Use of supercritical fluid in hydroprocessing heavy hydrocarbons

Abstract

This invention is directed to a process for producing a hydroprocessed product. The invention is particularly advantageous in that substantially longer run length can be attained relative to conventional hydroprocessing methods. This benefit is achieved by using a particular solvent as a co-feed component. In particular, the solvent component is comprised of at least one or more supercritical solvent compounds.

1 . A process for producing a hydroprocessed product, comprising:
 sending to a hydroprocessing zone a combined feed comprised of a heavy hydrocarbon oil component, wherein the heavy hydrocarbon oil component has a ASTM D86 10% distillation point of at least 650° F. (343° C.), and a solvent component in which a majority of the solvent is comprised of at least one supercritical hydrocarbon compound having a critical temperature and pressure; and   contacting the combined feed with a hydroprocessing catalyst in the presence of hydrogen at a temperature and pressure above the critical temperature and pressure of the at least one supercritical hydrocarbon compound to form the hydroprocessed product.   
     
     
         2 . The process of  claim 1 , wherein the heavy hydrocarbon oil component has an initial ASTM D86 boiling point of 650° F. (343° C.) or greater. 
     
     
         3 . The process of  claim 1 , wherein the heavy hydrocarbon oil component contains at least 0.0001 grams of Ni/V/Fe, on a total elemental basis of nickel, vanadium and iron. 
     
     
         4 . The process of  claim 1 , wherein the combined feed is comprised of from 30 wt % to 90 wt % of the heavy hydrocarbon oil component and from 10 wt % to 70 wt % of the solvent component, based on total weight of the combined feed. 
     
     
         5 . The process of  claim 1 , wherein the contacting of the combined feed with the hydroprocessing catalyst in the presence of hydrogen is carried out at a hydrogen partial pressure from 550 psig (3792 kPa-g) to 3000 psig (20684 kPa-g). 
     
     
         6 . The process of  claim 1 , wherein the solvent component is comprised of more than one supercritical hydrocarbon compound and contacting of the combined feed with the hydroprocessing catalyst in the presence of hydrogen is carried out at a total pressure that is higher than the critical pressure of the highest-boiling supercritical hydrocarbon compound in the solvent component. 
     
     
         7 . The process of  claim 6 , wherein the solvent component is comprised of a mixture of aromatic molecules having boiling points of from 200° F. (93° C.) to 750° F. (399° C.). 
     
     
         8 . The process of  claim 4 , wherein the solvent component is comprised of more than one supercritical hydrocarbon compound and contacting of the combined feed with the hydroprocessing catalyst in the presence of hydrogen is carried out at a temperature that is higher than the critical temperature of the highest-boiling supercritical hydrocarbon compound in the solvent component. 
     
     
         9 . The process of  claim 1 , wherein the contacting is carried out at a total pressure and at a temperature at which the combined feed and the hydroprocessed products are comprised of no more than one vapor and one liquid phase during contact. 
     
     
         10 . The process of  claim 1 , wherein the solvent component is comprised of at least one supercritical solvent compound selected from the group consisting of benzene, toluene, xylene, ethyl benzene, iso-propyl benzene, trimethylbenzene, and tetramethylbenzene. 
     
     
         11 . The process of  claim 1 , wherein the solvent component is comprised of a mixture of aromatic and hydroaromatic molecules having boiling points of from 200° F. (93° C.) to 750° F. (399° C.). 
     
     
         12 . The process of  claim 1 , wherein the solvent component has an ASTM D86 10% distillation point of at least 250° F. (120° C.). 
     
     
         13 . The process of  claim 1 , wherein the solvent component is a petroleum fraction with an API gravity of less than or equal to 35°. 
     
     
         14 . The process of  claim 1 , wherein the contacting is carried out at a temperature of from 320° F. (160° C.) to 900° F. (482° C.) and a pressure of from 600 psig (4137 kPa-g) to 3000 psig (20684 kPa-g). 
     
     
         15 . The process of  claim 1 , wherein the solvent component is comprised of trimethylbenzene. 
     
     
         16 . The process of  claim 7 , wherein the solvent component is comprised of trimethylbenzene. 
     
     
         17 . The process of  claim 15 , wherein the solvent component is comprised of at least 50 wt % trimethylbenzene, based on total weight of the solvent component. 
     
     
         18 . The process of  claim 16 , wherein all of the supercritical hydrocarbon compounds each have a critical temperature of at least 300° F. (149° C.) and a critical pressure of less than or equal to 500 psig (3447 kPa-g). 
     
     
         19 . The process of  claim 1 , wherein the heavy hydrocarbon oil component and the solvent component are combined prior to entering the hydroprocessing zone. 
     
     
         20 . The process of  claim 1 , wherein the hydroprocessing zone contains the catalyst in a fixed bed, and the conditions in the hydroprocessing zone include a temperature of from 350° F. (177° C.) to 800° F. (427° C.), a total pressure of from 800 psig (5516 kPa-g) to 1500 psig (10342 kPa-g), and a liquid hourly space velocity (LHSV) of the combined heavy hydrocarbon oil and solvent components of from 0.1 to 30 h −1 .