CA2252686C - Removal of phosphates from hydrocarbon streams - Google Patents
Removal of phosphates from hydrocarbon streams Download PDFInfo
- Publication number
- CA2252686C CA2252686C CA 2252686 CA2252686A CA2252686C CA 2252686 C CA2252686 C CA 2252686C CA 2252686 CA2252686 CA 2252686 CA 2252686 A CA2252686 A CA 2252686A CA 2252686 C CA2252686 C CA 2252686C
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- ceramic
- hydrocarbon stream
- phosphates
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- 229910019142 PO4 Inorganic materials 0.000 title claims abstract description 69
- 235000021317 phosphate Nutrition 0.000 title claims abstract description 69
- 150000003013 phosphoric acid derivatives Chemical class 0.000 title claims abstract description 56
- 229930195733 hydrocarbon Natural products 0.000 title claims abstract description 45
- 150000002430 hydrocarbons Chemical class 0.000 title claims abstract description 45
- 239000004215 Carbon black (E152) Substances 0.000 title claims abstract description 42
- 239000000919 ceramic Substances 0.000 claims abstract description 45
- 150000001875 compounds Chemical class 0.000 claims abstract description 31
- 239000002253 acid Substances 0.000 claims abstract description 25
- 239000000463 material Substances 0.000 claims abstract description 24
- 238000000034 method Methods 0.000 claims abstract description 22
- 229910000287 alkaline earth metal oxide Inorganic materials 0.000 claims abstract description 11
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 9
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 claims abstract description 8
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 claims abstract description 8
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 8
- 239000011575 calcium Substances 0.000 claims abstract description 8
- 229910052791 calcium Inorganic materials 0.000 claims abstract description 8
- 239000011777 magnesium Substances 0.000 claims abstract description 8
- 229910052749 magnesium Inorganic materials 0.000 claims abstract description 8
- 150000002736 metal compounds Chemical class 0.000 claims abstract description 7
- 239000011449 brick Substances 0.000 claims description 23
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 claims description 13
- 239000010452 phosphate Substances 0.000 claims description 13
- 238000005194 fractionation Methods 0.000 claims description 4
- 238000000354 decomposition reaction Methods 0.000 claims description 3
- 229910010293 ceramic material Inorganic materials 0.000 abstract description 12
- 150000007513 acids Chemical class 0.000 abstract description 8
- 150000007524 organic acids Chemical class 0.000 abstract description 7
- 235000005985 organic acids Nutrition 0.000 abstract description 6
- 230000008569 process Effects 0.000 abstract description 6
- 229910052809 inorganic oxide Inorganic materials 0.000 abstract description 5
- 239000006104 solid solution Substances 0.000 abstract description 4
- 239000011148 porous material Substances 0.000 abstract description 3
- 229910052710 silicon Inorganic materials 0.000 abstract description 3
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 abstract description 2
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical compound [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 abstract description 2
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 abstract description 2
- 238000001354 calcination Methods 0.000 abstract description 2
- 230000006378 damage Effects 0.000 abstract description 2
- 239000000203 mixture Substances 0.000 abstract description 2
- 239000011591 potassium Substances 0.000 abstract description 2
- 229910052700 potassium Inorganic materials 0.000 abstract description 2
- 239000010703 silicon Substances 0.000 abstract description 2
- 229910052708 sodium Inorganic materials 0.000 abstract description 2
- 239000011734 sodium Substances 0.000 abstract description 2
- 239000010779 crude oil Substances 0.000 description 12
- 239000012530 fluid Substances 0.000 description 12
- 238000012856 packing Methods 0.000 description 8
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 6
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 description 4
- 239000000126 substance Substances 0.000 description 4
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical group [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 3
- 230000015572 biosynthetic process Effects 0.000 description 3
- 239000000499 gel Substances 0.000 description 3
- 230000007246 mechanism Effects 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 239000003921 oil Substances 0.000 description 3
- 239000011574 phosphorus Substances 0.000 description 3
- 229910052698 phosphorus Inorganic materials 0.000 description 3
- 239000000047 product Substances 0.000 description 3
- 238000007670 refining Methods 0.000 description 3
- 150000003839 salts Chemical class 0.000 description 3
- 238000004448 titration Methods 0.000 description 3
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 2
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 2
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- CZLNXNATDOOWSZ-UHFFFAOYSA-N [Ca+2].[Mg+2].[O-2].[Al+3] Chemical compound [Ca+2].[Mg+2].[O-2].[Al+3] CZLNXNATDOOWSZ-UHFFFAOYSA-N 0.000 description 2
- 229910002092 carbon dioxide Inorganic materials 0.000 description 2
- 150000001735 carboxylic acids Chemical class 0.000 description 2
- 238000001311 chemical methods and process Methods 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 2
- QDOXWKRWXJOMAK-UHFFFAOYSA-N dichromium trioxide Chemical compound O=[Cr]O[Cr]=O QDOXWKRWXJOMAK-UHFFFAOYSA-N 0.000 description 2
- 238000002474 experimental method Methods 0.000 description 2
- 238000011049 filling Methods 0.000 description 2
- WWZKQHOCKIZLMA-UHFFFAOYSA-N octanoic acid Chemical compound CCCCCCCC(O)=O WWZKQHOCKIZLMA-UHFFFAOYSA-N 0.000 description 2
- 229920006395 saturated elastomer Polymers 0.000 description 2
- 229910000029 sodium carbonate Inorganic materials 0.000 description 2
- 239000000243 solution Substances 0.000 description 2
- 238000005979 thermal decomposition reaction Methods 0.000 description 2
- LNETULKMXZVUST-UHFFFAOYSA-N 1-naphthoic acid Chemical compound C1=CC=C2C(C(=O)O)=CC=CC2=C1 LNETULKMXZVUST-UHFFFAOYSA-N 0.000 description 1
- QYEXBYZXHDUPRC-UHFFFAOYSA-N B#[Ti]#B Chemical compound B#[Ti]#B QYEXBYZXHDUPRC-UHFFFAOYSA-N 0.000 description 1
- 229910020968 MoSi2 Inorganic materials 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 229910033181 TiB2 Inorganic materials 0.000 description 1
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 1
- 229910007948 ZrB2 Inorganic materials 0.000 description 1
- MCMNRKCIXSYSNV-UHFFFAOYSA-N ZrO2 Inorganic materials O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 1
- OBETXYAYXDNJHR-UHFFFAOYSA-N alpha-ethylcaproic acid Natural products CCCCC(CC)C(O)=O OBETXYAYXDNJHR-UHFFFAOYSA-N 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 229910000147 aluminium phosphate Inorganic materials 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 125000003118 aryl group Chemical group 0.000 description 1
- 239000011324 bead Substances 0.000 description 1
- 238000007068 beta-elimination reaction Methods 0.000 description 1
- VWZIXVXBCBBRGP-UHFFFAOYSA-N boron;zirconium Chemical compound B#[Zr]#B VWZIXVXBCBBRGP-UHFFFAOYSA-N 0.000 description 1
- 239000006227 byproduct Substances 0.000 description 1
- 239000001569 carbon dioxide Substances 0.000 description 1
- 230000003197 catalytic effect Effects 0.000 description 1
- 229910052681 coesite Inorganic materials 0.000 description 1
- 239000000356 contaminant Substances 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 229910052906 cristobalite Inorganic materials 0.000 description 1
- 238000006114 decarboxylation reaction Methods 0.000 description 1
- 230000030609 dephosphorylation Effects 0.000 description 1
- 238000006209 dephosphorylation reaction Methods 0.000 description 1
- 238000004821 distillation Methods 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 125000001183 hydrocarbyl group Chemical group 0.000 description 1
- 229910010272 inorganic material Inorganic materials 0.000 description 1
- 239000011147 inorganic material Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 150000004767 nitrides Chemical class 0.000 description 1
- 230000037361 pathway Effects 0.000 description 1
- 239000008188 pellet Substances 0.000 description 1
- 230000035699 permeability Effects 0.000 description 1
- 230000010399 physical interaction Effects 0.000 description 1
- 229920000137 polyphosphoric acid Polymers 0.000 description 1
- 230000009257 reactivity Effects 0.000 description 1
- 229910021332 silicide Inorganic materials 0.000 description 1
- FVBUAEGBCNSCDD-UHFFFAOYSA-N silicide(4-) Chemical compound [Si-4] FVBUAEGBCNSCDD-UHFFFAOYSA-N 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 235000012239 silicon dioxide Nutrition 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 229910052682 stishovite Inorganic materials 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- 229910003470 tongbaite Inorganic materials 0.000 description 1
- GAJQCIFYLSXSEZ-UHFFFAOYSA-L tridecyl phosphate Chemical compound CCCCCCCCCCCCCOP([O-])([O-])=O GAJQCIFYLSXSEZ-UHFFFAOYSA-L 0.000 description 1
- 229910052905 tridymite Inorganic materials 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 229910052726 zirconium Inorganic materials 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING 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
- C10G25/00—Refining of hydrocarbon oils in the absence of hydrogen, with solid sorbents
- C10G25/003—Specific sorbent material, not covered by C10G25/02 or C10G25/03
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/44—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminates
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Organic Chemistry (AREA)
- Oil, Petroleum & Natural Gas (AREA)
- Manufacturing & Machinery (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)
- Solid-Sorbent Or Filter-Aiding Compositions (AREA)
Abstract
Phosphates can be removed from a hydrocarbon stream by contacting said stream with a ceramic formed of a basic material which is insoluble in the hydrocarbon stream. A ceramic as used in this patent document is a solid solution formed by calcination of a compound. The removal of the organic acid is accomplished at temperatures ranging from 20°C to 400°C, a preferred temperature is between 200°C and 370°C. A hydrocarbon stream consists of C5+ hyrdocarbons. The basic material can be made up of one or more alkaline earth oxides, alkaline earth compounds, alkaline metal compounds, group IIIA element compounds, group IVA element compounds, group VIA element compounds. Preferred alkaline earth oxides are sodium, magnesium, potassium, calcium, aluminum and silicon. The support for the basic material can be made from any inorganic oxide. A preferred composition is a combination of two or more alkaline earth oxides blended with an inorganic oxide support and calcined to form a ceramic material. The ceramic material should contain a large surface area and pore size to allow efficient removal of the organic acids. For example, the surface area should be at least over 50 m2/g, and the higher the better. The ceramic material should be placed in a hot hydrocarbon stream to facilitate the destruction and removal of organic acids within the stream. Application of the process to acids is also described.
Description
TITLE OF THE INVENTION: Removal of Phosphates from Hydrocarbon Streams INVENTOR: Shaun T. E. Mesher FIELD OF THE INVENTION:
This invention relates to the removal of phosphates from hydrocarbon streams.
BACKGROUND OF THE INVENTION:
In the treatment of oil and gas wells by fracturing, a frac fluid is applied to an underground formation under sufficient pressure to form fractures in the formation, and thus improve flow of oil and gas from the formation into a well. It is desirable to retain the frac fluid close to the well bore and for this reason the frac fluids are made as gels and then pumped into the ground. The chemicals used to gel the frac fluids contain considerable phosphate and metal concentration. Upon completion of the fracturing treatment, pressure is released, the frac fluid breaks and the broken frac fluid is produced from the well along with reservoir fluid.
When the well is produced, the well production fluid is delivered to a refinery for refining into various hydrocarbon fluids. In the refining process, the phosphates have been found to cause contaniination and plugging of the refinery equipment. It has thus been found necessary either to remove the phosphates from the chemicals used to gel the frac fluid or remove them in the refinery itself. Customers of Trysol Canada Ltd. have requested a solution to the problem of removing phosphates from hydrocarbon streams. So far as the applicant is aware, the producers of the hydrocarbons have been unable to provide a satisfactory solution.
SUMMARY OF THE INVENTION
The inventor has thus addressed the need for removing phosphates from a hydrocarbon stream, particularly a broken frac fluid.
Phosphates are removed from a hydrocarbon stream by contacting the hydrocarbon stream with a ceramic formed from a basic material selected from the group consisting of alkaline earth oxides, alkaline earth compounds, alkaline metal compounds, group IIIA element compounds, group IVA element compounds and group VIA element compounds, wherein the ceramic chemically reacts with phosphates in the hydrocarbon stream and binds to the
This invention relates to the removal of phosphates from hydrocarbon streams.
BACKGROUND OF THE INVENTION:
In the treatment of oil and gas wells by fracturing, a frac fluid is applied to an underground formation under sufficient pressure to form fractures in the formation, and thus improve flow of oil and gas from the formation into a well. It is desirable to retain the frac fluid close to the well bore and for this reason the frac fluids are made as gels and then pumped into the ground. The chemicals used to gel the frac fluids contain considerable phosphate and metal concentration. Upon completion of the fracturing treatment, pressure is released, the frac fluid breaks and the broken frac fluid is produced from the well along with reservoir fluid.
When the well is produced, the well production fluid is delivered to a refinery for refining into various hydrocarbon fluids. In the refining process, the phosphates have been found to cause contaniination and plugging of the refinery equipment. It has thus been found necessary either to remove the phosphates from the chemicals used to gel the frac fluid or remove them in the refinery itself. Customers of Trysol Canada Ltd. have requested a solution to the problem of removing phosphates from hydrocarbon streams. So far as the applicant is aware, the producers of the hydrocarbons have been unable to provide a satisfactory solution.
SUMMARY OF THE INVENTION
The inventor has thus addressed the need for removing phosphates from a hydrocarbon stream, particularly a broken frac fluid.
Phosphates are removed from a hydrocarbon stream by contacting the hydrocarbon stream with a ceramic formed from a basic material selected from the group consisting of alkaline earth oxides, alkaline earth compounds, alkaline metal compounds, group IIIA element compounds, group IVA element compounds and group VIA element compounds, wherein the ceramic chemically reacts with phosphates in the hydrocarbon stream and binds to the
2 phosphates, thus removing them from the hydrocarbon stream.
Contacting the hydrocarbon stream with the ceramic preferably, particularly for large volume applications at a refinery, may comprise distilling the hydrocarbon stream in a tower packed with ceramic bricks, wherein the hydrocarbon stream is separated from the polar material upon passage through the ceraniic bricks. Preferably, the ceramic bricks are randomnly packed.
The method is preferably carried out at a temperature, for example greater than 260 degrees C, that promotes decomposition of phosphates absorbed onto the ceramic bricks.
A method for removing acids from a hydrocarbon stream comprising contacting the hydrocarbon stream with the ceramic bricks.
Apparatus for removing a polar material from a hydrocarbon stream preferably comprises a tower packed, at least filling a portion of the length of the tower, with ceramic bricks made from a basic material selected from the group consisting of alkaline earth oxides, alkaline earth compounds, alkaline metal compounds, group IIIA element compounds, group IVA element compounds and group VIA element compounds.
These and other aspects of the invention are described in the detailed description of the invention and claimed in the claims that follow.
BRIEF DESCRIPTION OF THE FIGURES
There will now be described preferred embodiments of the invention with reference to the figure, by way of example and without intending to limit the scope of the invention as defined by the claims, in which :
Fig. 1 shows a section through a tower packed with ceraniic according to the invention; and Fig. 2 shows an exemplary ceraniic brick in accordance with the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION
Phosphates can be removed from a hydrocarbon stream by contacting said stream with a ceramic formed of a basic material which is insoluble in the hydrocarbon stream. A
Contacting the hydrocarbon stream with the ceramic preferably, particularly for large volume applications at a refinery, may comprise distilling the hydrocarbon stream in a tower packed with ceramic bricks, wherein the hydrocarbon stream is separated from the polar material upon passage through the ceraniic bricks. Preferably, the ceramic bricks are randomnly packed.
The method is preferably carried out at a temperature, for example greater than 260 degrees C, that promotes decomposition of phosphates absorbed onto the ceramic bricks.
A method for removing acids from a hydrocarbon stream comprising contacting the hydrocarbon stream with the ceramic bricks.
Apparatus for removing a polar material from a hydrocarbon stream preferably comprises a tower packed, at least filling a portion of the length of the tower, with ceramic bricks made from a basic material selected from the group consisting of alkaline earth oxides, alkaline earth compounds, alkaline metal compounds, group IIIA element compounds, group IVA element compounds and group VIA element compounds.
These and other aspects of the invention are described in the detailed description of the invention and claimed in the claims that follow.
BRIEF DESCRIPTION OF THE FIGURES
There will now be described preferred embodiments of the invention with reference to the figure, by way of example and without intending to limit the scope of the invention as defined by the claims, in which :
Fig. 1 shows a section through a tower packed with ceraniic according to the invention; and Fig. 2 shows an exemplary ceraniic brick in accordance with the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION
Phosphates can be removed from a hydrocarbon stream by contacting said stream with a ceramic formed of a basic material which is insoluble in the hydrocarbon stream. A
3 ceramic is a solid solution formed by calcination of a compound. Polar material means an acid or phosphate.
The removal of the phosphate is accomplished at temperatures ranging from 20 C
to 400 C, a preferred temperature is between 200 C and 370 C. It is believed that the process is not significantly affected by pressure. A hydrocarbon stream comprises C5+
hydrocarbons. The basic material can be made up of one or more alkaline earth oxides, alkaline earth compounds, alkaline metal compounds, group IIIA element compounds, group IVA element compounds, group VIA element compounds. Preferred alkaline earth oxides are sodium, magnesium, potassium, calcium, aluminum and silicon. The support for the basic material can be made from any inorganic oxide. A preferred composition is a combination of two or more alkaline earth oxides blended with an inorganic oxide support and calcined to form a ceramic material. The ceramic material should contain a large surface area, pore size and mechanical strength to allow efficient removal of the phosphates and organic acids. For example, the surface area should be at least over 50 mZ/g, and the higher the better, without compromising the strength of the material. The ceramic material should be placed in a hot hydrocarbon stream to facilitate the destruction and removal of phosphates and organic acids within the stream.
Exemplary inorganic oxide supports are Al, Si, Zr, Ti. Exemplary basic mterials are magnesium, calcium and aluminum since these are inexpensive and readily available.
An exemplary material comprises a solid solution of calcined magnesium-calcium-aluminum oxide, wherein the magnesium is 5% by weight, calcium is 5% by weight and aluminum is 90% by weight of the metal component. A further examplary material comprises a solid solution of calcined magnesium-calcium-aluminum oxide, wherein the magnesium is 25% by weight, calcium is 25% by weight and aluminum is 50% by weight of the metal component. The ceramic may include fired metal oxide, eg A1Z03, Cr2O3, MgO, SiO2, Zr02, U2, a fired carbide, eg SiC, TiC, WC, Cr3C2, a fired boride, eg Cr3B2, TiB2, ZrB2, a silicide eg MoSi2, or a nitride, eg TiN. The ceramics are prepared in conventional manner, and may be obtained for example from Norton Chemical Process Products Company of Akron, Ohio.
The removal of the phosphate is accomplished at temperatures ranging from 20 C
to 400 C, a preferred temperature is between 200 C and 370 C. It is believed that the process is not significantly affected by pressure. A hydrocarbon stream comprises C5+
hydrocarbons. The basic material can be made up of one or more alkaline earth oxides, alkaline earth compounds, alkaline metal compounds, group IIIA element compounds, group IVA element compounds, group VIA element compounds. Preferred alkaline earth oxides are sodium, magnesium, potassium, calcium, aluminum and silicon. The support for the basic material can be made from any inorganic oxide. A preferred composition is a combination of two or more alkaline earth oxides blended with an inorganic oxide support and calcined to form a ceramic material. The ceramic material should contain a large surface area, pore size and mechanical strength to allow efficient removal of the phosphates and organic acids. For example, the surface area should be at least over 50 mZ/g, and the higher the better, without compromising the strength of the material. The ceramic material should be placed in a hot hydrocarbon stream to facilitate the destruction and removal of phosphates and organic acids within the stream.
Exemplary inorganic oxide supports are Al, Si, Zr, Ti. Exemplary basic mterials are magnesium, calcium and aluminum since these are inexpensive and readily available.
An exemplary material comprises a solid solution of calcined magnesium-calcium-aluminum oxide, wherein the magnesium is 5% by weight, calcium is 5% by weight and aluminum is 90% by weight of the metal component. A further examplary material comprises a solid solution of calcined magnesium-calcium-aluminum oxide, wherein the magnesium is 25% by weight, calcium is 25% by weight and aluminum is 50% by weight of the metal component. The ceramic may include fired metal oxide, eg A1Z03, Cr2O3, MgO, SiO2, Zr02, U2, a fired carbide, eg SiC, TiC, WC, Cr3C2, a fired boride, eg Cr3B2, TiB2, ZrB2, a silicide eg MoSi2, or a nitride, eg TiN. The ceramics are prepared in conventional manner, and may be obtained for example from Norton Chemical Process Products Company of Akron, Ohio.
4 Preferably, the method is carried out within a fractionation tower 10 as illustrated in Fig. 1. Fractionation tower 10 is located, in a refinery (not shown).
Preferably, the process is carried out at an early stage of the refining process, and may be applied to a crude feed. Care must be taken in the case of dirty crude feeds that the crude is not so contaminated that the pores in the ceramic will be filled with contaminants.
Dirty crudes should be treated to clean them up before being fed to the tower 10. The feed enters tower through line 12 in conventional manner. Heat is applied to the tower in conventional manner. Ceramic packing 14, 16, 18 and 20 fills portions of the tower as shown above and below the feed line 12. The ceramic packing is supported within the tower 10 in 10 conventional manner as for example on steel seives or trays. It is meant by "filling a portion of the tower" that the packing extends completely across the tower so that any fluid passing from the feed line 12 to one of the outlet lines must pass across the packing.
A mid-cut is taken at line 22, heavy cycle oil is taken at line 24 and light ends are removed from the tower 10 at line 26. The tower diameter will depend on the flow rate of the hydrocarbon stream. A tower that is completely filled with randomnly packed ceramic bricks is also acceptable, providing sufficient permeability is left to allow movement of product through the tower.
The ceramic packing is preferably formed from a 1/8 inch extruded ceramic brick 28 as shown for example in Fig. 2. This extrudate is preferably randomnly packed within the packing. Various shapes of extrudate may be used that promote random packing. The random packing of fine ceramic material supplies surface area for efficient distillation and removal of phosphate and organic acids by trapping and thermal decomposition.
Since the phosphates bind to the ceramic bricks, as the ceramic bricks become saturated with phosphate, the ceramic bricks should be removed and burnt to remove the phosphate.
The removal of phosphate is based on the basic principal of a two phase physical interaction between the phosphate and the basic inorganic material. The phosphate will bind to the basic material and become trapped within the ceramic matrix. In this case the ceramic material acts like a trap and holds the phosphate. With the addition of heat this trapping mechanism increases. In addition, some phosphates thermally decompose and the by-products if not trapped by the basic ceramic material could cause problems with corrosion and fouling within the plant. Unsaturated and saturated carboxylic acids in the hydrocarbon stream are harder to decompose but are also trapped within a basic material.
Once bonded to the material they are more likely to decompose with the addition of
Preferably, the process is carried out at an early stage of the refining process, and may be applied to a crude feed. Care must be taken in the case of dirty crude feeds that the crude is not so contaminated that the pores in the ceramic will be filled with contaminants.
Dirty crudes should be treated to clean them up before being fed to the tower 10. The feed enters tower through line 12 in conventional manner. Heat is applied to the tower in conventional manner. Ceramic packing 14, 16, 18 and 20 fills portions of the tower as shown above and below the feed line 12. The ceramic packing is supported within the tower 10 in 10 conventional manner as for example on steel seives or trays. It is meant by "filling a portion of the tower" that the packing extends completely across the tower so that any fluid passing from the feed line 12 to one of the outlet lines must pass across the packing.
A mid-cut is taken at line 22, heavy cycle oil is taken at line 24 and light ends are removed from the tower 10 at line 26. The tower diameter will depend on the flow rate of the hydrocarbon stream. A tower that is completely filled with randomnly packed ceramic bricks is also acceptable, providing sufficient permeability is left to allow movement of product through the tower.
The ceramic packing is preferably formed from a 1/8 inch extruded ceramic brick 28 as shown for example in Fig. 2. This extrudate is preferably randomnly packed within the packing. Various shapes of extrudate may be used that promote random packing. The random packing of fine ceramic material supplies surface area for efficient distillation and removal of phosphate and organic acids by trapping and thermal decomposition.
Since the phosphates bind to the ceramic bricks, as the ceramic bricks become saturated with phosphate, the ceramic bricks should be removed and burnt to remove the phosphate.
The removal of phosphate is based on the basic principal of a two phase physical interaction between the phosphate and the basic inorganic material. The phosphate will bind to the basic material and become trapped within the ceramic matrix. In this case the ceramic material acts like a trap and holds the phosphate. With the addition of heat this trapping mechanism increases. In addition, some phosphates thermally decompose and the by-products if not trapped by the basic ceramic material could cause problems with corrosion and fouling within the plant. Unsaturated and saturated carboxylic acids in the hydrocarbon stream are harder to decompose but are also trapped within a basic material.
Once bonded to the material they are more likely to decompose with the addition of
5 energy to the system.
The function of the basic ceramic material is two fold. It provides surface area to collect and trap the phosphate. It provides a catalytic medium in which phosphates and organic acids can thermally decompose. Decomposition may be advantageous in the case of acids because the organic moiety of the acid would be expelled from the basic ceramic material and the inorganic portion of the acid would be trapped, lengthening the lifetime of the basic ceramic material.
Thermal decarboxylation and dephosphorylation can occur by a number of possible mechanisms. Reactivity of the reaction for acids increases once the acid compound is converted to the acid salt. In the form of the acid salt, the acid becomes non-volatile and is more likely to be affected by thermal decomposition.
Possible mechanisms for removal of acids and phosphates are described below.
While this is a plausible reaction pathway the inventor is not bound by this proposal.
AI kal i ne RC~_ ~ + ~0 Thermal R~H Cei-amic Decompostion RH + AC + C02 (1) 0 (2) R1P- OH ~ alm~ R- 1P- O- AC + Fi20 ~ DecomI 2RH + AC- Or 0~
A post i on (5) (3) (4) An acid 1 or 3 when in contact with the alkaline ceramic (AC) will form an acid salt 2 and 4 releasing water. Once bound to the surface of the ceramic, the acid can do a
The function of the basic ceramic material is two fold. It provides surface area to collect and trap the phosphate. It provides a catalytic medium in which phosphates and organic acids can thermally decompose. Decomposition may be advantageous in the case of acids because the organic moiety of the acid would be expelled from the basic ceramic material and the inorganic portion of the acid would be trapped, lengthening the lifetime of the basic ceramic material.
Thermal decarboxylation and dephosphorylation can occur by a number of possible mechanisms. Reactivity of the reaction for acids increases once the acid compound is converted to the acid salt. In the form of the acid salt, the acid becomes non-volatile and is more likely to be affected by thermal decomposition.
Possible mechanisms for removal of acids and phosphates are described below.
While this is a plausible reaction pathway the inventor is not bound by this proposal.
AI kal i ne RC~_ ~ + ~0 Thermal R~H Cei-amic Decompostion RH + AC + C02 (1) 0 (2) R1P- OH ~ alm~ R- 1P- O- AC + Fi20 ~ DecomI 2RH + AC- Or 0~
A post i on (5) (3) (4) An acid 1 or 3 when in contact with the alkaline ceramic (AC) will form an acid salt 2 and 4 releasing water. Once bound to the surface of the ceramic, the acid can do a
6 number of things: 1) It can remain trapped on the surface. 2) Aromatic and unsaturated acids bound to the surface would easily decompose to give carbon dioxide and a hydrocarbon. 3) Phosphates bound to the surface would likely undergo beta elimination and lose the hydrocarbon groups attached to the phosphorus. The remaining phosphoric acid would then continue to bind phosphates eventually forming a polyphosphoric acid.
Analysis for phosphates was done by ICP with identification of the phosphorus element. Carboxylic acids were analyzed by titration with KOH via ASTM method D664.
Examples 1o 1. A light crude oil containing 78ppm phosphates was distilled to a maximum temperature of 370 C. The distillate 90% by volume contained 19ppm phosphates.
The residue 10% by volume contained 26ppm phosphates.
2. A light crude oil containing 78ppm phosphates was distilled over 4% sodium carbonate to a maximum temperature of 370 C. The distillate 90% by volume contained Oppm phosphates. The residue 10% by volume contained Oppm phosphates.
3. A light crude oil containing 78ppm phosphates was distilled over 4% HTCTM
to a maximum temperature of 370 C. The distillate 90% by volume contained Oppm phosphates. The residue 10% by volume contained Oppm phosphates.
2o 4. A light crude oil containing 78ppm phosphates was distilled over 33%
HTCTM to a maximum temperature of 370 C. The distillate 90% by volume contained Oppm phosphates. The residue 10% by volume contained Oppm phosphates.
5. A light crude oil containing 18ppm phosphates was distilled over used (xl) 4%
HTCTm to a maximum temperature of 370 C. The distillate 90% by volume
Analysis for phosphates was done by ICP with identification of the phosphorus element. Carboxylic acids were analyzed by titration with KOH via ASTM method D664.
Examples 1o 1. A light crude oil containing 78ppm phosphates was distilled to a maximum temperature of 370 C. The distillate 90% by volume contained 19ppm phosphates.
The residue 10% by volume contained 26ppm phosphates.
2. A light crude oil containing 78ppm phosphates was distilled over 4% sodium carbonate to a maximum temperature of 370 C. The distillate 90% by volume contained Oppm phosphates. The residue 10% by volume contained Oppm phosphates.
3. A light crude oil containing 78ppm phosphates was distilled over 4% HTCTM
to a maximum temperature of 370 C. The distillate 90% by volume contained Oppm phosphates. The residue 10% by volume contained Oppm phosphates.
2o 4. A light crude oil containing 78ppm phosphates was distilled over 33%
HTCTM to a maximum temperature of 370 C. The distillate 90% by volume contained Oppm phosphates. The residue 10% by volume contained Oppm phosphates.
5. A light crude oil containing 18ppm phosphates was distilled over used (xl) 4%
HTCTm to a maximum temperature of 370 C. The distillate 90% by volume
7 contained Oppm phosphates. The residue 10% by volume contained 1 ppm phosphates. ' 6. A light crude oil containing 360ppm phosphates was distilled over 4% HTCTM
to a maximum temperature of 370 C. The distillate 90% by volume contained l lppm phosphates. The residue 10% by volume contained 6ppm phosphates.
7. A light crude oil containing 6400ppm phosphorus added in the form of tridecylphosphate (16.28g, 31 mmol) was distilled over 4% HTCTM to a maximum temperature of 370 C. The distillate 90% by volume contained lOlppm phosphates. The residue 10% by volume contained 1000ppm phosphates.
1o 8. A light crude oil containing 78ppm phosphates was distilled over 4% Ty-Pac""I to a maximum temperature of 370 C. The distillate 90% by volume contained 25ppm phosphates. The residue 10% by volume contained 99ppm phosphates.
9. A light crude oil containing 78ppm phosphates was distilled over 4% sample #
9845479 to a maximum temperature of 370 C. The distillate 90% by volume 1s contained Oppm phosphates. The residue 10% by volume contained 3.9ppm phosphates.
10. A light crude oil containing 78ppm phosphates was distilled over 4% sample #
9845478 to a maximum temperature of 370 C. The distillate 90% by volume contained 0.3ppm phosphates. The residue 10% by volume contained 0.5ppm 20 phosphates.
11. A light crude oil containing 78ppm phosphates, naphthoic acid (39 mg, 270ppm) and octanoic acid (61.7 mg, 428ppm) was distilled over 4% sample # 9845479 to a
to a maximum temperature of 370 C. The distillate 90% by volume contained l lppm phosphates. The residue 10% by volume contained 6ppm phosphates.
7. A light crude oil containing 6400ppm phosphorus added in the form of tridecylphosphate (16.28g, 31 mmol) was distilled over 4% HTCTM to a maximum temperature of 370 C. The distillate 90% by volume contained lOlppm phosphates. The residue 10% by volume contained 1000ppm phosphates.
1o 8. A light crude oil containing 78ppm phosphates was distilled over 4% Ty-Pac""I to a maximum temperature of 370 C. The distillate 90% by volume contained 25ppm phosphates. The residue 10% by volume contained 99ppm phosphates.
9. A light crude oil containing 78ppm phosphates was distilled over 4% sample #
9845479 to a maximum temperature of 370 C. The distillate 90% by volume 1s contained Oppm phosphates. The residue 10% by volume contained 3.9ppm phosphates.
10. A light crude oil containing 78ppm phosphates was distilled over 4% sample #
9845478 to a maximum temperature of 370 C. The distillate 90% by volume contained 0.3ppm phosphates. The residue 10% by volume contained 0.5ppm 20 phosphates.
11. A light crude oil containing 78ppm phosphates, naphthoic acid (39 mg, 270ppm) and octanoic acid (61.7 mg, 428ppm) was distilled over 4% sample # 9845479 to a
8 maximum temperature of 370 C. The distillate 90% by volume contained Oppm in acids by titration with KOH. The residue 10% by volume contained Oppm in acids by titration with KOH.
In a further experiment, Vermillion condensate (from Vermillion, Alberta, Canada) was passed through two consecutive columns. This Vermillion condensate was a stabilized condensate (FRACSOLTm condensate available from Trysol Canada Limited of Calgary, Alberta, Canada) which had been used in well servicing and thus was contaminated with crude oil. The first column (1/2") was filled with glass beads, while the second column (1/4") was filled with 2.77 g of crushed TyPac 2 pellets. the flow rate was set at 0.9 mL/min to obtain a residence time of 5 minutes (space velocity = 11.8 h-1).
Tempeature was 302 degrees C. The sample was washed with NaOH and separated easily from the NaOH.
After each of 1, 2, 4 and 6 hours, 0 ppm phosphate remained in the sample. An attempt to run the process at a flow rate of 4.6 mL/min, residence time of 1 minute, did not work due to too great a pressure drop across the column.
From the result of experiment 11, the ceramic bricks herein described are believed to be effective in removing acid from hydrocarbons streams, including crude streams. where the crude contains acid in an amount not more than about 1 acid number.
Chemicals Sodium carbonate was supplied by Sigma-Aldrich Ltd. HTCTMwas supplied by Alcoa Alumina & Chemicals. Ty-Pac7m, sample # 9845478 and 9845479 were supplied by Norton Chemical Process Products Corporation.
Immaterial modifications may be made to the invention described herein without departing from the spirit of the invention.
In a further experiment, Vermillion condensate (from Vermillion, Alberta, Canada) was passed through two consecutive columns. This Vermillion condensate was a stabilized condensate (FRACSOLTm condensate available from Trysol Canada Limited of Calgary, Alberta, Canada) which had been used in well servicing and thus was contaminated with crude oil. The first column (1/2") was filled with glass beads, while the second column (1/4") was filled with 2.77 g of crushed TyPac 2 pellets. the flow rate was set at 0.9 mL/min to obtain a residence time of 5 minutes (space velocity = 11.8 h-1).
Tempeature was 302 degrees C. The sample was washed with NaOH and separated easily from the NaOH.
After each of 1, 2, 4 and 6 hours, 0 ppm phosphate remained in the sample. An attempt to run the process at a flow rate of 4.6 mL/min, residence time of 1 minute, did not work due to too great a pressure drop across the column.
From the result of experiment 11, the ceramic bricks herein described are believed to be effective in removing acid from hydrocarbons streams, including crude streams. where the crude contains acid in an amount not more than about 1 acid number.
Chemicals Sodium carbonate was supplied by Sigma-Aldrich Ltd. HTCTMwas supplied by Alcoa Alumina & Chemicals. Ty-Pac7m, sample # 9845478 and 9845479 were supplied by Norton Chemical Process Products Corporation.
Immaterial modifications may be made to the invention described herein without departing from the spirit of the invention.
Claims (12)
1. A method for removing phosphates from a hydrocarbon stream, the method comprising the step of contacting the hydrocarbon stream with a ceramic formed from a basic material selected from the group consisting of alkaline earth oxides, alkaline earth compounds, alkaline metal compounds, group IIIA element compounds, group IVA element compounds and group VIA element compounds, wherein the ceramic chemically reacts with phosphates in the hydrocarbon stream and binds to the phosphates, thus removing them from the hydrocarbon stream.
2. The method of claim 1 in which contacting the hydrocarbon stream with the ceramic comprises distilling the hydrocarbon stream in a tower packed with ceramic bricks over at least a portion of the length of the tower, wherein the hydrocarbon stream is separated from the phosphate upon passage through the ceramic bricks.
3. The method of claim 2 in which the ceramic bricks are randomnly packed.
4. The method of claim 1 in which the method is carried out at a temperature that promotes decomposition of phosphates absorbed onto the ceramic bricks.
5. The method of claim 1 in which the ceramic is made from a basic material selected from the group consisting of aluminum, calcium and magnesium.
6. Apparatus for removing polar material from a hydrocarbon stream, comprising:
a fractionation tower having at least a portion of the fractionation tower packed with ceramic bricks made from a basic material selected from the group consisting of alkaline earth oxides, alkaline earth compounds, alkaline metal compounds, group IIIA element compounds, group IVA element compounds and group VIA element compounds.
a fractionation tower having at least a portion of the fractionation tower packed with ceramic bricks made from a basic material selected from the group consisting of alkaline earth oxides, alkaline earth compounds, alkaline metal compounds, group IIIA element compounds, group IVA element compounds and group VIA element compounds.
7. The apparatus of claim 6 in which the ceramic bricks are randomnly packed.
8. The apparatus of claim 6 in which the ceramic bricks are made from a basic material selected from the group consisting of aluminum, calcium and magnesium.
9. A method for removing acid from a hydrocarbon stream, the method comprising the step of contacting the hydrocarbon stream with a ceramic formed from a basic material selected from the group consisting of alkaline earth oxides, alkaline earth compounds, alkaline metal compounds, group IIIA element compounds, group IVA element compounds and group VIA
element compounds, wherein the ceramic chemically reacts with acid in the hydrocarbon stream and binds to the acid, thus removing them from the hydrocarbon stream.
element compounds, wherein the ceramic chemically reacts with acid in the hydrocarbon stream and binds to the acid, thus removing them from the hydrocarbon stream.
10. The method of claim 9 in which contacting the hydrocarbon stream with the ceramic comprises distilling the hydrocarbon stream in a tower packed with ceramic bricks over at least a portion of the length of the tower, wherein the hydrocarbon stream is separated from the acid upon passage through the ceramic bricks.
11. The method of claim 10 in which the ceramic bricks are randomnly packed.
12. The method of claim 9 in which the ceramic is made from a basic material selected from the group consisting of aluminum, calcium and magnesium.
Priority Applications (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2252686 CA2252686C (en) | 1998-11-03 | 1998-11-03 | Removal of phosphates from hydrocarbon streams |
| US09/191,750 US6039865A (en) | 1997-12-19 | 1998-11-13 | Removal of phosphates from hydrocarbon streams |
| US10/247,606 US20030024855A1 (en) | 1997-12-19 | 2002-09-18 | Removal of phosphates from hydrocarbon streams |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2252686 CA2252686C (en) | 1998-11-03 | 1998-11-03 | Removal of phosphates from hydrocarbon streams |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2252686A1 CA2252686A1 (en) | 2000-05-03 |
| CA2252686C true CA2252686C (en) | 2009-01-06 |
Family
ID=29425579
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2252686 Expired - Fee Related CA2252686C (en) | 1997-12-19 | 1998-11-03 | Removal of phosphates from hydrocarbon streams |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2252686C (en) |
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1998
- 1998-11-03 CA CA 2252686 patent/CA2252686C/en not_active Expired - Fee Related
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| CA2252686A1 (en) | 2000-05-03 |
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