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Mild Resid Hydrocracking for Middle Distallates: A New Vacuum Resid Upgrading Alternative

IP.com Disclosure Number: IPCOM000219910D
Publication Date: 2012-Jul-17

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Page 01 of 11

MILD RESID flYDROCRACKING FOR MIDDLE DISTILLATES:

A NEW VACUUM RESID UPGRADING ALTERNATIVE

By R. B. Armstrong and

P. Sadhukhan


The M. W. Kellogg Company

and

H. Sue


Idemltsu Kosan Company, Limited

ABSTRACT

Idemitsu Kosan Company, Lid and The M. W. Kellogg Company have devel~a new

process called Mild Resid Hydrocracking (MRH). MRH produce~dlstfllate products including dlesel-range fuel directly from vacuum resid~r'tar sand extracts. MRH employs a suspended-bed slurry reactor at lower hydrogen pressure than other hydrogenative upgrading processes. The low pressure, relatively low hydrogen consumption, and efficient product oil handling system result in minimal operating costs as well as inexpensive main process equipment. The MRH reactor's specialized internal design assures good slurry mixing and gas distribution. The catalyst, suspended in the slurry phase, scavenges metals and coke. Catalyst-free product oil exits from the reactor through a separation zone. A small catalyst purge stream is removed from a separate outlet. Washing, steam stripping, and fluid bed conversion steps remove coke from the catalyst prior to recycle to the reactor.

MRH incorporates Kellogg's H~M process, which was conceived~ 1975.~mitsu Kosan Company has developed MRH, as a member of R~PA~. sponsored by~'~MITI.j starting in 1980. With Kellogg's process design and engineering assistance,

Idemitsu has built and operated a I bbl/day MP.H bench p~ant. This unit has demonstrated continuous operation and established yields, catalyst requirements, and hydrogen consumption data. Typical operation achieves 70 percent conversion of vacuum resid. Typically 20 to 30% of the distillate products are in the kerosine and diesel boiling ranges, requiring only minor downstream processing. Metals removal is 90%, and desulfurization exceeds 50%.

Gas oil product is suitable for Heavy Oil Cracking or hydrocracker feed. Idemitsu is currently building a I0 bbl/day MRH pilot plant at its research site In Chiba, Japan.


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MILD RESID HYDROCRACKING FOR MIDDLE DISTILLATES:

A NEW VACUUM RESID UPGRADING ALTERNATIVE

INTRODUCTION

The current worldwide surplus of crude production, refining capacity, and resid conversion seem likely to continue for several years. Even disruption of some supply sources will not severely upset the current fuel supply/demand balance. However, a number of recent reviews (for example, F. Fesharakl, 1985) have reported that an additional increase as small as one percent in world economic growth rate could absorb existing refining capacity, curb refined product exports, and stimulate demnnd for additional resld upgrading and production of fuels from other sources such as tar sands. The currently planned reductions in existing refining capacity, combined with prospects for demand growth in developing countries, increase the probability of additional installations of resid refining capacity within the next ten to twenty years.

In preparation for the pote...