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WO2006005085A2 - Method of treatment of fischer-tropsch derived hydrocarbons - Google Patents

Method of treatment of fischer-tropsch derived hydrocarbons Download PDF

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Publication number
WO2006005085A2
WO2006005085A2 PCT/ZA2005/000101 ZA2005000101W WO2006005085A2 WO 2006005085 A2 WO2006005085 A2 WO 2006005085A2 ZA 2005000101 W ZA2005000101 W ZA 2005000101W WO 2006005085 A2 WO2006005085 A2 WO 2006005085A2
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WO
WIPO (PCT)
Prior art keywords
acid
metal
treatment
oxygenates
hydrocarbons
Prior art date
Application number
PCT/ZA2005/000101
Other languages
French (fr)
Other versions
WO2006005085A3 (en
Inventor
Jan Mattheus Botha
Dieter Otto Leckel
Jacobus Lucas Visagie
Herman Preston
Donovan Smook
Original Assignee
Sasol Technology (Pty) Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Sasol Technology (Pty) Ltd filed Critical Sasol Technology (Pty) Ltd
Priority to AU2005260789A priority Critical patent/AU2005260789B2/en
Priority to GB0625235A priority patent/GB2429461B/en
Priority to BRPI0512754A priority patent/BRPI0512754B1/en
Publication of WO2006005085A2 publication Critical patent/WO2006005085A2/en
Publication of WO2006005085A3 publication Critical patent/WO2006005085A3/en
Priority to NO20070042A priority patent/NO343008B1/en

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Classifications

    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10GCRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G2/00Production of liquid hydrocarbon mixtures of undefined composition from oxides of carbon
    • C10G2/30Production of liquid hydrocarbon mixtures of undefined composition from oxides of carbon from carbon monoxide with hydrogen
    • C10G2/32Production of liquid hydrocarbon mixtures of undefined composition from oxides of carbon from carbon monoxide with hydrogen with the use of catalysts

Definitions

  • the invention relates to hydrothermal treatment of hydrocarbons prior to further processing.
  • the invention provides for a pre-treatment regime for Fischer-Tropsch (F-T) hydrocarbons prior to downstream processing.
  • F-T Fischer-Tropsch
  • the invention also relates to a chemical treatment of hydrocarbons prior to further processing.
  • the inventors have identified an area for process optimization in the processing of hydrocarbons.
  • the inventors have identified an area for process optimization in the processing of F-T synthesis products by hydroconversion in general.
  • F-T derived product streams contain oxygenates and to a certain extent metals and/or metal species.
  • Ketones, aldehydes, alcohols, esters and carboxylic acids are the main constituents of the oxygenate fraction.
  • Carboxylic acids and alcohols are able to form under appropriate conditions carboxylate and/or alkoxide complexes and/or metalloxanes with the metals and/or metal species present.
  • These metal carboxylates and/or alkoxides and/or metalloxanes may form deposits in processing equipment and catalyst beds. Eventually the deposits in the catalyst beds may grow to such an extent that shutdowns of reactors are inevitable.
  • the identified problem may be summarized as the plugging of downstream processing catalyst beds or bed by a constituent of said product streams or a reaction product of a constituent of said product, streams.
  • organometallic material and/or fine particulates are likely to be rich in aluminium, and/or silicon, and/or titanium, and/or zirconium, and/or cobalt, and/or iron, and/or alkaline earth elements such as calcium and barium etc.
  • the synthesis products from the F-T process were analyzed and it was found that the condensate fraction is devoid of metal impurities (1 ppm or less), but that the wax contains metal impurities in the order of 10 - 100 ppm. This indicates that the F-T process and/or filtration system and/or refractory materials and/or chemically leached metals or metal species may be the source of the metal impurities.
  • metal oxygenate species that contribute to bed plugging and either one or both may be important:
  • Fine particulates for example, fine particulates of less than 1 micron in diameter which can be stabilized by surface-active compounds (such as the oxygenates) allowing them to remain in suspension. However, when this surface layer is disrupted, the particulates precipitate and form deposits on collector media.
  • surface-active compounds such as the oxygenates
  • Organometallic type compounds for example, in the case of aluminium as the metal source, the formation of organoaluminium compounds of the Al-O-R type, like alkoxy-aluminium, aluminium carboxylates and alumoxanes, or of the Al-R type, like alkyl-aluminium, or combinations thereof are possible.
  • Bed-plugging has been seen with various catalysts and it occurs as a localized plug or as distributed particulate matter.
  • the F-T synthesis product stream carries organometallic material and/or solubilized fine catalyst particulates and/or filter aid and/or refractory material and/or chemically leached metals or metal species from the reactor system in low concentrations.
  • the wax contains oxygenates like acids and alcohols that help to keep the fine particulates in solubilized form in the wax.
  • oxygenates that keep the particulates in suspension, and/or the ligands of the organometallic components, are hydrogenated and/or protonated and the modified metal species are then deposited on the hydroconversion reactor catalyst bed, leading to what is termed "bed-plugging".
  • a method of treatment of hydrocarbons including hydrothermal treatment at a temperature of above 100 0 C of metal oxygenate components in F-T derived hydrocarbons.
  • the method may include chemical treatment of the metal oxygenate components in the F-T derived hydrocarbons, to modify the metal oxygenates,.
  • the method may include one or more of the following treating stages:
  • F-T derived hydrocarbons contain oxygenates and to a certain extent metals and/or metal species.
  • Ketones, aldehydes, alcohols, esters and carboxylic acids are the main constituents of the oxygenate fraction.
  • Carboxylic acids are able to form under appropriate conditions metal carboxylate complexes with the metal species present.
  • Alcohols are able to form under appropriate conditions metal alkoxide complexes with the metal species present.
  • the metal oxygenate may be a metal carboxylate, a metal alkoxide or a combination thereof or a metalloxane.
  • the metal oxygenate may be a carboxy substituted metalloxane.
  • the hydrothermal treatment may be carried out with water at above 100 0 C, preferably between 120 0 C to 370 0 C, and even as high a 400 0 C, typically 16O 0 C to 250 0 C and a pressure of 1 to 100 bar, preferably 5 to 50 bar..
  • the water for the hydrothermal treatment may be water added for the purpose of the hydrotreatment or reaction water already present in the F-T derived hydrocarbons, or a combination of both.
  • the hydrothermal treatment may be carried out in a substantially single liquid phase system in which both the hydrocarbons and water are present, said water being present at such levels as to ensure that substantially one liquid phase is present under the process conditions.
  • the hydrothermal treatment may be carried out in the presence of an adsorbent such as silica. Adsorption of the modified metal oxygenates takes place on the silica particles and these may subsequently be removed by filtration or other treating methods.
  • an adsorbent such as silica. Adsorption of the modified metal oxygenates takes place on the silica particles and these may subsequently be removed by filtration or other treating methods.
  • the hydrothermal treatment may also be achieved by maintaining the product stream under the temperature and pressure used in the F-T reactor after a primary filtration zone for sufficient time to enable particle growth and/or adsorption onto a filterable particle, i.e. the hydrothermal treatment may be carried out by maintaining the reactor conditions between primary and secondary filtration zones for sufficient time to allow for particle growth or adsorption onto a filterable particle.
  • the pressure may be selected to be higher than the water vapour pressure at the prevailing temperature. Sufficient time will be between 1 to 60 minutes, preferably between 1 to 30 minutes and more preferably between 5 to 10 minutes.
  • the optional chemical treatment may include trans-esterification to exchange longer hydrocarbon chain carboxylic acids or alcohols with shorter chain carboxylic acids.
  • the chemicals which may be used in the trans-esterification or ligand replacement step include, methanol, ethanol, oxalic acid, acetic acid, propanoic acetic, salicylic acid, succinic acid, tartaric acid, lactic acid, malonic acid, glycine acid, citric acid, carbonic acid, maleic acid, fumaric acid, phthalic acid, the anhydrides of these acids (e.g. maleic anhydride) and thermal decomposition products of these acids. Also included are solid acids such as silica-alumina and/or other mixed oxide systems that possess Br ⁇ nsted acidity. The interaction between these listed chemicals and the metal oxygenates may be speeded up by the thermal treatments.
  • Hydrothermal treatment may result in hydroxylation and formation of metal hydroxides and/or metal oxyhydroxides and/or metalloxanes.
  • the hydrothermal treatment may be done before, with or after the optional chemical treatment.
  • a method of treatment of hydrocarbons including chemical treatment with one or more chemical treatment agents in a single liquid phase of metal oxygenate components in F-T derived hydrocarbons to modify the metal oxygenates.
  • the chemical treatment may be followed by one or more of the following treating stages:
  • the chemical treatment agents which may be used in the trans-esterification or ligand replacement step include, methanol, ethanol, oxalic acid, acetic acid, propanoic acetic, salicylic acid, succinic acid, tartaric acid, lactic acid, malonic acid, glycine acid, citric acid, carbonic acid, maleic acid, fumaric acid, phthalic acid, the anhydrides of these acids (e.g. maleic anhydride) and thermal decomposition products of these acids. Also included are solid acids such as silica-alumina and/or other mixed oxide systems that possess Br ⁇ nsted acidity. The interaction between these listed chemicals and the metal oxygenates may be speeded up by the thermal treatments.
  • the chemical treatment may be carried out in a single liquid phase in which both the hydrocarbons and one or more chemical treatment agents are present, said chemical treatment agent or agents being present at levels below their saturation level in the hydrocarbons, for example wax.
  • the amounts of chemical treatment agents added may be such as to give a single liquid phase i.e. total dissolution of the chemical treatment agents in the hydrocarbons under the process conditions.
  • I he chemical treatment may include trans-esterification to exchange longer hydrocarbon chain carboxylic acids or alcohols with shorter chain carboxylic acids.
  • the polar solvents include, amongst others, water, melted organic acids, ethylene glycol, ionic liquids and combinations thereof.
  • Filter materials used in the filtration include clays, silica, silica-aluminas, silicated aluminas, cellulose, activated carbons, sintered metals and material filters such as nylons and polycarbonates.
  • the adsorbents and/or filterable particles include clays, silica, silica-aluminas, silicated aluminas, cellulose, activated carbons, sintered metals, titania and material filters such as nylons and polycarbonates.
  • the adsorbents may also be used as filter material.
  • the adsorbents may be added during the chemical and/or hydrothermal treatment, or during any of the downstream processes.
  • Reactor wax from a Low-Temperature F-T (LTFT) plant was analyzed and found to contain metal carboxylates (M x [ ⁇ 2CR]y), carboxy substituted metalloxanes ([M(O) x (OH)y( ⁇ 2CR) z ] n ), alkoxides and combinations thereof that were leached from the catalyst, and/or support, and/or reactor, and/or filter clays, and/or refractory materials.
  • metal carboxylates M x [ ⁇ 2CR]y
  • carboxy substituted metalloxanes [M(O) x (OH)y( ⁇ 2CR) z ] n
  • alkoxides and combinations thereof were leached from the catalyst, and/or support, and/or reactor, and/or filter clays, and/or refractory materials.
  • modified metal oxygenates obtained from the exchange of the longer hydrocarbon chain carboxylic acids with shorter chain carboxylic acids or hydroxylation with water, result in the modified metal oxygenates being more soluble in polar solvents like water or ethylene glycol and can be extracted from the wax by these polar solvents.
  • modified metal oxygenates obtained from the exchange of the longer hydrocarbon chain carboxylic acids with shorter chain carboxylic acids or hydroxylation with water result in the growth of the particles that can then be filtered out.
  • the modified metal oxygenates obtained from the exchange of the longer hydrocarbon chain carboxylic acid with shorter chain carboxylic acids or alcohols or hydroxylation with water, result in the formation of extractable/adsorbable particles onto an adsorbent.
  • the experimental set-up used for this investigation is displayed in Figure 1. It is a continuous process in down-flow mode. Application of pressure is optional. Water is pumped, using an HPLC pump, from a reservoir placed on a balance, through a 140°C hot pipe. The water (2 wt % relative to the wax) joins the molten wax which is heated up to 140 0 C. The combined streams then trickle over a sand bed heated to a temperature of 35O 0 C. The inert material is used for better distribution or mixing between the aqueous and wax phases and to increase the residence time, giving growth opportunity for the modified aluminium oxygenates and improving the efficiency of the separation process.
  • the product after the sand bed is passed through a 1 micron filter (or smaller) to collect the modified aluminium oxygenate agglomerates.
  • the wax product after the filter has an aluminium content of ⁇ 1 ppm Al as determined by ICP. Filters of a size bigger than 1 micron can be used optionally in combination with a filter aid.
  • PAA Polyacrylic acid
  • the wax (200 g) containing 50 ppm aluminium was first melted in an oven at 140 0 C, and then placed in the Parr autoclave, and heated to 165 0 C with stirring (700 rpm).
  • 0.1 wt % PAA was added to 2 wt % water and placed in a metal tube that was then connected to the Parr reactor. After the desired temperature was reached, the pressure of the vessel was increased to 10 bar through the metal tube. This ensured that all the aqueous solution was forced in the Parr autoclave.
  • the first sample was taken 5 minutes after this addition. Samples were also taken at 10 minutes.
  • the sampling bottle was placed in the oven at 140 0 C. This wax was then hot filtered (140 0 C) through a 0.45 ⁇ m filter paper. The wax was then analyzed for aluminium using ICP. As can be observed from the results, PAA was effective in removing the modified metal oxygenates at 165°C.
  • BA Use of hydrothermal conditions and a filterable particle/adsorbent to modify and adsorb modified metal oxygenates.
  • the wax (200 g) containing soluble metal oxygenates was first melted in an oven at 140 0 C. To the melted wax was added 0.1 -0.01 wt % Aerosil 380 (Degussa). The wax was then heated to 170 0 C with stirring (200 rpm). Water (4 ml) was placed in a metal tube that was connected to the Parr reactor. After the desired temperature was reached, a sample was taken. Thereafter, the water was added to the reaction mixture and samples were taken at 5 and 10 minutes (Table B4) and passed through a 2.5 micron filter. The water modified the metal complex so that it could adsorb onto the filterable particle.
  • wax (200 g) containing 45 ppm aluminium was first melted in an oven at 140 0 C, and then placed in the Parr autoclave, and heated to 170 0 C with stirring (700 rpm).
  • Maleic anhydride (0.1 wt %) dissolved in water (2 wt %) was placed in a metal tube that was then connected to the Parr reactor. After the desired temperature was reached, the pressure of the vessel was increased to 300psi through the metal tube. This ensured that all the aqueous solution was forced in the Parr autoclave. Two samples were taken after 15 minutes after this addition. After the wax was sampled, one sample was placed in the oven at 140 0 C.
  • This wax was then hot filtered (140 0 C) through a 0.8 ⁇ m filter paper.
  • Sample 2 was cooled down before being reheated to 140 0 C and filtered.
  • the aluminium content of the wax was determined using ICP analysis. Unlike the citric acid treated wax, the filterability of the maleic acid treated wax remained the same, whereas the reaction conditions determine the filterability of the citric acid treated wax.
  • contaminated wax was pumped at a set temperature through a 10 mm diameter tube containing adsorbent or filter material.
  • the pressure listed is caused by the wax flow rate and adsorbent characteristics.
  • experiment C1 contaminated wax containing 14 ppm aluminium and other metals such as cobalt, was pumped through a cellulose Arbocel BVB40 as filter/absorbent without water or acid been added (see table C1). No removal of aluminium was observed.
  • experiment C2 In experiment C2, experiment C1 was repeated but 2 wt % water was added to the wax (see Table C2). The addition of water led to the complete removal for continuous filtering of up to 2.5 hours.
  • experiment C3 experiment C2 was repeated but with Vitacel LOO as filter material/adsorbent.
  • experiment C4 was repeated but with Celpure S1000 as filter material/adsorbent.
  • experiment C5 was repeated but with spray dried Degussa silica (Aerosil 380) as filter material/adsorbent.
  • Table C3 Treatment of contaminated wax containing approx. 14 ppm aluminium.
  • Table C4 Treatment of contaminated wax containing approx. 16 ppm aluminium.

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Abstract

The invention provides a method of treatment of hydrocarbons, said method including hydrothermal treatment at a temperature of above 100°c or a chemical treatment with one or more chemical treatment agents, such as alcohols or carboxylic acids, in a single liquid phase, of metal oxygenate components in F-T derived hydrocarbons, such as F-T derived wax. The problem of plugging of downstream (hydro)processing catalyst bed or beds by a constituent of the f-t derived product stream is thereby at least partially alleviated.

Description

TREATMENT OF HYDROCARBONS
Field of the Invention
The invention relates to hydrothermal treatment of hydrocarbons prior to further processing. In particular, the invention provides for a pre-treatment regime for Fischer-Tropsch (F-T) hydrocarbons prior to downstream processing. The invention also relates to a chemical treatment of hydrocarbons prior to further processing.
Background to the Invention
The inventors have identified an area for process optimization in the processing of hydrocarbons. In particular, the inventors have identified an area for process optimization in the processing of F-T synthesis products by hydroconversion in general.
F-T derived product streams contain oxygenates and to a certain extent metals and/or metal species. Ketones, aldehydes, alcohols, esters and carboxylic acids are the main constituents of the oxygenate fraction. Carboxylic acids and alcohols are able to form under appropriate conditions carboxylate and/or alkoxide complexes and/or metalloxanes with the metals and/or metal species present. These metal carboxylates and/or alkoxides and/or metalloxanes may form deposits in processing equipment and catalyst beds. Eventually the deposits in the catalyst beds may grow to such an extent that shutdowns of reactors are inevitable.
The identified problem may be summarized as the plugging of downstream processing catalyst beds or bed by a constituent of said product streams or a reaction product of a constituent of said product, streams.
Summary of invention
Although not being bound by theory, the inventors believe that the plugging is being caused by organometallic material and/or fine particulates. The i organometallic material and/or fine particulates are likely to be rich in aluminium, and/or silicon, and/or titanium, and/or zirconium, and/or cobalt, and/or iron, and/or alkaline earth elements such as calcium and barium etc.
The synthesis products from the F-T process were analyzed and it was found that the condensate fraction is devoid of metal impurities (1 ppm or less), but that the wax contains metal impurities in the order of 10 - 100 ppm. This indicates that the F-T process and/or filtration system and/or refractory materials and/or chemically leached metals or metal species may be the source of the metal impurities.
There are possibly two forms of metal oxygenate species that contribute to bed plugging and either one or both may be important:
a) Fine particulates: for example, fine particulates of less than 1 micron in diameter which can be stabilized by surface-active compounds (such as the oxygenates) allowing them to remain in suspension. However, when this surface layer is disrupted, the particulates precipitate and form deposits on collector media.
b) Organometallic type compounds: for example, in the case of aluminium as the metal source, the formation of organoaluminium compounds of the Al-O-R type, like alkoxy-aluminium, aluminium carboxylates and alumoxanes, or of the Al-R type, like alkyl-aluminium, or combinations thereof are possible.
Bed-plugging has been seen with various catalysts and it occurs as a localized plug or as distributed particulate matter.
It is hypothesized that the F-T synthesis product stream carries organometallic material and/or solubilized fine catalyst particulates and/or filter aid and/or refractory material and/or chemically leached metals or metal species from the reactor system in low concentrations. The wax contains oxygenates like acids and alcohols that help to keep the fine particulates in solubilized form in the wax. During hydroconversion, it is believed that these oxygenates that keep the particulates in suspension, and/or the ligands of the organometallic components, are hydrogenated and/or protonated and the modified metal species are then deposited on the hydroconversion reactor catalyst bed, leading to what is termed "bed-plugging".
Thus the inventors, after deliberation and experimentation, propose the following solution which may at least partially alleviate the above described problem.
According to a first aspect of the invention, there is provided a method of treatment of hydrocarbons , said method including hydrothermal treatment at a temperature of above 1000C of metal oxygenate components in F-T derived hydrocarbons.
The method may include chemical treatment of the metal oxygenate components in the F-T derived hydrocarbons, to modify the metal oxygenates,.
The method may include one or more of the following treating stages:
(i) extracting the modified metal oxygenates with the aid of one or more polar solvents;
(ii) filtering the modified metal oxygenates after sufficient time has been allowed for particle growth and/or adsorption onto a filterable particle;
(iii) adsorbing the modified metal oxygenate onto an adsorbent;
(iv) settling of the modified metal oxygenates after sufficient time has been allowed for particle growth; (v) by centrifuging out the modified metal oxygenates after sufficient time has been allowed for particle growth;
(vi) by distilling the hydrocarbons from the treated streams;
(vii) flocculation of the modified metal oxygenates;
(viii) magnetic precipitation;
(ix) electrostatic precipitation/settling; and
(x) flotation of the modified metal oxygenates and fine particulates; or
(xi) any combination of one or more of the above treatments.
F-T derived hydrocarbons contain oxygenates and to a certain extent metals and/or metal species.
Ketones, aldehydes, alcohols, esters and carboxylic acids are the main constituents of the oxygenate fraction.
Carboxylic acids are able to form under appropriate conditions metal carboxylate complexes with the metal species present.
Alcohols are able to form under appropriate conditions metal alkoxide complexes with the metal species present.
The metal oxygenate may be a metal carboxylate, a metal alkoxide or a combination thereof or a metalloxane.
The metal oxygenate may be a carboxy substituted metalloxane.
The hydrothermal treatment may be carried out with water at above 1000C, preferably between 1200C to 3700C, and even as high a 4000C, typically 16O0C to 2500C and a pressure of 1 to 100 bar, preferably 5 to 50 bar..
The water for the hydrothermal treatment may be water added for the purpose of the hydrotreatment or reaction water already present in the F-T derived hydrocarbons, or a combination of both.
The hydrothermal treatment may be carried out in a substantially single liquid phase system in which both the hydrocarbons and water are present, said water being present at such levels as to ensure that substantially one liquid phase is present under the process conditions.
The hydrothermal treatment may be carried out in the presence of an adsorbent such as silica. Adsorption of the modified metal oxygenates takes place on the silica particles and these may subsequently be removed by filtration or other treating methods.
The hydrothermal treatment may also be achieved by maintaining the product stream under the temperature and pressure used in the F-T reactor after a primary filtration zone for sufficient time to enable particle growth and/or adsorption onto a filterable particle, i.e. the hydrothermal treatment may be carried out by maintaining the reactor conditions between primary and secondary filtration zones for sufficient time to allow for particle growth or adsorption onto a filterable particle. More specifically, the pressure may be selected to be higher than the water vapour pressure at the prevailing temperature. Sufficient time will be between 1 to 60 minutes, preferably between 1 to 30 minutes and more preferably between 5 to 10 minutes.
The optional chemical treatment may include trans-esterification to exchange longer hydrocarbon chain carboxylic acids or alcohols with shorter chain carboxylic acids.
The chemicals which may be used in the trans-esterification or ligand replacement step include, methanol, ethanol, oxalic acid, acetic acid, propanoic acetic, salicylic acid, succinic acid, tartaric acid, lactic acid, malonic acid, glycine acid, citric acid, carbonic acid, maleic acid, fumaric acid, phthalic acid, the anhydrides of these acids (e.g. maleic anhydride) and thermal decomposition products of these acids. Also included are solid acids such as silica-alumina and/or other mixed oxide systems that possess Brønsted acidity. The interaction between these listed chemicals and the metal oxygenates may be speeded up by the thermal treatments.
Hydrothermal treatment may result in hydroxylation and formation of metal hydroxides and/or metal oxyhydroxides and/or metalloxanes.
The hydrothermal treatment may be done before, with or after the optional chemical treatment.
According to a second aspect of the invention, there is provided a method of treatment of hydrocarbons , said method including chemical treatment with one or more chemical treatment agents in a single liquid phase of metal oxygenate components in F-T derived hydrocarbons to modify the metal oxygenates.
The chemical treatment may be followed by one or more of the following treating stages:
(i) extracting the modified metal oxygenates with the aid of one or more polar solvents;
(ii) filtering the modified metal oxygenates after sufficient time has been allowed for particle growth and/or adsorption onto a filterable particle;
(iii) adsorbing the modified metal oxygenate onto an adsorbent;
(iv) settling of the modified metal oxygenates after sufficient time has been allowed for particle growth; (v) by centrifuging out the modified metal oxygenates after sufficient time has been allowed for particle growth;
(vi) by distilling the hydrocarbons from the treated streams;
(vii) flocculation of the modified metal oxygenates;
(viii) magnetic precipitation;
(ix) electrostatic precipitation/settling; and
(x) flotation of the modified metal oxygenates and fine particulates; or (xi) any combination of one or more of the above treatments.
The chemical treatment agents which may be used in the trans-esterification or ligand replacement step include, methanol, ethanol, oxalic acid, acetic acid, propanoic acetic, salicylic acid, succinic acid, tartaric acid, lactic acid, malonic acid, glycine acid, citric acid, carbonic acid, maleic acid, fumaric acid, phthalic acid, the anhydrides of these acids (e.g. maleic anhydride) and thermal decomposition products of these acids. Also included are solid acids such as silica-alumina and/or other mixed oxide systems that possess Brønsted acidity. The interaction between these listed chemicals and the metal oxygenates may be speeded up by the thermal treatments.
The chemical treatment may be carried out in a single liquid phase in which both the hydrocarbons and one or more chemical treatment agents are present, said chemical treatment agent or agents being present at levels below their saturation level in the hydrocarbons, for example wax.
In the chemical treatment, the amounts of chemical treatment agents added may be such as to give a single liquid phase i.e. total dissolution of the chemical treatment agents in the hydrocarbons under the process conditions. I he chemical treatment may include trans-esterification to exchange longer hydrocarbon chain carboxylic acids or alcohols with shorter chain carboxylic acids.
The polar solvents include, amongst others, water, melted organic acids, ethylene glycol, ionic liquids and combinations thereof.
Filter materials used in the filtration include clays, silica, silica-aluminas, silicated aluminas, cellulose, activated carbons, sintered metals and material filters such as nylons and polycarbonates.
The adsorbents and/or filterable particles include clays, silica, silica-aluminas, silicated aluminas, cellulose, activated carbons, sintered metals, titania and material filters such as nylons and polycarbonates.
The adsorbents may also be used as filter material.
The adsorbents may be added during the chemical and/or hydrothermal treatment, or during any of the downstream processes.
Growing of filterable particulates is influenced by the thermal and/or hydrothermal treatment conditions, and optionally, depending on the acid used as the chemical treatment agent as well as the process conditions, reversible or irreversible particle growth may be obtained that in turn influences the removal of the modified metal species by filtration.
Examples of Employing the Method of the Invention
Reactor wax from a Low-Temperature F-T (LTFT) plant was analyzed and found to contain metal carboxylates (Mx[θ2CR]y), carboxy substituted metalloxanes ([M(O)x(OH)y(θ2CR)z]n), alkoxides and combinations thereof that were leached from the catalyst, and/or support, and/or reactor, and/or filter clays, and/or refractory materials.
The longer the hydrocarbon chain (-CR) of the carboxylate or alkoxide ligands attached to the metal, the more soluble is the component in the wax.
It is believed that on addition of the shorter chain carboxylic acids or anhydrides and/or water to the wax, the long chain oxygenates bonded to the metal species and/or particulates are exchanged by the shorter chain carboxylic acids and/or hydroxides if water is present by trans-esterification and/or ligand exchange and/or hydroxylation:
-The modified metal oxygenates, obtained from the exchange of the longer hydrocarbon chain carboxylic acids with shorter chain carboxylic acids or hydroxylation with water, result in the modified metal oxygenates being more soluble in polar solvents like water or ethylene glycol and can be extracted from the wax by these polar solvents.
- The modified metal oxygenates, obtained from the exchange of the longer hydrocarbon chain carboxylic acids with shorter chain carboxylic acids or hydroxylation with water result in the growth of the particles that can then be filtered out.
- The modified metal oxygenates, obtained from the exchange of the longer hydrocarbon chain carboxylic acid with shorter chain carboxylic acids or alcohols or hydroxylation with water, result in the formation of extractable/adsorbable particles onto an adsorbent.
Experimental
A) Demonstrating the removal of the metal species from the wax using hydrothermal treatment
The experimental set-up used for this investigation is displayed in Figure 1. It is a continuous process in down-flow mode. Application of pressure is optional. Water is pumped, using an HPLC pump, from a reservoir placed on a balance, through a 140°C hot pipe. The water (2 wt % relative to the wax) joins the molten wax which is heated up to 1400C. The combined streams then trickle over a sand bed heated to a temperature of 35O0C. The inert material is used for better distribution or mixing between the aqueous and wax phases and to increase the residence time, giving growth opportunity for the modified aluminium oxygenates and improving the efficiency of the separation process. The product after the sand bed is passed through a 1 micron filter (or smaller) to collect the modified aluminium oxygenate agglomerates. The wax product after the filter has an aluminium content of < 1 ppm Al as determined by ICP. Filters of a size bigger than 1 micron can be used optionally in combination with a filter aid.
B) Examples demonstrating the removal of the metal species from the wax by chemical treatment followed by filtration:
B.1- Citric acid as chemical treatment agent.
For Experiments CH1 , CH3 and CH5, 250 gram of F-T reactor wax containing the oxygenated aluminium species (carboxylates and/or alkoxides) were added to a 600 ml autoclave. The wax was heated to the treatment temperature before the citric acid was added to the autoclave (time zero) and the stirrer started. Wax samples were taken with time on line and passed through a 0.85 micron filter. The filtered wax samples were then analyzed for aluminium using ICP (see Table B1 for summary of the results).
Table B l
Figure imgf000012_0001
B.2.1 - Malθic anhydride as chemical treatment agent with different water levels for the hydrothermal treatment.
For experiments B2 a to c: wax (200 g) containing 50 ppm aluminium as aluminium oxygenates was first melted in an oven at 140 0C, and then placed in the Parr autoclave, and heated to 230 0C with stirring (700 rpm). Maleic anhydride (0.1 wt % in relation to wax loaded) was dissolved in water (4g in exp B2 a, 6g in exp B2b and 16g in exp B2 c) and placed in a metal tube that was then connected to the Parr reactor. After the desired temperature was reached, the pressure of the vessel was increased to 10 bar through the metal tube. This ensured that all the aqueous solution was forced in the Parr autoclave. The first sample was taken 5 minutes after this addition. Samples were also taken at 10 minutes. After the wax was sampled, the sampling bottle was placed in the oven at 140 0C. This wax was then hot filtered (140 0C) through a 0.45 μm filter paper. The wax was then analyzed for aluminium using ICP. As can be observed in Table B2A, water addition (hydrothermal treatment) improves the particle growth and thereby the filterability of the modified metal oxygenates from the wax.
Table B2A
Figure imgf000013_0001
B.2.2 Maleic anhydride treatment at different concentrations levels and different hydrothermal treatment temperatures.
In experiments B2 d to g: wax (200 g) containing 45 ppm aluminium was first melted in an oven at 140 0C, and then placed in the Parr autoclave, and heated to 230 0C for experiments B2 d to f, or 17O0C for experiment B2g, with stirring (700 rpm). Maleic anhydride (see Table B2B for wt % added) was dissolved in 4 g of water and placed in a metal tube that was then connected to the Parr reactor. After the desired temperature was reached, the pressure of the vessel was increased to 300psi through the metal tube. This ensured that all the aqueous solution was forced in the Parr autoclave. The first sample was taken 5 minutes after this addition. Samples were also taken at 10 minutes. After the wax was sampled, the sampling bottle was placed in the oven at 1400C. This wax was then hot filtered (140 0C) through a 0.8 μm filter paper. The wax was then analyzed for aluminium using ICP. As can be observed from the results listed in Table B2B, maleic acid levels down to 0.01 wt % were sufficient to promote particle growth and thereby the filterability on the modified metal oxygenates from the wax at 2300C, but needed more time at 1700C. As these temperatures are above the decomposition temperature of maleic acid, it is speculated that the decomposition product of maleic acid, i.e. fumaric acid, is the active chemical agent.
Table B2B
Figure imgf000014_0001
B.3 - Polyacrylic acid (PAA)
The wax (200 g) containing 50 ppm aluminium was first melted in an oven at 140 0C, and then placed in the Parr autoclave, and heated to 165 0C with stirring (700 rpm). 0.1 wt % PAA was added to 2 wt % water and placed in a metal tube that was then connected to the Parr reactor. After the desired temperature was reached, the pressure of the vessel was increased to 10 bar through the metal tube. This ensured that all the aqueous solution was forced in the Parr autoclave. The first sample was taken 5 minutes after this addition. Samples were also taken at 10 minutes. After the wax was sampled, the sampling bottle was placed in the oven at 140 0C. This wax was then hot filtered (140 0C) through a 0.45 μm filter paper. The wax was then analyzed for aluminium using ICP. As can be observed from the results, PAA was effective in removing the modified metal oxygenates at 165°C.
Table B3
Figure imgf000015_0001
BA: Use of hydrothermal conditions and a filterable particle/adsorbent to modify and adsorb modified metal oxygenates.
The wax (200 g) containing soluble metal oxygenates was first melted in an oven at 140 0C. To the melted wax was added 0.1 -0.01 wt % Aerosil 380 (Degussa). The wax was then heated to 170 0C with stirring (200 rpm). Water (4 ml) was placed in a metal tube that was connected to the Parr reactor. After the desired temperature was reached, a sample was taken. Thereafter, the water was added to the reaction mixture and samples were taken at 5 and 10 minutes (Table B4) and passed through a 2.5 micron filter. The water modified the metal complex so that it could adsorb onto the filterable particle.
Table B4 ppm of Al wt % silica Time (min) Al (ppm) % Al removal in starting added wax
45 0.1 5 1 98
10 <1 >98
27 0.05 5 3 91
10 <1 >98
66 0.01 5 25 62
10 22 67
B.5 Influence of acid used on grown particle stability.
For experiments B5 a to e: wax (250 g) containing the soluble metal complexes was first melted in an oven at 165 0C. To the melted wax was added 0.1 wt % citric acid. After the desired temperature was reached, a sample was taken after 5 minutes and treated as specified in Table B5.
Table B5
Figure imgf000016_0001
In experiment B5f, wax (200 g) containing 45 ppm aluminium was first melted in an oven at 140 0C, and then placed in the Parr autoclave, and heated to 1700C with stirring (700 rpm). Maleic anhydride (0.1 wt %) dissolved in water (2 wt %) was placed in a metal tube that was then connected to the Parr reactor. After the desired temperature was reached, the pressure of the vessel was increased to 300psi through the metal tube. This ensured that all the aqueous solution was forced in the Parr autoclave. Two samples were taken after 15 minutes after this addition. After the wax was sampled, one sample was placed in the oven at 140 0C. This wax was then hot filtered (140 0C) through a 0.8 μm filter paper. Sample 2 was cooled down before being reheated to 1400C and filtered. The aluminium content of the wax was determined using ICP analysis. Unlike the citric acid treated wax, the filterability of the maleic acid treated wax remained the same, whereas the reaction conditions determine the filterability of the citric acid treated wax.
TableB5B: experiment B5 f.
Wt % Maleic Temperature Sample K ppm Al) Sample 2 (ppm Al) anhydride
0.1 17O0C <1 <1
C.1 Adsorbing the modified metal oxygenate onto an adsorbent.
In these experiments, contaminated wax was pumped at a set temperature through a 10 mm diameter tube containing adsorbent or filter material. The pressure listed is caused by the wax flow rate and adsorbent characteristics. In experiment C1 , contaminated wax containing 14 ppm aluminium and other metals such as cobalt, was pumped through a cellulose Arbocel BVB40 as filter/absorbent without water or acid been added (see table C1). No removal of aluminium was observed.
In experiment C2, experiment C1 was repeated but 2 wt % water was added to the wax (see Table C2). The addition of water led to the complete removal for continuous filtering of up to 2.5 hours.
In experiment C3, experiment C2 was repeated but with Vitacel LOO as filter material/adsorbent.
In experiment C4, experiment C2 was repeated but with Celpure S1000 as filter material/adsorbent.
In experiment C5, experiment C2 was repeated but with spray dried Degussa silica (Aerosil 380) as filter material/adsorbent.
In experiment C6 a to j, the wax and water mixture was pumped through a packed bed with 19 minutes residence time, before been pumped through a Fitracel 9001 filter material. For experiments C6 a to e only water was added. This was done at different temperatures. For experiments C6 f to j, a 0.1 M maleic acid in water solution was also added at different temperatures.
F535 GCC Rev 4 - Sasol
Figure imgf000018_0001
F535 GCC Rev 4 - Sasol
Table C2. Treatment of contaminated wax containing approx. 14 ppm aluminium
Figure imgf000019_0001
.
F535 GCC Rev 4 - Sasol
Table C3: Treatment of contaminated wax containing approx. 14 ppm aluminium.
00
Figure imgf000020_0001
F535 GCC Rev 4 - Sasol
Table C4: Treatment of contaminated wax containing approx. 16 ppm aluminium.
Figure imgf000021_0001
F535 GCC Rev 4 - Sasol
Table C5 : Treatment of contaminated wax containing approx. 22 ppm aluminium
Figure imgf000022_0001
F535 GCC Rev 4 - Sasol
Figure imgf000023_0001

Claims

Claims
1. A method of treatment of hydrocarbons, said method including hydrothermal treatment at a temperature of above 100°C of metal oxygenate components in F-T derived hydrocarbons.
2. A method as claimed in claim 1 , said method including chemical treatment of the metal oxygenate components in the F-T derived hydrocarbons, to modify the metal oxygenates.
3. A method as claimed in claim 1 or claim 2, wherein the treatment is followed by one or more of the following treating stages:
i) extracting the modified metal oxygenates with the aid of one or more polar solvents; ii) filtering the modified metal oxygenates after sufficient time has been allowed for particle growth and/or adsorption onto a filterable particle; iii) adsorbing the modified metal oxygenate onto an adsorbent; iv) settling of the modified metal oxygenates after sufficient time has been allowed for particle growth; v) by centrifuging out the modified metal oxygenates after sufficient time has been allowed for particle growth; vi) by distilling the hydrocarbons from the treated streams; vii) flocculation of the modified metal oxygenates; viii) magnetic precipitation; ix) electrostatic precipitation/settling; and x) flotation of the modified metal oxygenates and fine particulates; or any combination of one or more of the above treatments.
4. A method as claimed in any one of the preceding claims , wherein the metal oxygenate is a metal carboxylate, a metal alkoxide, a metalloxane, or a combination of two or more thereof.
5. A method as claimed in any one of claims 1 to 3, wherein the metal oxygenate is a carboxy substituted metalloxane.
6. A method as claimed in any one of the preceding claims, wherein the hydrothermal treatment is carried out with water at above 100°C.
7. A method as claimed in claim 6, wherein the hydrothermal treatment is carried out with water between 120°C to 37O0C.
8. A method as claimed in claim 6, wherein the hydrothermal treatment is carried out with water at temperature of up to 400°C.
9. A method as claimed in any one of the preceding claims, wherein the water for the hydrothermal treatment is selected from water added for the purpose of the hydrotreatment, reaction water already present in the F-T derived hydrocarbons, or a combination of both.
10. A method as claimed in any one of the preceding claims, wherein the hydrothermal treatment is carried out in a substantially single liquid phase system in which both the hydrocarbons and water are present, said water being present at such levels as to ensure that substantially one liquid phase is present under the process conditions.
11. A method as claimed in any one of the preceding claims, wherein the hydrothermal treatment is carried out in the presence of an adsorbent.
12. A method as claimed in claim 11 , wherein the adsorbent includes silica.
13. A method as claimed in claim 12, wherein adsorption of the modified metal oxygenates takes place on the silica particles and these particles are subsequently removed by filtration or other treatment methods.
14. A method as claimed in any one of the preceding claims, wherein the hydrothermal treatment is achieved by maintaining the product stream under the temperature and pressure used in the F-T reactor after a primary filtration zone for sufficient time to enable particle growth and/or adsorption onto a filterable particle.
15. A method as claimed in claim 14, wherein the pressure is selected to be higher than the water vapour pressure at the prevailing temperature.
16. A method as claimed in any one of the preceding claims, wherein the chemical treatment includes trans-esterification to exchange longer hydrocarbon chain carboxylic acids or alcohols with shorter chain carboxylic acids.
17. A method as claimed in claim 16, wherein the chemicals which are used in the trans-esterification or ligand replacement step are selected from the group including methanol, ethanol, oxalic acid, acetic acid, propanoic acetic, salicylic acid, succinic acid, tartaric acid, lactic acid, malonic acid, glycine acid, citric acid, carbonic acid, maleic acid, fumaric acid, phthalic acid, the anhydrides of these acids, and thermal decomposition products of these acids.
18. A method as claimed in claim 16, wherein the chemicals which are used in the trans-esterification or ligand replacement step are selected from the group including silica-alumina and/or other mixed oxide systems that possess Brønsted acidity.
19. A method as claimed in any one of the preceding claims, wherein the hydrothermal treatment results in hydroxylation and formation of one or more of metal hydroxides, metal oxyhydroxides, and metalloxanes.
20. A method as claimed in any one of the preceding claims, wherein the hydrothermal treatment is performed before, with or after the chemical treatment.
21. A method of treatment of hydrocarbons , said method including chemical treatment with one or more chemical treatment agents in a single liquid phase of metal oxygenate components in F-T derived hydrocarbons to modify the metal oxygenates.
22. A method as claimed in claim 21 , wherein the chemical treatment is , followed by one or more of the following treating stages: i) extracting the modified metal oxygenates with the aid of one or more polar solvents; ii) filtering the modified metal oxygenates after sufficient time has been allowed for particle growth and/or adsorption onto a filterable particle; iii) adsorbing the modified metal oxygenate onto an adsorbent; iv) settling of the modified metal oxygenates after sufficient time has been allowed for particle growth; v) by centrifuging out the modified metal oxygenates after sufficient time has been allowed for particle growth; vi) by distilling the hydrocarbons from the treated streams; vii) flocculation of the modified metal oxygenates; viii) magnetic precipitation; ix) electrostatic precipitation/settling; and x) flotation of the modified metal oxygenates and fine particulates; or any combination of one or more of the above treatments.
23. A method as claimed in claim 21 , wherein the chemical treatment agents which are used in the trans-esterification or ligand replacement step are selected from the group including methanol, ethanol, oxalic acid, acetic acid, propanoic acetic, salicylic acid, succinic acid, tartaric acid, lactic acid, malonic acid, glycine acid, citric acid, carbonic acid, maleic acid, fumaric acid, phthalic acid, the anhydrides of these acids, and thermal decomposition products of these acids, and solid acids including but not limited to silica-alumina and/or other mixed oxide systems that possess Brønsted acidity.
24. A method as claimed in claim 21 , wherein the chemical treatment is carried out in a single liquid phase in which both the hydrocarbons and one or more chemical treatment agents are present, said chemical treatment agent or agents being present at levels below their saturation level in the hydrocarbons.
25. A method as claimed in any one of claims 21 to 24, wherein the polar solvents are selected from the group including at least water, melted organic acids, ethylene glycol, ionic liquids, and combinations thereof.
26. A method as claimed in any one of claims 21 to 25, wherein one or more of the adsorbents, filter material, and filterable particles are selected from the group including at least clays, silica, silica-aluminas, silicated aluminas, cellulose, activated carbons, sintered metals, titania and material filters such as nylons and polycarbonates.
27. A method as claimed in any one of the claims 21 to 26, wherein the adsorbents are added during the chemical treatment, the hydrothermal treatment, during any of the downstream processes, or during two or more of the aforementioned steps.
PCT/ZA2005/000101 2004-07-06 2005-07-04 Method of treatment of fischer-tropsch derived hydrocarbons WO2006005085A2 (en)

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WO2010112690A1 (en) 2009-04-03 2010-10-07 IFP Energies Nouvelles Method for the production of middle distillates, comprising the hydroisomerisation and hydrocracking of a heavy fraction originating from a fischer-tropsch effluent
WO2014202596A1 (en) * 2013-06-20 2014-12-24 L'Air Liquide, Société Anonyme pour l'Etude et l'Exploitation des Procédés Georges Claude Process for removing metals from high-boiling hydrocarbon fractions
WO2016118982A2 (en) 2015-01-20 2016-07-28 The Petroleum Oil And Gas Corporation Of South Africa (Pty) Ltd Ltft catalyst fines removal
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US2661362A (en) * 1947-11-26 1953-12-01 Standard Oil Dev Co Removal of oxygenated organic compounds from hydrocarbons
BRPI0112706B1 (en) * 2000-07-24 2016-01-19 Sasol Tech Pty Ltd methods for forming a fischer-tropsch catalyst precursor, and method for forming a fischer-tropsch catalyst
RU2181747C1 (en) * 2000-12-25 2002-04-27 Новицкая Людмила Алексеевна Method of production of liquid hydrocarbon products from carbon dioxide
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