# US 7,407,571 B2 · Method of and apparatus for upgrading and gasifying heavy hydrocarbon feeds

> Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt

- Number: US 7,407,571 B2
- Document ID: US7407571B2
- Status: Granted
- Kind: B2
- Application number: 10/470,331
- Filed: 2002-12-24
- Published: 2004-06-24
- Granted: 2008-08-05
- Earliest claimed: 2001-12-26
- Assignees: Ormat Industries Ltd.
- Inventors: Philip Rettger; Randall Goldstein; Jim Arnold; Yoram Bronicki; J. Robert Friday
- Web page: https://patentgrep.com/patent/US7407571B2

## CPC

- C10G 69/14: plural parallel stages only
- C10G 49/007: {in the presence of hydrogen from a special source or of a special composition or having been purified by a special treatment}
- C10G 55/04: including at least one thermal cracking step
- C10G 69/06: including at least one step of thermal cracking in the absence of hydrogen
- Y10S 585/921: using recited apparatus structure
- C10G: CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION (cracking to hydrogen or synthesis gas C01B; cracking or pyrolysis of hydrocarbon gases to individual hydrocarbons or mixtures thereof of definite or specified constitution C07C; cracking to cokes C10B); RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- Y10S: TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS

## Abstract

A novel apparatus for producing sweet synthetic crude from a heavy hydrocarbon feed includes: an upgrader for receiving the heavy hydrocarbon feed and producing a distillate fraction including sour products, and high-carbon content by-products; a gasifier for receiving the high-carbon content by-products and producing synthetic fuel gas and sour by-products; a hydroprocessing unit for receiving the sour by-products and hydrogen gas, thereby producing gas and sweet crude; and a hydrogen recovery unit for receiving the synthetic fuel gas and producing further hydrogen gas and hydrogen-depleted synthetic fuel gas, the further hydrogen gas being supplied to the hydroprocessing unit.

## Claims

### Claim 1

An apparatus for producing sweet synthetic crude from a heavy hydrocarbon feed comprising:
a) an upgrader for receiving said heavy hydrocarbon feed and producing a distillate fraction including sour products, and high-carbon content by-products;
b) a gasifier for receiving said high-carbon content by-products and producing synthetic fuel gas and sour by-products;
c) a hydroprocessing unit for receiving said sour by-products and hydrogen gas, thereby producing gas and said sweet crude; and
d) a hydrogen recovery unit for receiving said synthetic fuel gas and producing further hydrogen gas and hydrogen-depleted synthetic fuel gas, said further hydrogen gas being supplied to said hydroprocessing unit;
wherein said gasifier gasifies said high-carbon by-products in the presence of oxygen and produces ash and a gas mixture, and said apparatus further comprises:
e) a scrubber which receives said gas mixture and water and produces sour water and a clean sour gas mixture; and
f) a first gas processor which receives said clean sour gas mixture and produces a sweet synthetic fuel gas
g) a second gas processor which receives a portion of said clean sour gas mixture and produces a processed gas mixture; and
h) a system for producing hydrogen-enriched gas mixture from a synthetic fuel gas;
wherein said system comprises a membrane.

### Claim 2 (depends on 1)

The apparatus according to claim 1, wherein said upgrader comprises:
a) a distillation column for receiving said heavy hydrocarbon feed and producing said distillate fraction, and a non-distilled fraction containing sulfur, asphaltene and metals;
b) a solvent deasphalting unit for processing said non-distilled fraction and producing a deasphalted oil stream and an asphaltene stream, an outlet of said deasphalting unit containing said deasphalted oil being connected to an inlet of a thermal cracker and wherein said asphaltene stream comprises said high-carbon by-products; and
c) said thermal cracker thermally cracking said deasphalted oil and forming a thermally cracked stream.

### Claim 3 (depends on 2)

The apparatus according to claim 2, wherein an outlet of said thermal cracker is connected to an inlet of said distillation column and supplies said thermally cracked stream to said distillation column.

### Claim 4 (depends on 2)

The apparatus according to claim 2, wherein a catalyst is present in said thermal cracker to aid in thermally cracking said deasphalted oil.

### Claim 5 (depends on 1)

The apparatus according to claim 1, further comprising:
a carbon monoxide water/gas shift reactor which receives at least a portion of said processed gas mixture and produces a hydrogen-enriched gas mixture.

### Claim 6 (depends on 5)

The apparatus according to claim 5 wherein said system comprises a pressure swing absorber.

### Claim 7 (depends on 5)

The apparatus according to claim 5 wherein said system comprises a cryogenic separator.

### Claim 8 (depends on 1)

The apparatus according to claim 1 wherein said system comprises a pressure swing absorber.

### Claim 9 (depends on 1)

The apparatus according to claim 1 wherein said system comprises a cryogenic separator.

### Claim 10 (depends on 1)

The apparatus according to claim 1, wherein said first gas processor comprises:
a) a solvent contactor which receives lean solvent from a solvent regenerator and said clean sour gas mixture and produces a sweet product and rich solvent;
b) said solvent regenerator receiving said rich solvent and producing said lean solvent and acid gas;
c) a sulfur recovery unit which receives said acid gas and produces sulfur and a sulfur-depleted gas which is incinerated as required and vented to the atmosphere; and
d) a liquid recovery unit which receives said sweet product and produces sweet synthetic fuel gas and sour water.

### Claim 11 (depends on 5)

The apparatus according to claim 5, wherein said first and said second gas processors each comprise:
a) a solvent contactor which receives lean solvent from a solvent regenerator and said clean sour gas mixture and produces a sweet product and rich solvent;
b) said solvent regenerator receiving said rich solvent and producing said lean solvent and acid gas; and
c) a sulfur recovery unit which receives said acid gas and produces sulfur and a sulfur-depleted gas which is incinerated as required and vented to the atmosphere.

### Claim 12 (depends on 2)

The apparatus according to claim 2, further comprising a first gas processor which receives sour gas from said distillation column, said first gas processor comprising:
a) a solvent contactor which receives lean solvent from a solvent regenerator and said sour gas and produces a sweet product and rich solvent;
b) said solvent regenerator receiving said rich solvent and producing said lean solvent and acid gas;
c) a sulfur recovery unit which receives said acid gas and produces sulfur and a sulfur-depleted gas which is incinerated as required and vented to the atmosphere; and
d) a liquid recovery unit which receives said sweet product and produces sweet gas synthetic fuel gas and sour water.

### Claim 13 (depends on 12)

The apparatus according to claim 12, further comprising a second gas processor which receives further sour gas from said hydroprocessing unit, said second gas processor comprising:
a) a further solvent contactor which receives further lean solvent from a further solvent regenerator and said further sour gas and produces a further sweet product and further rich solvent;
b) said further solvent regenerator receiving said further rich solvent and producing said further lean solvent and a further acid gas;
c) a further sulfur recovery unit which receives said further acid gas and produces further sulfur and a further sulfur-depleted gas which is incinerated as required and vented to the atmosphere; and
d) a further liquid recovery unit which receives said further sweet product and produces further sweet synthetic fuel gas and sour water.

### Claim 14 (depends on 1)

The apparatus according to claim 1, further comprising a water treatment apparatus which receives sour water from said upgrader, said hydroprocessing unit and said gasifier, said water treatment apparatus comprising a striper which receives said sour water and steam and produces stripped water, hydrogen sulfide and ammonia.

### Claim 15 (depends on 2)

The apparatus according to claim 2, further comprising a hydrogen recovery unit for receiving said synthetic fuel gas and producing hydrogen gas and hydrogen-depleted synthetic fuel gas, said hydrogen gas being supplied to said hydroprocessing unit.

### Claim 16

An apparatus for producing sweet synthetic crude from a heavy hydrocarbon feed comprising:
a) an upgrader comprising:
I. a distillation column for receiving said heavy hydrocarbon feed and producing a distillate fraction, and a non-distilled fraction containing sulfur, asphaltene and metals;
II a solvent deasphalting unit for processing said non-distilled fraction and producing a deasphalted oil stream and an asphaltene stream, an outlet of said deasphalting unit containing said deasphalted oil being connected to an inlet of a thermal cracker and wherein said asphaltene stream comprises said high-carbon by-products;
III said thermal cracker thermally cracking said deasphalted oil and forming a thermally cracked stream;
b) a gasifier for gasifying said asphaltenes in the presence of air or oxygen and producing ash and a gas mixture:
c) a scrubber which receives said gas mixture and water and produces sour water and a clean sour gas mixture;
d) a first gas processor which receives said clean sour gas mixture and produces a sweet synthetic fuel gas, said first gas processor comprises:
I a solvent contactor which receives lean solvent from a solvent regenerator and said clean sour gas mixture and produces a sweet product and rich solvent;
II said solvent regenerator receiving said rich solvent and producing said lean solvent and acid gas;
III a sulfur recovery unit which receives said acid gas and produces sulfur and a sulfur-depleted gas which is incinerated as required and vented to the atmosphere; and
IV a liquid recovery unit which receives said sweet product and produces sweet synthetic fuel gas and sour water;
e) a hydroprocessing unit for receiving said sour products and hydrogen gas, thereby producing gas and said sweet crude, said hydroprocessing unit comprising:
I a hydroprocessor which receives said distillate feed and hydrogen gas and produces a high-pressure hydroprocessed product;
II a first flash vessel which receives said high-pressure hydroprocessed product and produces high pressure sour gas and high pressure flashed product;
III a second flash vessel which receives said high pressure flashed product and produces low pressure sour gas and low pressure flashed product;
IV a stripper which receives said low pressure flashed product and steam and produces low pressure sour gas, sour water and sweet synthetic crude;
V a first solvent contactor in fluid communication with a first solvent regenerator and containing a clean solvent, said first solvent contactor receiving said high pressure high pressure sour gas from said first flash vessel and producing sweet recycle gas which is fed to said hydroprocessor and sour solvent, said first solvent regenerator receiving said sour solvent and producing said clean solvent which is fed to said first solvent contactor and hydrogen sulfide and ammonia; and
VI a second solvent contactor in fluid communication with a second solvent regenerator and containing clean solvent, said second solvent contactor receiving said low pressure sour gas from said second flash vessel and from said stripper and producing fuel gas and sour solvent, said second solvent regenerator receiving said sour solvent and producing said clean solvent which is fed to said second solvent contactor; and
f) a hydrogen recovery unit for receiving said synthetic fuel gas and producing further hydrogen gas and hydrogen-depleted synthetic fuel gas, said further hydrogen gas being supplied to said hydroprocessing unit.

### Claim 17

A method for producing sweet synthetic crude from a heavy hydrocarbon feed comprising:
a) upgrading said heavy hydrocarbon feed in an upgrader and thereby producing a distillate feed including sour products, and high-carbon content by-products;
b) gasifying in a gasifier said high-carbon contentby-products and producing synthetic fuel gas and sour by-products;
c) hydroprocessing said sour products along with hydrogen gas, thereby producing gas and said sweet crude; and
d) recovering hydrogen in a hydrogen recovery unit from said synthetic fuel gas and producing further hydrogen gas and hydrogen-depleted synthetic fuel gas, and supplying said further hydrogen gas to said hydroprocessing unit, wherein said gasifying step is conducted in the presence of air or oxygen and produces ash and a gas mixture;
e) scrubbing said gas mixture along with water thereby producing sour water and a clean sour gas mixture;
f) processing said clean sour gas mixture in a first gas processor thereby producing a sweet synthetic fuel gas;
g) processing a portion of said clean sour gas mixture thereby producing a processed gas mixture; and
h) producing a hydrogen-enriched gas mixture from a synthetic fuel gas using a system having a membrane.

### Claim 18 (depends on 17)

The method according to claim 17, wherein said upgrading step further comprises the steps of:
a) distilling in a distillation column said heavy hydrocarbon feed and producing a distillate fraction, and a non-distilled fraction containing sulfur, asphaltene and metals;
b) solvent deasphalting in a solvent deasphalting unit said non-distilled fraction and producing a deasphalted oil stream and an asphaltene stream, supplying said deasphalted oil being connected to an inlet of a thermal cracker and wherein said asphaltene stream comprises said high-carbon by-products;
c) thermally cracking said deasphalted oil and forming a thermally cracked stream.

### Claim 19 (depends on 17)

The apparatus according to claim 17, wherein said apparatus further comprises:
a) a solvent contactor which receives lean solvent from a solvent regenerator and said clean sour gas mixture and produces a sweet product and rich solvent;
b) said solvent regenerator receiving said rich solvent and producing said lean solvent and acid gas;
c) a sulfur recovery unit which receives said acid gas and produces sulfur and a sulfur-depleted gas which is incinerated as required and vented to the atmosphere; and
d) a liquid recovery unit which receives said sweet product and produces sweet synthetic fuel gas and sour water.

### Claim 20 (depends on 18)

The method according to claim 18, wherein a first step of processing sour gas in said first gas processor, said first processor, comprises:
a) contacting said sour gas with lean solvent in a solvent contactor thereby producing a sweet product and rich solvent;
b) regenerating said lean solvent in a solvent regenerator to which is fed said rich solvent, thereby also producing acid gas, and supplying said lean solvent to said solvent contactor;
c) recovering sulfur from said acid gas in a sulfur recovery unit thereby producing a sulfur-depleted gas which is incinerated as required and vented to the atmosphere; and
d) producing sweet synthetic fuel gas and sour water in a liquid recovery unit which receives said sweet product.

### Claim 21 (depends on 20)

The method according to claim 20, further comprising a second step of processing further sour gas from said hydroprocessing unit in a second gas processor, said second processing step comprising:
a) contacting said further sour gas with a further lean solvent in a further solvent contactor thereby producing a further sweet product and further rich solvent;
c) regenerating said further lean solvent in a further solvent regenerator to which is fed said further rich solvent, thereby also producing further acid gas, and supplying said further lean solvent to said further solvent contactor;
d) further recovering sulfur from said further acid gas in a further sulfur recovery unit thereby producing a further sulfur-depleted gas which is incinerated as required and vented to the atmosphere; and
e) and further producing sweet synthetic fuel gas and sour water in a further liquid recovery unit which receives said further sweet product.

### Claim 22 (depends on 17)

The method according to claim 17, further comprising the step of treating sour water from said upgrader, said hydroprocessing unit and said gasifier, said water treatment step comprising stripping said sour water in a stripper along with steam thereby producing stripped water, hydrogen sulfide and ammonia.

### Claim 23

An apparatus for upgrading a heavy hydrocarbon feed comprising:
a) a first distillation column for receiving said heavy hydrocarbon feed and producing a first distillate fraction, and a first non-distilled fraction containing sulfur, asphaltene and metals;
b) a solvent deasphalting unit for processing said non-distilled fraction and producing a deasphalted oil stream and a first asphaltene stream, an outlet of said deasphalting unit containing said deasphalted oil being connected to an inlet of a thermal cracker and wherein said first asphaltene stream comprises high-carbon by-products, said thermal cracker thermally cracking said deasphalted oil and forming a thermally cracked stream;
c) a second distillation column for receiving said thermally cracked deasphalted oil and producing a second distillate fraction and a second non-distilled fraction containing sulfur, asphaltene and metals;
d) a further solvent deasphalting unit for processing said second non-distilled fraction and producing a second deasphalted oil stream and a second asphaltene stream, an outlet of said further deasphalting unit containing said deasphalted oil being connected to an inlet of said first distillation column and wherein said second asphaltene stream comprises said high-carbon by-products; and
e) means for combining said first asphaltene stream and said second asphaltene stream.

### Claim 24 (depends on 23)

The apparatus according to claim 23, wherein said second deasphalted oil stream is fed to said thermal cracker.

### Claim 25 (depends on 23)

The apparatus according to claim 23, further comprising a gas processor which receives gas from said first distillation column.

### Claim 26 (depends on 25)

The apparatus according to claim 25 wherein said gas processor comprises:
a) a solvent contactor which receives lean solvent from a solvent regenerator and said clean sour gas mixture and produces a sweet product and rich solvent;
b) said solvent regenerator receiving said rich solvent and producing said lean solvent and acid gas;
c) a sulfur recovery unit which receives said acid gas and produces sulfur and a sulfur-depleted gas which is incinerated as required and vented to the atmosphere; and
d) a liquid recovery unit which receives said sweet product and produces sweet synthetic fuel gas and sour water.

### Claim 27 (depends on 23)

The apparatus according to claim 23, further comprising a hydroprocessing unit for receiving at least a portion of said distillate fraction and producing gas and sweet synthetic crude.

### Claim 28 (depends on 27)

The apparatus according to claim 27 wherein said hydroprocessing unit comprises:
a) a hydroprocessor which receives distillate feed and hydrogen gas and produces a high-pressure hydroprocessed product;
b) a first flash vessel which receives said high-pressure hydroprocessed product and produces high pressure sour gas and high pressure flashed product;
c) a second flash vessel which receives said high pressure flashed product and produces low pressure sour gas and low pressure flashed product;
d) a stripper which receives said low pressure flashed product and steam and produces low pressure sour gas, sour water and sweet synthetic crude;
e) a first solvent contactor in fluid communication with a first solvent regenerator and containing a clean solvent, said first solvent contactor receiving said high pressure sour gas from said first flash vessel and producing sweet recycle gas which is fed to said hydroprocessor and sour solvent, said first solvent regenerator receiving said sour solvent and producing said clean solvent which is fed to said first solvent contactor and hydrogen sulfide and ammonia; and
f) a second solvent contactor in fluid communication with a second solvent regenerator and containing clean solvent, said second solvent contactor receiving said low pressure sour gas from said second flash vessel and from said stripper and producing fuel gas and sour solvent, said second solvent regenerator receiving said sour solvent and producing said clean solvent which is fed to said second solvent contactor.

### Claim 29 (depends on 27)

The apparatus according to claim 27 wherein said gas is fed to a gas processor.

### Claim 30 (depends on 23)

The apparatus according to claim 23 wherein said first distillate fraction is combined with said second distillate fraction.

### Claim 31 (depends on 23)

The apparatus according to claim 23 wherein gas from said second distillation column is fed to a gas processor.

### Claim 32

A method for upgrading a heavy hydrocarbon feed comprising the steps of:
a) distilling said heavy hydrocarbon feed in a first distillation column and producing a first distillate fraction, and a first non-distilled fraction containing sulfur, asphaltene and metals;
b) solvent deasphalting said non-distilled fraction and producing a deasphalted oil stream and a first asphaltene stream, connecting an outlet of said deasphalting unit containing said deasphalted oil to an inlet of a thermal cracker and wherein said first asphaltene stream comprises high-carbon byproducts, said thermal cracker thermally cracking said deasphalted oil and forming a thermally cracked stream;
c) distilling said thermally cracked deasphalted oil in a second distillation column for and producing a second distillate fraction and a second non-distilled fraction containing sulfur, asphaltene and metals;
d) further solvent deasphalting said second non-distilled fraction and producing a second deasphalted oil stream and a second asphaltene stream, connecting an outlet of said further deasphalting unit containing said deasphalted oil to an inlet of said first distillation column and wherein said second asphaltene stream comprises also high-carbon by-products; and
e) combining said first asphaltene stream and said second asphaltene stream.

### Claim 33 (depends on 32)

The method according to claim 32, further comprising the step of feeding said second deasphalted oil stream to said thermal cracker.

### Claim 34 (depends on 32)

The method according to claim 32, further comprising the step of processing gas from said first distillation column.

### Claim 35 (depends on 34)

The method according to claim 34 wherein said gas processing comprises the steps of:
a) contacting said gas with lean solvent in a solvent contactor thereby producing a sweet product and rich solvent;
b) regenerating said lean solvent in a solvent regenerator to which is fed said rich solvent, thereby also producing acid gas, and supplying said lean solvent to said solvent contactor;
c) recovering sulfur from said acid gas in a sulfur recovery unit thereby producing a sulfur-depleted gas which is incinerated as required and vented to the atmosphere; and
d) producing sweet synthetic fuel gas and sour water in a liquid recovery unit which receives said sweet product.

### Claim 36 (depends on 32)

The apparatus according to claim 32, further comprising the step of hydroprocessing at least a portion of said distillate fraction and producing gas and sweet synthetic crude.

### Claim 37 (depends on 36)

The apparatus according to claim 36 wherein said wherein said hydroprocessing step further comprises the steps of:
a) hydroprocessing said distillate feed along with hydrogen gas and produces a high-pressure hydroprocessed product;
c) flashing in a first flash vessel said high-pressure hydroprocessed product thereby producing high pressure sour gas and high pressure flashed product;
d) flashing in a second flash vessel said high pressure flashed product and producing low pressure sour gas and low pressure flashed product;
e) stripping in a stripper said low pressure flashed product along with steam and producing low pressure sour gas, sour water and sweet synthetic crude;
f) contacting said high pressure sour gas with a clean solvent in a first solvent contactor which is in fluid communication with a first solvent regenerator, thereby producing sweet recycle gas which is fed to said hydroprocessor and sour solvent, regenerating said sour solvent in said solvent regenerator thereby producing said clean solvent, and feeding said clean solvent to said first solvent contactor; and
g) contacting said low pressure sour gas from said second flash vessel and said stripper with a second clean solvent in a second solvent contactor which is in fluid communication with a second solvent regenerator thereby producing fuel gas and sour solvent, regeneratoring sour solvent in said second solvent regenerator thereby producing said second clean solvent and feeding said second clean solvent to said second solvent contactor.

### Claim 38 (depends on 36)

The apparatus according to claim 36 further comprising the step of processing said gas.

### Claim 39 (depends on 32)

The apparatus according to claim 32 further comprising the step of combining said first distillate fraction with said second distillate fraction.