Staged hydrocarbon conversion process
View Patent ↗Systems and methods for staging an investment in hydrocarbon processing are provided. In a first stage, a hydrocarbon feed can be apportioned equally or unequally into first and second portions. The first portion can be mixed with one or more oxidants and gasified to provide a first effluent, at least a portion of which can be combusted to provide steam. The second portion can be mixed with one or more solvents to provide one or more fungible hydrocarbon products, at least a portion of which can be sold to generate capital. In a second stage, the hydrocarbon feed can be mixed with one or more solvents and one or more non-catalytic solids and the resultant mixture thermally cracked to provide one or more hydrocarbon products and coked non-catalytic solids. The coked, non-catalytic solids can be regenerated and recycled.
1. A method for staged processing of one or more hydrocarbons comprising:
a first stage comprising:
mixing all or a portion of one or more hydrocarbons with steam and one or more oxidants to provide a first mixture;
gasifying in a second reaction zone all or a portion of the first mixture to provide a first product; and
heating a first reaction zone using all or a portion of the first product; and
a second stage comprising:
removing the first product from the first reaction zone;
mixing the one or more hydrocarbons, with one or more solvents and one or more non-catalytic solids to form a second mixture;
thermally cracking at least a portion of the second mixture in the first reaction zone to provide one or more hydrocarbon products;
separating the non-catalytic solids from the one or more hydrocarbon products;
thermally regenerating the non-catalytic solids using the second reaction zone; and
recycling at least a portion of the regenerated non-catalytic solids to the first reaction zone.
2. The method of claim 1 , wherein the thermal cracking in the first reaction zone is conducted at a temperature above the bulk critical temperature of the one or more solvents.
3. The method of claim 1 , wherein the one or more non-catalytic solids comprise: refractory oxides, inert materials, combinations thereof, derivatives thereof, and mixtures thereof.
4. The method of claim 3 , wherein the refractory oxides are selected from a group consisting of SiO2, Al2O3, AlPO4, TiO2, ZrO2, and Cr2O3.