Process for sulfone conversion by super electron donors

Abstract

A process wherein an electron donor agent is provided for the decomposition of sulfones and sulfoxides formed after the oxidative desulfurization of a sulfur-containing hydrocarbon stream.

1 . A method of upgrading a hydrocarbon feedstock by removal of sulfones and sulfoxides therefrom, which comprises the steps of
 a. supplying a hydrocarbon feedstock to an oxidation reactor, the hydrocarbon feedstock comprising sulfur-containing compounds;   b. contacting the hydrocarbon feedstock with an oxidant in the presence of a catalyst in the oxidation reactor under conditions sufficient to selectively oxidize sulfur compounds present in the hydrocarbon feedstock to produce a hydrocarbon stream that comprises hydrocarbons and oxidized sulfur-containing compounds;   c. separating the oxidized sulfur-containing hydrocarbon stream into an aqueous phase and a non-aqueous oxidized effluent;   d. recovering the non-aqueous oxidized effluent and contacting it with an electron donor agent to oxidize sulfones and sulfoxides present in the non-aqueous oxidized effluent; and,   e. separating and recovering the hydrocarbon stream from which the sulfones and sulfoxides have been removed.   
     
     
         2 . The process according to  claim 1 , wherein from about 1 to about 5 mole equivalents of an electron donor agent is used based on the sulfone and sulfoxide content of the feedstock. 
     
     
         3 . The process according to  claim 2 , wherein from about 1 to about 3 mole equivalents of an electron donor agent is used. 
     
     
         4 . The process according to  claim 1 , wherein the decomposition is effected at a temperature from about 100° C. to about 300° C. 
     
     
         5 . The process according to  claim 4 , wherein the decomposition is effected at about 100° C. to about 200° C. 
     
     
         6 . The process according to  claim 5 , wherein the decomposition is effected about 100° C. to about 150° C. 
     
     
         7 . The process according to  claim 1 , wherein the decomposition is conducted at a pressure of about 3 kg/cm 2  to about 30 kg/cm 2 . 
     
     
         8 . The process according to  claim 1 , wherein the decomposition is conducted at about 0.05 h −1  to about 4.0 h −1 . 
     
     
         9 . The process according to  claim 1 , wherein the electron donor agent must have an oxidation potential sufficient to effect reductive cleavage of the sulfones and the sulfoxides. 
     
     
         10 . The process according to  claim 9 , wherein the electron donor is a tetraazaalkene. 
     
     
         11 . The process according to  claim 8 , wherein the bisimidazole is bisimidazolylidene. 
     
     
         12 . The process according to  claim 1 , wherein the hydrocarbon feedstock is crude oil, oil, shale oil, coal liquids, intermediate refinery products and distilled fractions thereof. 
     
     
         13 . The process according to  claim 9 , wherein the electron donor agent has at least a half potential of −1.2V in dimethylformanide when referenced to a saturated calomel electrode. 
     
     
         14 . The process according to  claim 12 , wherein the hydrocarbon feeds stock boils in the range of about 36° C. to about 2000° C. 
     
     
         15 . The process according to  claim 1 , wherein after step c), the non-aqueous oxidized effluent is subjected to solvent extraction. 
     
     
         16 . The process according to  claim 15 , wherein the solvent is a polar solvent. 
     
     
         17 . The process according to  claim 15 , wherein the extraction is conducted between about 20° C. and about 60° C. and at a pressure between about 1 and about 10 bars. 
     
     
         18 . The process according to  claim 15 , wherein after the step of extraction, the extracted effluent is subjected to adsorption. 
     
     
         19 . The process of  claim 18 , wherein the adsorbent materials are selected from the group consisting of activated carbon, silica gel, alumina, natural clays, polar polymers applied silica gel, activated carbon and alumina. 
     
     
         20 . The process according to  claim 18 , wherein the adsorption zone is operated between about 20° C. and about 60° C. and at a pressure between about 1 and about 15 bars.