US 2010/0163459 A1 · HEAVY OIL UPGRADE PROCESS INCLUDING RECOVERY OF SPENT CATALYST

Abstract

A process to upgrade heavy oil and convert the heavy oil into lower boiling hydrocarbon products is provided. The process employs a catalyst slurry comprising catalyst particles with an average particle size ranging from 1 to 20 microns. In the upgrade process, spent slurry catalyst in heavy oil is generated as an effluent stream, which is subsequently recovered/separated from the heavy oil via membrane filtration. In one embodiment, filtration sedimentation is used for the separation of the heavy oil from the catalyst particles. Valuable metals can be recovered from catalyst particles for subsequent re-use in a catalyst synthesis unit, generating a fresh slurry catalyst.

Claims30

Dependent claims

A process for reducing heavy oil concentration in a composition containing 2-40 wt. % catalyst particles in heavy oil, the process comprising passing a mixture of solvent and the composition comprising catalyst particles in heavy oil through a filtration sedimentation assembly comprising:

at least a filtration membrane having a plurality of channels arranged in parallel, the channels having an angle of inclination at least 45° from a horizontal surface, wherein the membrane has an average pore size selected for separating the feed stream into:
a) a filtrate stream comprising solvent and at least 50% of the heavy oil in the composition;
and b) a retentate stream containing catalyst particles having a reduced heavy oil content and a portion of the solvent;
and
a receiving chamber for receiving the retentate.

2 more elements

A system for reducing heavy oil concentration in a composition comprising 2-40 wt. % catalyst particles in heavy oil, the system comprising:

a filtration sedimentation assembly for receiving a solvent and the composition comprising catalyst particles in heavy oil, the filtration sedimentation assembly has at least a filtration membrane in the form of a plurality of channels arranged in parallel and having an angle of inclination at least 45° from a horizontal surface, wherein the membrane has an average pore size selected for separating the solvent and the composition into:
a) a filtrate stream comprising solvent and at least 50% of the heavy oil in the feed stream;
and b) a retentate stream containing catalyst particles having a reduced heavy oil content and a portion of the solvent;
and
a receiving chamber for receiving the retentate;
a separator for receiving the filtrate stream and separating the heavy oil from the solvent;
and
means for receiving the retentate stream and separating the heavy oil from the catalyst particles.

5 more elements

Dependencies are inferred from the claim text.

Heavy oil upgrade process including recovery of spent catalyst

Life of this patent

Heavy oil upgrade process including recovery of spent catalyst

Life of this patent

Abstract

Claims30