Multistage resid hydrocracking
Processes and systems for upgrading resid hydrocarbon feeds are disclosed. The process system may operate in two different operating modes, maximum conversion and maximum quality effluent. The process system may be reversibly transitioned between the different operating modes. The system has the ability to reversibly transition between the two modes without shutting down the system or losing production.
1. A process for upgrading resid in a system comprising:
a first ebullated bed reactor;
a first separator;
a stripping tower;
a fractionation system; and
a solvent deasphalting system;
the process comprising:
operating the system in a first mode to produce a feed for a residual fluid catalytic cracking (RFCC) unit, the first mode comprising:
reacting a deasphalted oil and a vacuum distillate in the first ebullated bed reactor containing a hydrotreating catalyst to form a first effluent;
separating the first effluent in the first separator into a first gas phase and a first liquid phase;
stripping the first liquid phase in the stripping tower to produce a strippers bottom and a stripper overhead;
fractionating the stripper overhead in the fractionation system to produce at least one atmospheric distillate and an atmospheric bottoms;
fractionating the atmospheric bottoms in the fractionation system to produce the vacuum distillate and a vacuum bottoms;
solvent deasphalting the vacuum bottoms in the solvent deasphalting system to produce the deasphalted oil; and
transporting the strippers bottoms as the feed to the RFCC unit;
wherein the first mode is operated with a first particle size distribution providing low pressure drop under a range of bed expansions from 5% to 25%;
operating the system in a second mode to maximize the resid conversion in the first ebullated bed reactor, the second mode comprising:
reacting the deasphalted oil in the first ebullated bed reactor containing a hydrocracking catalyst to form a second effluent;
separating the second effluent in the first separator into a second gas phase and a second liquid phase;
fractionating the second liquid phase in the fractionation system to produce at least one atmospheric distillate and an atmospheric bottoms;
fractionating the atmospheric bottoms in the fractionation system to produce the vacuum distillate and the vacuum bottoms; and
solvent deasphalting the vacuum bottoms to produce the deasphalted oil;
wherein the second mode is operated with a second particle size distribution providing low pressure drop under a range of bed expansions from 40% to 60%;
transitioning the system between the first mode and the second mode, wherein the transitioning comprises:
removing the hydrotreating catalyst from the first ebullated bed reactor while simultaneously adding a hydrocracking catalyst to the first ebullated bed reactor and increasing a speed of an ebullating pump;
fractionating the first liquid phase in the fractionation system to produce the at least one atmospheric distillate and the atmospheric bottoms.
2. The process of claim 1 , wherein the system further comprises:
a second ebullated bed reactor; and
a second separator;
the second mode further comprises:
reacting a resid hydrocarbon in the second ebullated bed reactor containing a hydrocracking catalyst to form a third effluent;
separating the third effluent in the second separator into a third gas phase and a third liquid phase; and
fractionating the third liquid phase in the fractionation system to produce the at least one atmospheric distillate and the atmospheric bottoms.
3. The process of claim 1 , further comprising transitioning the system between the second mode back to the first mode.
4. The process of claim 1 , wherein transitioning further comprises lowering the temperature of the first ebullated bed reactor.
5. The process of claim 2 , further comprising
cooling the first gas phase and the second gas phase to recover a hydrogen-containing gas fraction and a distillate fraction; and
feeding the distillate fraction to the first liquid phase product and the second reactor effluent.
6. The process of claim 5 , further comprising recycling at least a portion of the recovered hydrogen to the first ebullated bed reactor.
7. The process of claim 5 , further comprising recycling at least a portion of the recovered hydrogen to the second ebullated bed reactor.
8. The process of claim 2 , further comprising cooling the second bottoms fraction via direct heat exchange with at least one of a portion of the resid or a portion of the first bottoms fraction.
9. A process for upgrading resid in a system comprising:
a first ebullated bed reactor;
a first separator;
a stripping tower;
a fractionation system;
a solvent deasphalting system;
a second ebullated bed reactor; and
a second separator;
the process comprising:
operating the system in a first mode to produce a feed for a residual fluid catalytic cracking (RFCC) unit, the first mode comprising:
reacting a deasphalted oil and a vacuum distillate in the first ebullated bed reactor containing a hydrotreating catalyst to form a first effluent;
separating the first effluent in the first separator into a first gas phase and a first liquid phase;
stripping the first liquid phase in the stripping tower to produce a strippers bottom and a stripper overhead;
fractionating the stripper overhead in the fractionation system to produce at least one atmospheric distillate and an atmospheric bottoms;
fractionating the atmospheric bottoms in the fractionation system to produce the vacuum distillate and a vacuum bottoms;
solvent deasphalting the vacuum bottoms in the solvent deasphalting system to produce the deasphalted oil; and
transporting the strippers bottoms as the feed to the RFCC unit;
wherein the first mode is operated with a first particle size distribution providing low pressure drop under a range of bed expansions from 5% to 25%;
operating the system in a second mode to maximize the resid conversion in the first ebullated bed reactor, the second mode comprising:
reacting the deasphalted oil in the first ebullated bed reactor containing a hydrocracking catalyst to form a second effluent;
separating the second effluent in the first separator into a second gas phase and a second liquid phase;
fractionating the second liquid phase in the fractionation system to produce at least one atmospheric distillate and an atmospheric bottoms;
fractionating the atmospheric bottoms in the fractionation system to produce the vacuum distillate and the vacuum bottoms; and
solvent deasphalting the vacuum bottoms to produce the deasphalted oil;
reacting a resid hydrocarbon in the second ebullated bed reactor containing a hydrocracking catalyst to form a third effluent;
separating the third effluent in the second separator into a third gas phase and a third liquid phase; and
fractionating the third liquid phase in the fractionation system to produce the at least one atmospheric distillate and the atmospheric bottoms
wherein the second mode is operated with a second particle size distribution providing low pressure drop under a range of bed expansions from 40% to 60%;
transitioning the system between the first mode and the second mode, wherein the transitioning comprises:
removing the hydrotreating catalyst from the first ebullated bed reactor while simultaneously adding a hydrocracking catalyst to the first ebullated bed reactor and increasing a speed of an ebullating pump;
fractionating the first liquid phase in the fractionation system to produce the at least one atmospheric distillate and the atmospheric bottoms.
10. The process of claim 9 , further comprising transitioning the system between the second mode back to the first mode.
11. The process of claim 9 , wherein transitioning further comprises lowering the temperature of the first ebullated bed reactor.
12. The process of claim 9 , further comprising
cooling the first gas phase and the second gas phase to recover a hydrogen-containing gas fraction and a distillate fraction; and
feeding the distillate fraction to the first liquid phase product and the second reactor effluent.
13. The process of claim 12 , further comprising recycling at least a portion of the recovered hydrogen to the first ebullated bed reactor.
14. The process of claim 12 , further comprising recycling at least a portion of the recovered hydrogen to at least one of the second ebullated bed reactor.
15. The process of claim 9 , further comprising cooling the second bottoms fraction via direct heat exchange with at least one of a portion of the resid and a portion of the first bottoms fraction.