The invention generally concerns the production of olefins from catalytic cracking of alkane (paraffinic) hydrocarbons. In particular, the invention concerns catalytically cracking a hydrocarbons stream that includes C5 and C6 hydrocarbons to produce a mixed butenes stream, which can be converted via self-metathesis into methane, ethylene, propylene, and C5+ gasoline hydrocarbons.
The conversion of hydrocarbons such as light naphtha into light olefins via catalytic cracking produces commercially valuable C2 to C3 olefins and less valuable olefins such as n-butenes and iso-butenes (“mixed butenes”). To increase the value of the mixed butenes, conventional processes combine the mixed butenes with liquid propane gas (LPG) and sell the combined stream as LPG. Other methods to increase the value of the mixed butene stream is to process the C4 hydrocarbons into C5 olefins that can be further cracked to produce propylene and ethylene. By way of example, U.S. Pat. No. 7,728,185 to Senetar et al. describes a process to increase the propylene yield from a hydrocarbon cracking unit. The process includes separating a C4 stream into a normal butane stream containing n-butane and 2-butene, and an iso-butane stream containing iso-butane, iso-butene, and 1-butene. The iso-butane stream is passed to an alkylation reactor to dimerize some of the iso-butane stream to form larger hydrocarbons having 8 or more carbon atoms. The larger hydrocarbons are readily separated from unreacted C4 hydrocarbons and are passed to an olefin cracking unit to produce ethylene and propylene.
While various attempts to increase ethylene and propylene production and to utilize the C4 stream from a hydrocarbon cracking process have been described, there is still a need to utilize the C4 stream produced from a hydrocarbon cracking processes in a cost effective and efficient manner.
An alternate process to increase the production of more economically desired products from a mixed C4 hydrocarbons stream (e.g., n-butene and iso-butene mixture) produced from a hydrocarbon catalytic cracking process has been developed. The process is premised on subjecting the mixed C4 hydrocarbons stream obtained from a hydrocarbon catalytic cracking process to self-metathesis conditions under conditions sufficient to produce C5+ gasoline hydrocarbons and C1-3 hydrocarbons. The process successfully integrates the hydrocarbon cracking process with a self-metathesis of C4 hydrocarbons to produce more economically viable products, notably, gasoline hydrocarbons, methane, ethylene, and propylene.
Embodiments of the present invention describe processes for producing olefins. A process can include: (a) catalytically cracking a hydrocarbons stream comprising C5 and C6 hydrocarbons under conditions sufficient to form a first stream comprising C5+ gasoline hydrocarbons, C1 to C4 hydrocarbons, (b) fractionating the first stream to produce at least a (1) first stream comprising C5+ gasoline hydrocarbons, and (2) a gaseous stream comprising the C1 to C4 hydrocarbons and residual C5+ hydrocarbons; (c) separating the gaseous stream into a gaseous mixed C4 hydrocarbons stream comprising n-butene and iso-butene, a gaseous C3 hydrocarbons stream, and a second C5+ gasoline hydrocarbons stream; (d) contacting the mixed C4 gaseous stream with a metathesis catalyst under conditions sufficient to produce a second gaseous stream comprising methane, ethylene and/or propylene, and a product stream comprising C5+ gasoline hydrocarbons; and (e) mixing the step (d) second gaseous stream with the step (c) gaseous stream. The separated second C5+ gasoline hydrocarbons stream can be mixed with the C5+ gasoline hydrocarbons product stream.
The step (c) separation can include (i) producing a gaseous product stream comprising C1 and C2 hydrocarbons and a gaseous C3+ hydrocarbons stream that can include the gaseous mixed C4 hydrocarbons, the gaseous C3 hydrocarbons, and the residual C5+ gasoline hydrocarbons; and (ii) separating the gaseous C3+ hydrocarbons stream into a gaseous C3 hydrocarbons stream, a gaseous mixed C4 hydrocarbons stream comprising n-butene and iso-butene, and the C5+ gasoline hydrocarbons stream. In some embodiments, the gaseous C3+ hydrocarbons stream can be separated into a gaseous C3/C4 stream and the C5+ gasoline hydrocarbons stream. The gaseous C3/C4 stream can be separated into the gaseous C3 hydrocarbons stream and a gaseous mixed C4 hydrocarbons stream that includes the n-butene and iso-butene, which can be provided to the step (c) metathesis reaction. In certain instances the gaseous mixed C4 hydrocarbons stream can include C4 acyclic alkanes and the C4 hydrocarbons stream, and can be separated into a C4 olefins stream that includes the n-butene and the iso-butene and a C4 acyclic alkanes stream. The C4 olefins stream can be provided to the metathesis reaction of step (d).
In some embodiments, the second gaseous stream of step (d) can include C4 hydrocarbons. Embodiments of the process can include separating the separating the second gaseous stream into a gaseous C1-3 hydrocarbons stream and a C4 hydrocarbons stream and mixing the gaseous C1-3 hydrocarbons stream with the step (c) gaseous stream. The C4 hydrocarbons stream can be separated into a C4 olefins stream and a C4 acyclic alkane stream and providing the C4 olefins stream to step (d).
Embodiments of the catalytic hydrocarbon cracking conditions can include contacting the hydrocarbons stream with a catalyst at a catalyst to hydrocarbon ratio of 3:1 to 40:1. In some embodiments, the contacting can be performed in the presence of water, steam, or both. The conditions can also include a temperature of 500-700° C. and/or a pressure of 0.05 MPa to 0.5 MPa. In some embodiments, the catalyst can include an acidic catalyst. The acidic catalyst can be a zeolite catalyst such as a medium pore zeolite catalyst (e.g., a ZSM-5, a modified ZSM-5 or a mixture of both), a large pore catalyst (e.g., a Y zeolite, an ultra-stable zeolite Y or a mixture of both), or a mixture of both. In certain embodiments, step (a) can be performed in a catalytic cracker unit comprising a fixed catalyst bed, a moving catalyst bed, or fluidized catalyst bed.
Embodiments of step (c) of the process can include a temperature of 200 to 550° C. and/or a pressure of 0.1 MPa to 2.0 MPa. A metathesis catalyst can include a Column 6 metal (e.g., tungsten (W), or molybdenum (Mo)) or compound thereof, a noble metal (e.g., rhodium (Rh)) or a compound thereof, or a combination thereof.
The following includes definitions of various terms and phrases used throughout this specification.
The term “catalyst” means a substance which alters the rate of a chemical reaction. “Catalytic” or “catalytically active” means having the properties of a catalyst.
The term “cracking” means to break a carbon-carbon bond of a hydrocarbon molecule to produce a hydrocarbon having fewer carbon atoms than the starting hydrocarbon molecule.
The term “gasoline hydrocarbons” refers to a hydrocarbons stream containing hydrocarbons having up to 12 carbons suitable to be made into gasoline. For example, C5+ gasoline hydrocarbons refer to a hydrocarbons stream having C5 to C12 hydrocarbons.
The terms “about” or “approximately” are defined as being close to as understood by one of ordinary skill in the art. In one non-limiting embodiment, the terms are defined to be within 10%, preferably within 5%, more preferably within 1%, and most preferably within 0.5%.
The terms “wt. %,” “vol. %,” or “mol. %” refers to a weight, volume, or molar percentage of a component, respectively, based on the total weight, the total volume of material, or total moles, that includes the component. In a non-limiting example, 10 grams of component in 100 grams of the material is 10 wt. % of component.
The term “substantially” and its variations are defined to include ranges within 10%, within 5%, within 1%, or within 0.5%.
The terms “inhibiting” or “reducing” or “preventing” or “avoiding” or any variation of these terms, when used in the claims and/or the specification, includes any measurable decrease or complete inhibition to achieve a desired result.
The term “effective,” as that term is used in the specification and/or claims, means adequate to accomplish a desired, expected, or intended result.
The use of the words “a” or “an” when used in conjunction with any of the terms “comprising,” “including,” “containing,” or “having” in the claims, or the specification, may mean “one,” but it is also consistent with the meaning of “one or more,” “at least one,” and “one or more than one.”
The words “comprising” (and any form of comprising, such as “comprise” and “comprises”), “having” (and any form of having, such as “have” and “has”), “including” (and any form of including, such as “includes” and “include”) or “containing” (and any form of containing, such as “contains” and “contain”) are inclusive or open-ended and do not exclude additional, unrecited elements or method steps.
The processes of the present invention can “comprise,” “consist essentially of,” or “consist of” particular ingredients, components, compositions, etc. disclosed throughout the specification. With respect to the transitional phase “consisting essentially of,” in one non-limiting aspect, a basic and novel characteristic of the processes of the present invention are their abilities to produce C2 and C3 hydrocarbons and a C5+ hydrocarbons stream from a mixed C4 stream produced from catalytically cracking a C5-6 hydrocarbons stream.
In the context of the present invention, twenty embodiments are now described. Embodiment 1 is a process for producing olefins. The process includes the steps of (a) catalytically cracking a hydrocarbons stream containing C5 and C6 hydrocarbons under conditions sufficient to form a cracked hydrocarbons stream containing C5+ gasoline hydrocarbons, and gaseous C1 to C4 hydrocarbons; (b) fractionating the first stream to produce at least (1) a first stream containing C5+ gasoline hydrocarbons, and (2) a gaseous stream containing the C1 to C4 hydrocarbons and residual C5+ hydrocarbons; (c) separating the gaseous stream into a gaseous mixed C4 hydrocarbons stream containing n-butene and iso-butene, a gaseous C3 hydrocarbons stream, and a C5+ gasoline hydrocarbons stream; (d) contacting the mixed C4 gaseous stream with a metathesis catalyst under conditions sufficient to produce a second gaseous stream containing methane, ethylene and/or propylene, and a product stream containing C5+ gasoline hydrocarbons; and (e) mixing the step (d) second gaseous stream with the step (c) gaseous stream. Embodiment 2 is the process of embodiment 1, further containing mixing the C5+ gasoline hydrocarbons product stream with the C5+ gasoline hydrocarbons stream. Embodiment 3 is the process of any one of embodiments 1 to 2, wherein separating the gaseous stream of step (c) includes the steps of (i) producing a gaseous product stream containing C1 and C2 hydrocarbons and a gaseous C3+ hydrocarbons stream containing the gaseous mixed C4 hydrocarbons, the gaseous C3 hydrocarbons, and the residual C5+ gasoline hydrocarbons; and (ii) separating the gaseous C3+ hydrocarbons stream into a gaseous C3 hydrocarbons stream, a gaseous mixed C4 hydrocarbons stream containing n-butene and iso-butene, and the second C5+ gasoline hydrocarbons stream. Embodiment 4 is the process of embodiment 3, further containing separating the C3+ hydrocarbons stream into a gaseous C3/C4 stream and the second C5+ gasoline hydrocarbons stream. Embodiment 5 is the process of embodiment 4, further containing separating the gaseous C3/C4 stream into the gaseous C3 hydrocarbons stream and the gaseous mixed C4 hydrocarbons stream containing the n-butene and the iso-butene. Embodiment 6 is the process of embodiment 5, wherein the gaseous mixed C4 hydrocarbons stream contains C4 acyclic hydrocarbons and the process further includes the step of separating the gaseous mixed C4 hydrocarbons stream into a C4 olefins stream and a C4 acyclic alkanes stream, and providing the C4 olefins stream to step (d). Embodiment 7 is the process of any one of embodiments 1 to 6, wherein the second gaseous stream of step (d) contains C4 hydrocarbons. Embodiment 8 is the process of embodiment 7, wherein the process includes separating the second gaseous stream into a gaseous C1-3 hydrocarbons stream and a C4 hydrocarbons stream and mixing the gaseous C1-3 hydrocarbons stream with the step (c) gaseous stream. Embodiment 9 is the process of embodiment 8, further including the step of separating the C4 hydrocarbons stream into a C4 olefins stream and a C4 acyclic alkane stream and providing the C4 olefins stream to step (d). Embodiment 10 is the process of any one of embodiments 1 to 9, wherein the step (a) conditions include contacting the hydrocarbons stream with a catalyst at a catalyst to hydrocarbon ratio of 3:1 to 40:1. Embodiment 11 is the process of any one of embodiments 1 to 10, wherein the catalytic cracking conditions include a temperature of 500-700° C. and a pressure of 0.05 MPa to 0.5 MPa. Embodiment 12 is the process of any one of embodiments 1 to 11, wherein the catalytic cracking conditions include an acidic catalyst. Embodiment 13 is the process of embodiment 12, wherein the acidic catalyst contains a medium pore zeolite catalyst, a large pore catalyst, or a mixture of both. Embodiment 14 is the process of embodiment 13, wherein the medium pore zeolite catalyst is a ZSM-5, a modified ZSM-5 or a mixture of both and the large pore zeolite catalyst is a Y zeolite, an ultra-stable zeolite Y, or a mixture of both. Embodiment 15 is the process of any one of embodiments 1 to 14, wherein the step (a) is performed in a catalytic cracker unit including a fixed catalyst bed, a moving catalyst bed, or fluidized catalyst bed. Embodiment 16 is the process of any one of embodiments 1 to 15, wherein the catalytic cracking conditions include water, steam or both. Embodiment 17 is the process of any one of embodiments 1 to 16, wherein the step (d) metathesis conditions include a temperature of 200 to 550° C. and a pressure of 0.1 MPa to 2.0 MPa. Embodiment 18 is the process of any one of embodiments 1 to 17, wherein the step (d) catalyst includes a Column 6 metal or compound thereof, a noble metal or a compound thereof, or a combination thereof. Embodiment 19 is the process of embodiment 18, wherein the Column 6 metal is tungsten, molybdenum, or both. Embodiment 20 is the process of any one of embodiments 18 to 19, wherein the noble metal is rhenium.
Other objects, features, and advantages of the present invention will become apparent from the following figures, detailed description, and examples. It should be understood, however, that the figures, detailed description, and examples, while indicating specific embodiments of the invention, are given by way of illustration only and are not meant to be limiting. Additionally, it is contemplated that changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description. In further embodiments, features from specific embodiments may be combined with features from other embodiments. For example, features from one embodiment may be combined with features from any of the other embodiments. In further embodiments, additional features may be added to the specific embodiments described herein.
Advantages of the present invention may become apparent to those skilled in the art with the benefit of the following detailed description and upon reference to the accompanying drawings.
While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings. The drawings may not be to scale.
An alternate process to produce C5+ gasoline hydrocarbons and methane, ethylene propylene from a gaseous stream produced from catalytically cracking of a C5-6 hydrocarbons stream has been discovered. The process successfully integrates a self-metathesis of C4 hydrocarbons process into a catalytically cracking of hydrocarbons process to produce more commercially valuable products from a mixed C4 hydrocarbons stream. The mixed C4 hydrocarbons stream used in this process can be produced from the aforementioned hydrocarbon catalytic cracking reaction, thereby providing a sustainable process for value added commercial products such as methane, ethylene, propylene and C5+ hydrocarbons.
These and other non-limiting aspects of the present invention are discussed in further detail in the following sections with reference to the figures.
In catalytic cracking unit 104, hydrocarbons stream 102 can be contacted with a hydrocracking catalyst under conditions suitable to produce a cracked hydrocarbons stream 106. Cracked hydrocarbons stream 106 can include C5+ gasoline hydrocarbons and gaseous C1 to C4 (C1-4) hydrocarbons. Catalytic cracking unit 102 can be any unit capable of cracking hydrocarbons into smaller molecular weight hydrocarbons (i.e., having a lower carbon number than hydrocarbons stream 102). Non-limiting examples of catalytic cracking units include a fixed catalyst bed catalytic cracker, a moving catalyst bed catalytic cracker, or fluidized catalyst bed catalytic cracker. In embodiments when a fluidized bed catalytic cracker is used, the hydrocarbons stream can flow through the catalyst bed in an upwardly or downwardly direction. The hydrocracking catalyst used for cracking the hydrocarbons stream can be an acidic catalyst. Acidic hydrocracking catalysts can include medium pore zeolites, large pore zeolites, and mixtures thereof. Non-limiting examples of medium pore zeolites can include ZSM-5, modified ZSM-5, spray dried ZSM-5, spray dried modified ZSM-5 and the like. Non-limiting examples of large pore zeolite catalyst can include a Y zeolite, an ultra-stable zeolite Y or a mixture of both. Zeolite catalysts can be obtained from commercial vendors such as Grace Catalysts Technologies (U.S.A.), Sigma-Aldrich® (U.S.A.), or Zeolyst International, (U.S.A.). Contacting conditions can include temperature, pressure, residence time and the like. Average temperatures in catalytic cracking unit 104 can range from 500° C. to 700° C., 525° C. to 625° C., 550° C. to 600° C., or any value or range there between. Average pressures in catalytic cracking unit 104 can range from 0.1 MPa to 2 MPa, or 0.5 to 1.5 MPa, or 0.75 to 1.0 MPa or any value or range there between. In embodiments when a fluidized bed catalytic cracker is used, a residence time of hydrocarbons stream 102 in the fixed catalyst bed can be 1 to 10 seconds, or 2 to 9 seconds, or 3 to 8 seconds, or any value or range there between. In a non-limiting example, a C5-6 hydrocarbons stream can be contacted with a zeolite catalyst and 25 wt. % steam in a fluidized bed reactor at a temperature of 650 to 690° C. to produce first hydrocarbons stream 106 and second hydrocarbons stream 108.
Cracked hydrocarbons stream 106 can exit catalytic cracking unit 104 and enter fractionation unit 108. In fractionation unit 108, cracked hydrocarbons stream 106 can be separated into a plurality of streams that can include gaseous hydrocarbons stream 110 and C5+ gasoline hydrocarbons stream 112. In some embodiments, C5+ gasoline hydrocarbons stream 112 can be recycled to catalytic cracking unit 104. Other streams (not shown) that can be produced from fractionation unit 108 include light and heavy cycle oil, heavy hydrocarbons, coke, and the like. The other streams can be sold, transported, recycled, or sent to other processing units. Fractionation unit 108 can be any fractionation unit known in the art capable of separating a hydrocarbons stream. Fractionation unit can include one or more units, one or more distillation plates, etc.
Gaseous hydrocarbons stream 110 can include from C1 to C4 hydrocarbons (e.g., methane, ethane, propane, butane, n-butene and iso-butene, propylene, ethane, or mixtures thereof) and residual C5+ gasoline hydrocarbons. Gaseous hydrocarbons stream 110 can enter gas separation unit 114 and be subjected to conditions to sufficient to hydrocarbons into gaseous C1-2 hydrocarbon steam 116, gaseous C3 hydrocarbons stream 118, gaseous mixed C4 hydrocarbons stream 120, and C5+ gasoline hydrocarbons stream 122. Gas separation unit 114 can include one or more cryogenic distillation units, membrane units, debutanizers, de-ethanizers, or any known separation unit capable of separating hydrocarbons. Gaseous C1-2 hydrocarbon steam 116 can include methane and/or C2 hydrocarbons, preferably ethylene and ethane. In some embodiments, gaseous C1-2 hydrocarbon steam contains none or substantially no methane. Gaseous C3 hydrocarbons stream can include propylene and propane. Gaseous C1-2 hydrocarbon steam 116 and/or gaseous C3 hydrocarbons stream can exit gaseous separation unit 114 and be stored, transported, sold, or provided to other processing units. Second C5+ gasoline hydrocarbons stream 122 can be stored, sold, transported to other processing units to be additized or further processed for use as gasoline, combined with other C5+ gasoline hydrocarbons streams, or combinations thereof. Mixed C4 hydrocarbons stream 120 can include C4 alkanes and C4 olefins. In some embodiments, mixed C4 hydrocarbons stream includes 0 to 100 vol. % n-butene and/or 0 to 100 vol. % iso-butene.
Mixed C4 hydrocarbons stream 120 that includes n-butene and iso-butene (mixed butenes) can exit separation unit 114 and enter C4 metathesis unit 124. In C4 metathesis unit 124, mixed C4 hydrocarbons stream 120 can be contacted with a catalyst under conditions sufficient to produce gaseous product stream 126 and product stream 128 that includes C5+ gasoline hydrocarbons. Gaseous product stream 126 can includes C2-4 olefins (e.g., ethylene, propylene, butylene, or mixtures thereof) and methane. The conversion of mixed butenes to C5+ hydrocarbons can be shown in the following chemical equations:
1-C4H8+2-C4H8→C3H6+2-C5H10 (1)
Iso-C4H8+2-C4H8→C3H6+H3C—C(CH3)═C(H)—CH2—CH3 (2)
Iso-C4H8+1-C4H8→C2H4+H3C—C(CH3)═C(H)—CH2—CH3 (3)
1-C4H8+1-C4H8→C2H4+3-C6H12 (4).
Other reactions such as oligomerization, cracking, self-metathesis of isobutylene and isomerization of normal butenes can also occur in C4 metathesis unit 124. Conditions sufficient to convert the n-butene and iso-butene hydrocarbons into higher molecular weight (i.e., higher carbon number) compounds include a temperature of 200° C. to 550° C., 250° C. to 500° C., 300° C. to 450° C., or 400° C. to 450° C. or any value or range there between and a pressure of 0.1 MPa to 2.0 MPa, 0.5 MPa to 1.5 MPa, or any value or range there between. The catalyst in metathesis unit 116 can be any catalyst capable of catalyzing a C4 metathesis reaction. The metathesis catalyst can include a metal from Column 6 of the Periodic Table (e.g., W or Mo) or compounds thereof and/or a noble metal (e.g., Rh) or compounds thereof. In a preferred aspect, the catalyst can be W/Rh or Mo/Rh. Non-limiting examples of metathesis catalysts are described in U.S. Pat. No. 6,683,019 to Gartside et al., or can be obtained from commercial vendors such as Aperion synthesis (Poland) or Sigma-Aldrich® (U.S.A.).
Referring to
Referring to
Referring to
The present invention will be described in greater detail by way of specific examples. The following examples are offered for illustrative purposes only, and are not intended to limit the invention in any manner. Those of skill in the art will readily recognize a variety of noncritical parameters which can be changed or modified to yield essentially the same results.
A zeolite catalyst was tested for light naphtha cracking using a fluidized bed pilot plant on a single pass. The light straight run naphtha (LSRN) composition is listed in Table 1. Reactor temperature, steam/feed ratio, and residence time are listed in Table 2. Recycle of C5+ gasoline hydrocarbons stream to the reactor would increase the conversion and yields of light olefins. As can be seen the yields of C4 is around 11.3 wt. %.
The self-metathesis reactions of mixed butenes including isobutenes were simulated. The simulation used more than eight reactions. The product distribution is shown in Table 3. It was determined that the yield of C1-3 olefins was about 23 wt. %.
The products from the integration of the catalytic cracking process of Example 1 with the C4 metathesis reaction of Example 2 are shown in Table 4. Inventors:
This application is a national phase application under 35 U.S.C. § 371 of International Application No. PCT/IB2017/057968 filed Dec. 14, 2017, which claims priority to U.S. Provisional Patent Application No. 62/437,306 filed Dec. 21, 2016. The entire contents of each of the above-referenced disclosures is specifically incorporated by reference herein without disclaimer.
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