about 200 deg. C allows separation of product
LAOs by distillation methods. Advantageously, the use of HDC having
a boiling point equal to or less than about 350 deg. C reduces the
difficulty of mixing the HDCs with the disulfide oil and
supercritical water.
[0050] Non-limiting example HDCs include partially hydrogenated
multi-ring aromatic compounds such as 1,2,3,4-tetrahydronaphthalene
(or tetralin, having a boiling point of about 207 deg. C),
alkylated derivatives of tetralin including
6-butyl-1,2,3,4-tetrahydronaphthalene (or 6-butyl tetralin) and
7-ethyl-1,2,3,4-tetrahydronaphthalene (or 7-ethyl tetralin),
9,10-dihydroanthracene (having a boiling point of about 312 deg.
C), alkylated derivatives of 9,10-dihydroanthracene,
9,10-dihydrophenanthrene (having a boiling point of about 308 deg.
C), and alkylated derivatives of 9,10-dihydrophenanthrene.
Non-limiting example HDCs also include normal paraffinic
hydrocarbons having six or greater carbon atoms such as n-eicosane
(C21), n-docosane (C22), and n-octacosane (C28).
[0051] Disulfide oil feed 202 and hydrogen donor feed 204 are
passed to mixer 102 to produce mixed stream 208. Mixer 102 can be
any type of mixing device capable of mixing disulfide oil feed 202
and hydrogen donor feed 204. Non-limiting examples of mixing
devices suitable for use as mixer 102 can include a tee junction, a
static mixer, an inline mixer, and impeller-embedded mixer. Mixed
stream 208 can have an HDC-to-disulfide mole ratio ranging between
about 0.01:1 and about 2:1, alternately between about 0.05:1 and
about 1:1, or alternately between about 0.1:1 and about 0.5:1. In
at least one embodiment, mixed stream 208 has an HDC-to-disulfide
mole ratio is about 0.2:1.
[0052] The mole quantity of HDCs included in hydrogen donor feed
204 can be determined by the mole quantity of disulfide compounds
included in the disulfide oil feed 202 to produce mixed stream 208.
Without being bound by any theory, one mole of tetralin can donate
four moles of hydrogen atoms for LAO production and convert to one
mole of naphthalene (having a boiling point of about 218 deg. C).
One mole of 9,10-dihydroanthracene or 9,10-dihydrophenanthrene can
donate two moles of hydrogen atoms for LAO production and convert
to one mole of anthracene or phenanthrene, respectively. One mole
of disulfide compound requires two moles of hydrogen atoms from the
HDC to produce two moles of LAO molecules. Although the
HDC-to-disulfide mole ratio accordingly ranges between about 0.5:1
and about 1:1, the mole ratio can be adjusted to a range between
about 0.1:1 and about 0.5:1 to prevent undesirable reactions
between the HDC, the LAO, and the disulfide compounds.
[0053] Mixed stream 208 can be passed to pump 106. Pump 106 can be
any type of pump capable of increasing the pressure of mixed stream
208. In at least one embodiment, pump 106 is a diaphragm metering
pump. The pressure of mixed stream 208 can be increased in pump 106
to produce mixed stream 210. The pressure of mixed stream 210 can
be greater than about 22 MPa. In at least one embodiment, the
pressure of mixed stream 210 is greater than about 22.06 MPa, which
is greater than the critical pressure of water.
[0054] Mixed stream 210 can be passed to heat exchanger 110. Heat
exchanger 110 can be any type of heat exchanger capable increasing
the temperature of mixed stream 210. Non-limiting examples of heat
exchanger 110 can include an electric heater, a fired heater, and a
cross exchanger. The temperature of mixed stream 210 can be
increased in heat exchanger 110 to produce mixed stream 212. The
temperature of mixed stream 212 can range between about room
temperature and about 250 deg. C, alternately between about 50 deg.
C and about 200 deg. C, or alternately between about 80 deg. C. and
about 150 deg. C. In at least one embodiment, the temperature of
mixed stream 212 ranges between about 80 deg. C and about 150 deg.
C.
[0055] Water feed 206 is introduced to the process 100. Water feed
206 can be a demineralized water. Water feed 206 can have a
conductivity less than about 1.0 microSiemens per centimeter
(.mu.S/cm), alternately less than about 0.5 .mu.S/cm, or
alternately less than about 0.1 .mu.S/cm. In at least one
embodiment, water feed 206 has a conductivity less than about 0.1
.mu.S/cm. Water feed 206 can have a sodium content less than about
10 micrograms per liter (.mu.g/L), alternately less than about 5
.mu.g/L, or alternately less than about 1 .mu.g/L. In at least one
embodiment, water feed 206 has a sodium content less than about 1
.mu.g/L. Water feed 206 can have a chloride content less than about
5 .mu.g/L, alternately less than about 3 .mu.g/L, or alternately
less than about 1 .mu.g/L. In at least one embodiment, water feed
206 has a chloride content less than about 1 .mu.g/L. Water feed
206 can have a silica content less than about 5 .mu.g/L,
alternately less than about 4 .mu.g/L, or alternately less than
about 3 .mu.g/L. In at least one embodiment, water feed 206 has a
silica content less than about 3 .mu.g/L.
[0056] Water feed 206 can be passed to pump 104. Pump 104 can be
any type of pump capable of increasing the pressure of water feed
206. In at least one embodiment, pump 104 is a diaphragm metering
pump. The pressure of water feed 206 can be increased in pump 104
to produce water stream 214. The pressure of water stream 214 can
be greater than about 22 MPa. In at least one embodiment, the
pressure of water stream 214 is greater than about 22.06 MPa, which
is greater than the critical pressure of water.
[0057] Water stream 214 can be passed to heat exchanger 108. Heat
exchanger 108 can be any type of heat exchanger capable increasing
the temperature of water stream 214. Non-limiting examples of heat
exchanger 108 can include an electric heater, a fired heater, and a
cross exchanger. The temperature of water stream 214 can be
increased in heat exchanger 108 to produce water stream 216. The
temperature of water stream 216 can range between about 200 deg. C
and about 600 deg. C, alternately between about 300 deg. C and
about 550 deg. C, or alternately between about 350 deg. C. and
about 500 deg. C. In at least one embodiment, the temperature of
water stream 216 ranges between about 374 deg. C and about 500 deg.
C, which is greater than the critical temperature of water.
[0058] In some embodiments, disulfide oil feed 202, hydrogen donor
feed 204, and water feed 206 can each separately be pressurized to
a pressure of greater than about 22 MPa, alternately between about
23 MPa and about 30 MPa, or alternately between about 24 MPa and
about 26 MPa.
[0059] In some embodiments, disulfide oil feed 202, hydrogen donor
feed 204, and water feed 206 can each separately be heated to a
temperature ranging between about 200 deg. C and about 600 deg. C,
alternately between about 300 deg. C and about 550 deg. C, or
alternately between about 350 deg. C. and about 500 deg. C.
[0060] Mixed stream 212 and water stream 216 are passed to mixer
112 to produce mixed stream 218. Mixer 112 can be any type of
mixing device capable of mixing mixed stream 212 and water stream
216. Non-limiting examples of mixing devices suitable for use as
mixer 112 can include a tee junction, a static mixer, an inline
mixer, and impeller-embedded mixer. Mixed stream 218 can have an
oil-to-water weight (wt/wt) ratio ranging between about 1:1 and
about 0.1:1 at standard temperature and pressure (SATP),
alternately between about 0.7:1 and about 0.2:1 at SATP, or
alternately between about 0.5:1 and about 0.2:1 at SATP. In at
least one embodiment, mixed stream 218 has an oil-to-water weight
ratio ranging between about 0.5:1 and about 0.2:1 at SATP.
[0061] Mixed stream 218 is introduced to reactor 114. Reactor 114
is maintained at a temperature and pressure such that the water is
in its supercritical state. Reactor 114 can be maintained at a
temperature ranging between about 300 deg. C and about 550 deg. C,
alternately between about 380 deg. C. and about 475 deg. C, or
alternately between about 420 deg. C and about 450 deg. C. In at
least one embodiment, reactor 114 is maintained at a temperature
ranging between about 420 deg. C and about 450 deg. C. Means for
maintaining such temperature of reactor 114 can include a strip
heater, immersion heater, tubular furnace, heat exchanger, or like
devices known in the art. Reactor 114 can be maintained at a
pressure greater than about 22 MPa, alternately between about 23
MPa and about 30 MPa, or alternately between about 24 MPa and about
28 MPa. In at least one embodiment, reactor 114 is maintained at a
pressure ranging between about 25 MPa and about 27 MPa. Reactor 114
can be a horizontal tubular type reactor, vertical tubular type
reactor, inclined tubular type reactor, vessel type reactor, CSTR
type and combinations of the same. In at least one embodiment,
reactor 114 includes a tubular reactor, which advantageously
prevents precipitation of reactants or products in the reactor.
Reactor 114 can include an upflow reactor, a downflow reactor, and
a combination of an upflow reactor and a downflow reactor. Reactor
114 can have a Reynolds number greater than about 3,000,
alternately greater than about 4,000, or alternately greater than
about 5,000. In at least one embodiment, reactor 114 has a Reynolds
number greater than about 5,000. Maintaining such Reynolds number
in reactor 114 ensures full development of turbulence in reactor
114 to prevent secondary reactions of produced LAOs. The components
of mixed stream 218 can have a residence time in reactor 114
ranging between about 0.1 minute (min) and about 60 min,
alternately between about 0.2 min and about 30 min, or alternately
between about 0.5 min and about 10 min. The residence time is
calculated by assuming that the density of the reactants is
substantially identical to that of water at operating conditions of
reactor 114. The residence time can be controlled such that
secondary reactions of produces LAOs are prevented.
[0062] In reactor 114, the disulfide compounds undergo homolytic
splitting of the disulfide (S--S) bond in supercritical water
conditions to produce thiyl radicals as shown in the following
reaction:
RCH.sub.2--CH.sub.2--S--S--CH.sub.2--CH.sub.2--R'.fwdarw.RCH.sub.2--CH.s-
ub.2--S.+R'CH.sub.2--CH.sub.2--S. Reaction (3)
where R and R' each represents an alkyl group containing at least
one carbon. In the absence of HDCs, the resulting homolytically
split thiyl radicals can undergo rearrangement to produce LAOs as
shown in the following reactions.
RCH.sub.2--CH.sub.2--S.RCH.dbd.CH.sub.2+HS. Reaction (4)
R'CH.sub.2--CH.sub.2--S.R'CH.dbd.CH.sub.2+HS. Reaction (5)
However, the presence of HS. radicals as wells as other hydrogen
containing radicals such as the thiyl radical itself can induce
secondary reactions such as double bond migration (isomerization)
to produce internal olefins, cyclization to produce naphthenes, and
aromatization to produce aromatics. The presence of HDCs (for
example, tetralin) prevent such secondary reactions as shown in the
following reaction by removing HS. radicals:
##STR00001##
where
##STR00002##
is tetralin and
##STR00003##
is naphthalene, which is the dehydrogenated product of tetralin. As
shown in Reaction (6), a partially hydrogenated multi-ring aromatic
compound such as tetralin donates hydrogen atoms and converts to
its stable, fully aromatic form, naphthalene.
[0063] In at least one embodiment, reactor 114 is in the absence of
an external supply of catalyst. In at least one embodiment, reactor
114 is in the absence of an external supply of hydrogen. The
product of reactor 114 is collected via effluent stream 220.
[0064] Effluent stream 220 can be passed to heat exchanger 116 such
that effluent stream 220 is cooled. Heat exchanger 116 can be any
type of heat exchange device capable of reducing the temperature of
effluent stream 220. Non-limiting examples of heat exchanger 116
can include double pipe type exchanger, shell-and-tube type
exchanger, and air cooler. In some embodiments, heat exchanger 116
and heat exchanger 108 are integrated as a single heat exchanger
such that effluent stream 220 can be cooled and water stream 214
can be heated. The temperature of effluent stream 220 can be
reduced in heat exchanger 116 to produce effluent stream 222. The
temperature of effluent stream 222 can range between about 20 deg.
C and about 350 deg. C, alternately between about 30 deg. C and
about 200 deg. C, or alternately between about 50 deg. C and about
110 deg. C. In at least one embodiment, the temperature of effluent
stream 222 ranges between about 50 deg. C and about 110 deg. C.
[0065] Effluent stream 222 is passed to pressure reducer 118 to
produce effluent stream 224. Pressure reducer 118 can be any type
of device capable of reducing the pressure of a fluid stream.
Non-limiting examples of pressure reducer 118 can include a
pressure let-down valve, a pressure control valve, a back pressure
regulator, and a coil. Multiple pressure reducers 118 can be
connected in series. In at least one embodiment, pressure reducer
118 includes two or three serially connected pressure control
valves. The pressure of effluent stream 222 is reduced such that
the pressure of effluent stream 222 can range between about 0.01
MPa and about 10 MPa, alternately between about 0.01 MPa and about
7 MPa, or alternately between about 0.01 MPa and about 5 MPa. In at
least one embodiment, the effluent stream 224 is at about ambient
pressure (that is, about 0.10 MPa). The pressure of effluent stream
224 is maintained at a pressure greater than the steam pressure of
water at the temperature of effluent stream 224.
[0066] Effluent stream 224 is introduced to separator 120.
Separator 120 can be any type of separation device capable of
separating a fluid stream into a gas phase stream and a liquid
phase stream. Effluent stream 224 is separated to produce gas
stream 226 and liquid stream 228. Gas stream 226 can include
gaseous products of reactor 114. Non-limiting example gaseous
products include hydrogen sulfide, methane, ethane, ethylene,
propane, propylene, n-butane, isobutane, .alpha.-butylene,
cis-.beta.-butylene, trans-.beta.-butylene, and isobutylene. Liquid
stream 228 can include liquid products of reactor 114. In some
embodiments, liquid stream 228 can include hydrogen sulfide
dissolved in the liquid products of reactor 114.
[0067] Liquid stream 228 is introduced to separator 122. Separator
122 can be any type of separation device capable of separating a
liquid stream into a hydrocarbon-containing stream and a water
stream. Liquid stream 228 is separated to produce hydrocarbon
stream 230 and water stream 232. In some embodiments, separator 122
is operated in the absence of a demulsifying agent. In some
embodiments, water stream 232 includes hydrocarbons having a
density greater than that of water.
[0068] Hydrocarbon stream 230 is introduced to distillation unit
124. Distillation unit 124 includes distillation columns that are
capable of separating hydrocarbon stream 230 into LAO stream 234
and byproduct stream 236. LAO stream 234 includes LAOs. Byproduct
stream 236 can include organic sulfur compounds other than
disulfides, unreacted and reacted HDCs, and unreacted
disulfides.
[0069] In an alternate embodiment, as shown in FIG. 3, distillation
unit 124 can include distillation columns that are capable of
separating multiple components included in hydrocarbon stream 230.
An example process 100 using a disulfide oil including dipentyl
disulfide and an HDC including tetralin can produce hydrocarbon
stream 230 having a composition as shown in Table 1.
TABLE-US-00001 TABLE 1 Boiling Products Chemical Components Point
(deg. C.) Gaseous Hydrogen Sulfide (Previously -60 dissolved in
liquid product) LAOs 1-Pentene 30 Organic Sulfur 1-Pentanethiol 125
Compounds Other Than Disulfides Unreacted HDCs Tetralin 208
(1,2,3,4- Tetrahydronaphthalene) Reacted (or Naphthalene 218
Dehydrogenated) HDCs Unreacted Disulfides Dipentyl Disulfide 264
and Other Heavy (1-(Pentyldisulfanyl)Pentane) Compounds
[0070] Accordingly, distillation unit 124 can have multiple columns
to separate certain components of hydrocarbon stream 230 based on
the boiling points of the components. For example, distillation
unit 124 can separate hydrocarbon stream 230 having components as
shown in Table 1 into hydrogen sulfide stream 302 (collected from
the top of distillation unit 124), LAO stream 304 (collected via
column corresponding to boiling points ranging between about 0 deg.
C and 80 deg. C), organic sulfur stream 306 (collected via column
corresponding to boiling points ranging between about 80 deg. C and
180 deg. C), HDC stream 308 (collected via column corresponding to
boiling points ranging between about 180 deg. C and 240 deg. C),
and disulfide stream 310 (collected from bottom of distillation
unit 124). One skilled in the relevant art would recognize that the
boiling point ranges of the columns are not fixed but can be
adjusted to different ranges,
[0071] In some embodiments, HDC stream 308 includes unreacted HDCs
and reacted HDCs. Reacted HDCs such as naphthalene (or in some
embodiments, 1,2-dihydronaphthalene, which is a partially
dehydrogenated product of tetralin) can be regenerated via
catalytic partial hydrogenation to produce tetralin. Non-limiting
example catalysts used for regeneration of dehydrogenated HDCs
include platinum-alumina catalysts and nickel-based catalysts.
[0072] In some embodiments, disulfide stream 310 can be recycled to
the process 100 via disulfide oil feed 202.
Example
[0073] The disclosure is illustrated by the following examples,
which are presented for illustrative purposes only, and are not
intended as limiting the scope of the invention which is defined by
the appended claims.
Example
[0074] An experiment was conducted using a laboratory scale unit
with a process similar to that shown in FIG. 1. A disulfide oil
feed (stream 202) was prepared by mixing dipentyl disulfide and
toluene. A hydrogen donor feed (stream 204) was prepared. The
hydrogen donor feed included tetralin. The disulfide oil feed and
the hydrogen donor feed were combined using a tee fitting (stream
208). The mixed stream had a composition as shown in Table 2.
TABLE-US-00002 TABLE 2 Fraction (wt. %) Dipentyl Disulfide 31.8
Tetralin 4.0 Toluene 64.2
[0075] The mixed stream was pumped using a syringe pump at a mass
flow rate of about 176 grams per hour (g/hr) (stream 210) and
subsequently heated by a tubular furnace to a temperature of about
125 deg. C (stream 212).
[0076] A water feed (stream 206) was prepared. The water included
in the water feed was produced by a laboratory scale water
purification unit. The water included in the water feed had
properties compliant to ASTM type I grade. The water feed was
pumped using a syringe pump at a mass flow rate of about 426 g/hr
(stream 214) and subsequently heated by a tubular furnace to a
temperature of about 510 deg. C (stream 216).
[0077] The mixed stream and the water feed were combined using a
tee fitting (stream 218). The mixed stream was introduced to a
tubular reactor (reactor 114) made of 316L stainless steel tubing.
The inner diameter of the tubing was 0.083 inch. The outer diameter
of the tubing was 0.25 inch. The length of the tubing was 12.6
meters. The tubing was arranged in a helical configuration such
that the diameter of the tubular reactor was about 50 centimeters.
The direction of the flow was downward. The helical tubing was
placed in a box furnace. The box furnace was controlled in a manner
such that the temperature of the effluent was maintained at about
446 deg. C. The residence time of the reactants in the tubular
reactor was calculated to be about 0.5 min. The Reynolds number of
the helically configured tubular reactor was about 3,300.
[0078] The effluent (stream 220) was cooled using a double-tube
type cooler to a temperature of about 45 deg. C (stream 222) where
cold water was flowing on the exterior of the cooler. The cooled
stream was depressurized using a back pressure regulator to ambient
pressure (stream 224). The depressurized stream was collected in a
bottle equipped with a condenser to capture light hydrocarbons.
Water (stream 232) was separated from the bottle.
[0079] The experiment was run for about one hour, where the
resulting hydrocarbon product (stream 230) collected via the bottle
contained about 12.7 grams of 1-pentene and about 32.3 grams of
dipentyl disulfide. For about one hour, about 56.0 grams (=176
g/hr.times.31.8%) of dipentyl disulfide was introduced to the
process. The conversion rate of dipentyl disulfide was about 42.3%
(=1-(32.3/56.0)). The theoretical amount of 1-pentene produced at a
42.3% conversion rate was about 16.1 grams
(=2.times.70.1.times.(56.0-32.3)/206.4). The calculated yield was
about 82% (=12.7/16.1).
Comparative Example
[0080] A control experiment was conducted similar to Example but in
the absence of the hydrogen donor feed. The calculated yield was
less than about 60%. The control experiment produced other
byproducts such as 1-pentanethiol, isomerized paraffins, and other
high molecular weight compounds (for example, coke or asphaltenes).
These byproducts were believed to be produced from inter-radical
reactions or secondary reactions due to the presence of HS.
radicals as wells as other hydrogen containing radicals such as the
thiyl radical.
[0081] The results show that the addition of HDCs enhances the
yield of LAOs by decomposing disulfide oil in the presence of
supercritical water.
[0082] Further modifications and alternative embodiments of various
aspects of the disclosure will be apparent to those skilled in the
art in view of this description. Accordingly, this description is
to be construed as illustrative only and is for the purpose of
teaching those skilled in the art the general manner of carrying
out the embodiments described in the disclosure. It is to be
understood that the forms shown and described in the disclosure are
to be taken as examples of embodiments. Elements and materials may
be substituted for those illustrated and described in the
disclosure, parts and processes may be reversed or omitted, and
certain features may be utilized independently, all as would be
apparent to one skilled in the art after having the benefit of this
description. Changes may be made in the elements described in the
disclosure without departing from the spirit and scope of the
disclosure as described in the following claims. Headings used
described in the disclosure are for organizational purposes only
and are not meant to be used to limit the scope of the
description.
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