WO2010117300A1 - Plant and devices for the deep processing of raw hydrocarbons - Google Patents

Abstract

The invention relates to the oil refining, petrochemical, chemical and oil and power industries, namely to the processing of raw hydrocarbons. The technical result is an increase in the yield of light target products and in the depth of industrial processing of raw materials. Raw hydrocarbons are heated by direct contact with high-boiling, high-molecular fractions, which are heated to a subcritical temperature that is less than the initial temperature of avalanche-type uncontrolled thermal cracking, then the mixture of raw hydrocarbons and high-molecular fractions is exposed to a mechanical and wave action of different possible natures within a wide frequency range in order to initiate a controlled process of bond-breaking in the molecules, i.e. thermomechanical cracking. The method makes it possible to increase processing depth by 1.5-15 times, depending on the initial raw feedstock composition. Correspondingly, the yield of the best and most valuable fuel compositions such as gasoline, kerosene and diesel fractions, and petrochemical products is also increased. The claimed plant and devices are simple to operate and do not entail substantial capital investments and operating costs.

Description

 Installation and devices for advanced hydrocarbon processing

The invention relates to the oil refining, petrochemical and chemical industries, as well as to the fuel and energy industry, and specifically to the field of preparation and deep processing of oil, including heavy oil, residues of oil refining and petrochemical industries, natural bitumen, coal, oil shale, vegetable products and other hydrocarbon media, solid, liquid, gaseous, hereinafter raw materials, and can be used in the production of hydrocarbon fuels, petrochemical and chemical products. In addition, the application of the invention allows to solve many environmental problems and leads to improved environmental conditions. The preparation and deep processing of oil, oil residues and other raw materials means not only the removal of harmful impurities from raw materials, but also, most importantly, an increase in the number of light target products higher than their potential content in the feedstock, which can further significantly increase the processing depth and profitability total processing industry. Light target products or fractions are understood as fractions for further processing and obtaining light target commodity products with a boiling point mainly up to 350-360 ⁰ C, containing fuel, i.e. the most expensive gas, gasoline, kerosene and diesel fractions, as well as products for the petrochemical and chemical industries (benzene, toluene and others). In the future, light target fractions or products, of which, when light final target products (liquefied gas, tested gasoline, diesel fuel, petrochemical products and others) receive final processing. Heavy commercial products - coke, bitumen, bitumen emulsions, coatings, oils and other commercial products.

Technological schemes and oil refining plants have several options. There is a full technological cycle, which includes the following main industries: production of fuels, production of petrochemical products, production of lubricants and special oils, production of additives. Specialized variants of technological schemes and installations are possible: only fuel or only fuel-oil (Dekhterman A.Sh. Oil refining according to the fuel option. M., "Chemistry", 1988, p.13). In all cases, devices for preliminary evaporation of oil are used at the beginning of the technological process. The preliminary evaporation of gas and the bulk of gasoline allows you to reduce the pressure at the inlet of the feed pump, relieve the furnace from heating light fractions, reduce the vapor velocity and reduce the diameter of the main distillation column. At large oil refineries (refineries), distillation column apparatuses are used for this purpose.

The primary distillation of oil at the refinery is carried out in two ways: by single evaporation in one distillation column and with preliminary evaporation of light fractions, or by double evaporation (Bagirov I.T. High-performance atmospheric and atmospheric-vacuum installations. M., Chemistry, 1964, p. 5; Dekhterman A.Sh. Oil refining according to the fuel variant. M., "Chemistry", 1988, p. 41). The latter method is used most often, since it allows you to increase the depth of selection of distillates within their potential content in raw materials. We briefly consider the sequence of operations of primary distillation carried out according to the classical scheme.

Before the oil is fed for separation, its preparation is required. Oil preparation is carried out in blocks ELOU (electro-dehydrating and desalting plant). Equipment difficult to manufacture and operate, explosive (Dekhterman A.Sh. Oil refining according to the fuel version. M., "Chemistry", 1988, p. 36).

To separate the hydrocarbon feed (including oil) it is heated. At the enterprises of the oil refining and petrochemical industries, this operation is carried out by supplying heat through a dividing wall (coil) by burning fuel. For this purpose, various tube furnaces are used (Entus HP, Sharikhin V.V. Tube furnaces in the oil refining and petrochemical industries. M., Chemistry, 1987, p. 6.). Liquid and gaseous hydrocarbons are heated in them. In this case, the following processes can occur: heating, evaporation, overheating. Heated hydrocarbon feed passes through the coils. Heat transfer to the raw material occurs, as noted, through its wall. There is a limitation on the thermal stress of the heating surface. Deposits of salts or coke on the coil walls cause a rapid increase in the temperature of the pipe walls, which ultimately leads to a sharp reduction in the service life of the chimneys. Therefore, for raw materials containing resinous compounds, the heat stress is set low. The decrease in oil reserves of traditional fields increases interest in the production and, consequently, the processing of heavy oil (Ratov AH, Nemirovskaya GB. Problems of oil development in the Ulyanovsk region. "Chemistry and technology of fuels and oils ", N ° 4, 1995). Therefore, the use of tubular heaters for such oil becomes problematic. In addition, coils require the use of high alloy, expensive steel. In general, a tube furnace is a complex and expensive equipment with a limited resource.

The separation of oil into fractions is based on the difference in the boiling point of its components. The low-boiling part passes into the vapor phase and, after condensation, forms a distillate. For a clear separation of the mixture, atmospheric or vacuum distillation is used (A. Dekhterman, Oil refining according to the fuel version. M., Chemistry, 1988, p. 26). Rectification apparatus refers to a fairly technologically advanced and structurally-used equipment. However, it is sophisticated equipment. Column distillation apparatuses used at large refineries are quite expensive to manufacture and operate. Therefore, at the stage of preliminary separation of oil, it is advisable to use simpler devices, such as evaporators (Dekhterman A.Sh. Oil refining according to the fuel version. M., "Chemistry", 1988, p.23). The evaporator is a cylindrical tank. At the bottom of its housing is an integrated tubular heat exchanger. Inside the tubes of the heat exchanger serves a coolant for heating the product (oil). Typically, water vapor is used as a heat transfer medium. The light part of the oil (gasoline fraction) evaporates and is discharged through the upper fitting. The remaining oil is poured through the drain plate and is discharged through the corresponding fitting. The amount of evaporated part of the oil depends on the temperature in the apparatus, that is, on the surface of the heat exchanger and the temperature of the coolant. The surface of the heat exchanger during operation is covered by deposits of oil and heat transfer conditions are much worse. This process is significantly accelerated with increasing temperature of the coolant. Therefore, devices of this type have limitations in terms of intensifying the process of separation and evaporation of part of the liquid hydrocarbon feedstock. The temperature of the process is 200 - 230 ⁰ C. This temperature corresponds to a certain evaporated part of the oil (feedstock). In the present invention, this apparatus is used as a prototype of an evaporation and separation apparatus.

However, such processing of oil and oil products does not allow solving the problem of deep processing of oil-containing fractions in order to maximize the extraction and efficient use of the obtained processing products (higher than their potential content in raw materials), and without deep processing, processing plants are practically unprofitable.

For the processing of heavy oil-containing fractions in order to obtain an additional amount of light oil products, the method of catalytic cracking of oil products is widely known - the method of thermal decomposition of heavy oil fractions in the presence of a catalyst (Rudin M.G., Drabkin A.E. Oil refinery quick reference guide. L.: Chemistry. 1980 , p. 70-73). The method includes heating the feedstock to a temperature of 470-550 ⁰ C, mixing it with water vapor and then with a catalyst, treating the mixture in a reactor, followed by catalytic decomposition of the feedstock and separating it into fractions, as well as isolating and regenerating the catalyst at a temperature of 590-670 ⁰ C.

However, the known method is expensive and difficult to implement.

Known installation for the implementation of catalytic cracking petroleum products, which contains an interconnected device for processing raw materials, a device for separating final products, in turn communicated with a device for cooling and condensing the final product, in communication with a device for separating hydrocarbon gases (Rudin M.G., Drabkin A.E. A quick reference to the oil refinery. L .: Chemistry. 1980, p.70-73.).

The specified installation is very cumbersome, difficult to maintain and does not allow to intensify the chemical-technological processes with processed raw materials.

Known methods for processing heavy oil-containing fractions using, along with thermal and catalytic, physical methods of exposure to activate the processed raw materials.

A known method of processing by sequential extraction of fractions from hydrocarbons using electromagnetic energy with a frequency of 300 MHz-300 GHz (US patent 5055180, C 10 G 1/00, 1991).

The disadvantage of this method is the impossibility of a more complete use of raw materials in the processing process due to the dependence on the intensity of the electromagnetic field.

Known methods for refining petroleum products by exposing the latter to ionizing radiation (neutron flux or gamma radiation) followed by catalytic cracking of the impact products (RF patent 2100404, C 10 G 15/10, 1995).

However, the application of the method is difficult in industrial production due to the complexity and difficulties of controlling the process. In addition, the method is not safe to use.

Known methods for processing heavy oily fractions using wave exposure to a wide range of frequencies. In the known method of processing fuel oil by vacuum distillation to obtain distillate fractions, the liquid phase of the still bottom is exposed to acoustic vibrations with a frequency of 0.1-200 kHz and a power of 0.2-3 W / cm ² (USSR copyright certificate 1377281, 1988).

However, the known method is characterized by high energy costs for creating a deep vacuum, and the use of only the acoustic frequency range does not provide reliable destruction of highly viscous media, a long period of time is required for the processing of fuel oil. In addition, this method is intended for the processing of fuel oil only and does not allow the processing of, for example, used motor or lubricating oils.

There is also known a method of cracking petroleum products using an ultrasonic frequency spectrum. According to this method, the raw material (oil-containing product) and dispersant are fed into the treatment zone, ultrasonic treatment is carried out with a radiation intensity of 1-10 MW / m ² in a closed circulation circuit at a static pressure in the range from 0.2 to 5 MPa, and the subsequent separation of the processed raw materials into liquid and vapor phases and obtaining the final product from the vapor phase (RF patent 2078116, C 10 G 15/00, 1995).

Although this method allows to increase the yield of light oil products, however, it does not allow controlling the process of obtaining final products due to a closed cycle and has a number of technological disadvantages: it is carried out at high temperatures and pressures, it is difficult to implement, energy-intensive.

Installation for implementing the specified method of cracking oil contains interconnected device for processing of raw materials, which is simultaneously an ultrasonic generator, a separation chamber for separating spent raw materials and a device for condensing the vapor phase. A device for processing raw materials is a housing in which interconnected chambers are formed, each of which has a rotor mounted on the drive shaft and a stator. The last chamber is communicated with the first, forming a closed loop. Behind the last chamber there is a separation chamber having a channel for diverting the resulting vapor phase for condensation in the refrigeration chamber. The emitter of ultrasonic frequencies are the mechanical components of the system (rotor, stator, bearings).

The disadvantage of this installation is the use of a complex mechanical system (rotor, stator, bearings) in the operation of the installation, which sharply reduces its reliability. In addition, the use of mechanical components as emitters with an intensity of more than 100 kW / m ² leads to intensive destruction of their surface due to the occurrence of cavitation processes.

Due to these drawbacks, methods of direct physical impact, for example, of a wave of various nature, have not been applied and are not used in industry. In addition, the methods of direct physical impact are unreasonably energetically expensive, because the conversion of thermal energy into wave energy has a very low efficiency and to activate vibrational levels of molecules, many times more energy is needed than when the same effect is achieved with direct heating.

A known method of thermal processing of heavy oily fractions, including thermal cracking of heavy oily fractions into phases and obtaining from the vapor phase final products, characterized in that before thermal cracking, the feedstock is preliminarily subjected to a wave treatment in a separate treatment zone by forming a wide range of frequencies from the acoustic to the light range in the medium being processed, after which the impact products are fed to thermal cracking, which is carried out in the mode of primary oil refining at atmospheric pressure and a maximum heating temperature of 360 ⁰ C (patent of the Russian Federation RU2215775). The disadvantage of this method is that for the excitation of vibrational levels of molecules and their activation for further cracking, it is necessary to add a certain amount of energy to the processed medium. In the thermal or catalytic process, the necessary energy is introduced by direct heating of the feed. Further, raw materials, for example in catalytic cracking, are fed to catalysts that reduce the activation energy of molecular bond breaking and contribute to the cracking process. In this method, the activation energy of molecules is introduced into the medium due to ((formation of a wide spectrum of frequencies from the acoustic to the light range in the medium being processed)). Taking into account the fact that when raw materials are activated by direct heating, heat is directly used to excite vibrational levels of molecules, and to activate the same molecules by wave action, it is first necessary to spend heat (energy) to create a wave effect, and this process has a very low efficiency , then the energy costs during the implementation of this method become unreasonably high. Those. To significantly excite vibrational levels of molecules (and this is equivalent to heating the raw material hundreds of degrees) in this method, it is necessary to use much more energy than with direct thermal heating. Moreover, for pre-processing of raw materials takes a long time, the process is periodic, which is a big obstacle to the industrial implementation of this method.

Known devices for acoustic processing of liquid (patent SU 410823 ((Hydrodynamic emitter of a vortex type, patent SU 546389 ((Device for ultrasonic processing))). However, they do not give the effect of increasing the depth of processing, ie cracking, the main application is the creation emulsions.

Known devices for acoustic and cavitation processing, in which the processing is carried out due to the movement of the rotor, the disk is a rotary pulsation apparatus (patent RU 2115176 ((Cavitation generator ”, patent RU 211 1554 ((Ultrasonic oscillation generator))). In these devices, acoustic and cavitation treatment of the liquid occurs in thin layers directly adjacent to the moving rotor or disk, and not in the entire volume, therefore, the liquid treatment in such devices gives a small, within the limits of measurement error, increase in the depth of processing and in the industry has not found wide use in hydrocarbon feedstock cracking purposes. In general, such devices are used to emulsify liquids. Due to the fact that the devices moving parts are present, life of such devices is insufficient.

The closest analogue (prototype) for the claimed device is the device according to patent RU 2164629 ((Method for cavitation of a fluid flow and a device for its implementation)). The cavitation method is hydrodynamic. The process occurs due to the fact that a cavitator in the form of a working fluid of various shapes is placed in the flow of the processed fluid, and the area of the maximum cross section of the working fluid in a plane perpendicular to the axis pipeline, is more than 0.8 of the cross-section of the pipeline, but not equal to it. It is known that cavitation occurs during the flow around a poorly streamlined body, in the rear of which there is a zone of low pressure. At a certain critical flow rate, the pressure in the rear zone decreases to atmospheric pressure, as a result of which bubbles form here, filled with gas or steam, and then a cavity. When bubbles or caverns are separated from the cavitator, they fall into the region of increased flow pressure and collapse, performing a certain work that can be used as useful, for example, to intensify chemical and other processes. Because Since the working fluid (cavitator) occupies more than 0.8 of the pipeline cross-section, the cavitation process occurs only in this zone, which makes up no more than 20% of the total volume of the processed liquid, which does not allow thermomechanical cracking of the entire volume of raw materials. In addition, the cavitator is not fixed rigidly, but changes its position under the influence of a moving stream. The streamlined body always strives to occupy a position in which the hydrodynamic drag is minimal, i.e. such a position in which the flow of fluid around this body will be the best for these conditions of movement of the medium. This will lead to an even greater reduction in the cavitation zone and a decrease in cavitation and acoustic effects on the raw materials.

As already mentioned, the most famous and widely used processes of deep processing are catalytic - catalytic cracking, hydrocracking and other processes. (V. Sukhanov. Catalytic processes in oil refining. M., "Chemistry", 1973. Prokopyuk C. G., Masagutov R. M. Industrial catalytic cracking plants. M., "Chemistry", 1974.). To serious The disadvantages of such processes include the following: high pressures (up to 15 MPa) and heating temperatures of the feedstock (450-550 ⁰ C and higher) lead to a serious increase in capital costs, poisoning of the catalysts and the need for their regeneration to very high current operating costs. Suffice it to say that due to the high cost of such processes, most Russian refineries do not have the ability to implement them.

Thermal cracking has been known for a very long time (Smidovich EV, Oil and gas processing technology. 4.2. M., Chemistry, 1968. VE Parkhomenko, Oil and gas processing technology. M., Gostoptekhizdat, 1959.). The disadvantages of thermal cracking include the following. When the raw material is heated with increasing temperature, the number of bond breaks slowly and smoothly increases, but when a critical temperature is reached (depending on the properties and composition of the feedstock), this number increases sharply, the process of bond breaking is avalanche-like, uncontrollable. This leads to coking of the equipment and a decrease in the overhaul mileage, the process is periodic. There are a lot of gases and unsaturated hydrocarbons in thermal cracking products, which increases the requirements for further equipment in obtaining marketable products - gasoline, diesel fuel and others, which, ultimately, leads to an increase in capital and operating costs. Therefore, recently, thermal cracking processes, especially in the fuel version, are rarely used. High temperatures of heating of raw materials (470-550 ⁰ C and above) and pressure (up to 7 MPa) also lead to high capital costs, and coking of equipment and low overhaul mileage of equipment - to increase operating costs. The closest analogue (prototype) for the installation of advanced processing according to the invention is thermal cracking.

The technical result of the application of the invention is to increase the yield of light target products and increase the depth of industrial processing of raw materials, simplify and cheapen the process and equipment for the preparation and advanced processing of raw materials, reduce operating and capital costs with a high depth of further processing, save and rational use of hydrocarbon raw materials.

The aim of the invention is to increase the yield of light light fractions (gasoline, kerosene and diesel, petrochemicals) higher than their potential content in raw materials and increase the depth of processing, which leads to optimal and rational use of raw materials for their further processing, reducing operating and capital costs, simplicity and reliability of equipment design, simplicity and reliability of control and adjustment of the thermomechanical cracking process, reduction of coking and increase of spacing ntnogo path equipment, the continuity of the process, improving the quality of thermomechanical cracking products for further processing as compared with thermal cracking, reduction of harmful impurities, the solution of environmental problems, recycling of free oil and other gases. The main goal is to increase the processing depth of any hydrocarbon feedstock, which ultimately leads to an increase in the profitability of the entire processing industry.

This goal is achieved by the fact that in the installation for the preparation and processing of liquid hydrocarbon raw materials, including preparation (preliminary cleaning of water and harmful impurities), supply and heating raw materials, separation of raw materials into fractions, removal of separation products, a separation apparatus is built in, in which the hydrocarbon mixture is divided into two parts - the light separation part (low boiling fractions of NKF) and the heavy high molecular weight part of separation (high boiling fractions of VKF). Raw materials are preheated in recuperative heat exchangers to optimize energy costs due to the heat of one or all separation products (NKF and VKF). If the heat of separation products or commercial products is used for other purposes (depends on the task), the raw materials are preheated in a separate or general (but separate from heating VKF coil) with heating VKF heating furnace (heater) to a temperature above 20 ÷ 50 ⁰ C to reduce viscosity and increase fluidity of raw materials, especially heavy and highly viscous. Raw materials are usually heated to a temperature not exceeding 450 ^° C so that coking of heating equipment does not begin, although in some cases (depending on the composition of the raw materials), the heating temperature of the raw materials can be even higher. Simultaneously with heating, the raw material can also be subjected to thermal cracking. The heavy high molecular weight liquid separation part (high boiling fractions of VKF) obtained after the separation apparatus is heated in a heating furnace of VKF (heater) separately from the raw material to a temperature above 300 ⁰ C or heated and subjected to thermal cracking. Typically, the heating of the liquid part of the separation in one pass through the coil of the furnace or heater does not exceed 250 ^° C, but may be more, and the mass fraction of VKF subjected to thermal cracking in the heating furnace or heater does not exceed 50% to prevent intense formation of coke deposits on the surfaces of coil heaters. Preferably, the VKF speed in the furnace coil (heater) should be higher than 1 m / s (optimally 3 ÷ 10 m / s), which can significantly reduce or even avoid coking of the coil (heating channel VKF). Then the raw materials and heated VKF are sent to the direct mixing device, in which the raw materials are finally heated, and they are heated to a certain subcritical temperature, which is lower than the onset temperature of the avalanche-like uncontrolled thermal cracking, but not more than 300 ⁰ C (depending on the composition and properties of the initial raw materials), i.e. heated so that uncontrolled thermal cracking has not yet begun. Direct contact of VKF, heated to a high temperature (for example, up to 400 ⁰ C and higher, depending on the process conditions), and colder oil or other liquid hydrocarbon feedstocks (for example, at a temperature of 200 ⁰ C) leads to an explosive nature of the heating of the feedstock, the occurrence of oscillations and local cavitation zones, which in turn initiates thermomechanical cracking of heavy molecules of raw materials and VKF already in the mixing device. Then the mixture of raw materials and VKF is sent to a thermomechanical cracking device, in which the mixture to initiate a controlled process of breaking the bonds of molecules (thermomechanical cracking) is subjected to mechanical and wave effects of a different nature and a wide range of frequencies, for example cavitation, sound, ultrasonic vibrations, and for cavitation processing heated to subcritical temperature of the raw material and the imposition of acoustic exposure use such devices, the action of which is based on hyd dynamic effects movement of multiphase fluids at speeds exceeding 5 m / s for channels of various shapes. The specific speed value is chosen empirically based on the analysis of separation products (NKF and VKF). The mixture processed in the thermomechanical cracking device sent to the separation apparatus, in which the processed mixture of raw materials and the heavy high molecular weight liquid separation part (high boiling fractions of VKF) are separated into the light vapor-gas part (low boiling fractions of NKF) and the heavy liquid part of separation (high boiling fractions of VKF). To increase the interfacial surface of the separated media and to more efficiently and quickly separate them, a mixture of raw materials and VKF is sprayed (dispersed) into the separation apparatus with a decrease in pressure. The heavy liquid part of the separation (high-boiling fractions of VKF) after the separation apparatus, mainly with a boiling point above 350-360 ⁰ C, is partially sent to the block for producing heavy commercial products (such as coke, bitumen, bitumen emulsions, coatings, oils and others) in place preparation and processing of raw materials according to this invention or cooled and transported to a remote place to obtain heavy commercial products. Partially return to the reprocessing according to this invention at the beginning of the process to increase the yield of light products and the depth of processing, and the return part of the VKF is circulated in a closed loop - separation apparatus, VKF heating furnace (heater), separation apparatus, the ratio of the costs of the circulating VKF and raw materials is range l ÷ SO. The light gas-vapor part (NKF), which contains both light fractions of the feedstock and light fractions of the products of thermal cracking VKF and thermomechanical cracking of a mixture of raw materials and VKF, is sent to the separation device (filtration, droplet separation, rectification), and the temperature in the separation device corresponds to the maximum the end boiling temperature of light fractions of the desired commercial products, for example 350-360 ⁰ C for the diesel fraction. This boundary temperature can be changed depending on the set tasks and requirements for the resulting products. After the separation device, light reaction fractions, mainly with a boiling point up to 350-360 ⁰ C, are sent to the unit for producing light commercial products (such as liquefied gas, gasoline, kerosene, diesel fuel, petrochemical products) at the place of preparation and processing of the raw materials of this invention , or after cooling and condensation is transported to a remote place to obtain light commercial products. The filtrate after the separator to obtain an additional amount of light target products is returned to the reprocessing at the beginning of the process together with the circulating part of the VKF. Devices for mixing raw materials and VKF, wave and mechanical processing of the mixture, dispersion (spraying), and separation of the combined gas and vapor separation of NKF are built into the apparatus for separating the mixture into liquid (VKF) and combined gas (NKF) parts, and the quality of the separation products and their ratio depending the properties of the feedstock are controlled by the temperature and pressure of the circulating VKF at the outlet of the furnace (heater) and raw materials, the temperature and pressure of the mixture in the separation apparatus, the temperature of the NKF in the separator, the flow of raw materials, circulating liquid Asti CCF and their ratio, and the raw speed of the circulating liquid portion CCF and mixtures thereof in the mixing device, processing the dispersion (spraying). The speed control of raw materials, the circulating liquid part of the VKF and their mixtures in the mixing and processing devices can be carried out by changing the mechanical parameters of the design of these devices. The separation level of the combined-cycle phase of the NKF and the liquid phase of the VKF in the separation apparatus is maintained at given values of the above technological parameters by the value of the consumption of HCF directed to obtain heavy commercial products, and the number of built-in the apparatus for mixing raw materials and VKF, processing and dispersing (spraying) the mixture can be more than one of each type and depends on the productivity of the processing industry. It is quite effective to use a distillation column as a separation apparatus, while the heavy high molecular weight liquid part of the separation (high boiling fractions of VKF) is the bottom residue, and the sum of all other light fractions after the column is low boiling fractions of NKF.

It is possible to use rotary-pulsation devices (RPA), light and radioactive irradiation devices, sound and ultrasound from various types of external sources (piezo-emitters, magneto-emitters, and other devices) as reagents and catalysts as processing devices for raw materials, VKF, and their mixtures.

The installation may include a device for mixing preheated raw materials and circulating VKF to the furnace (heater) heating VKF. In this case, the VKF heating furnace (heater) is used to heat the mixture of raw materials and VKF to subcritical temperature or to heat and thermally crack the mixture. The mixture is then sent to a thermomechanical processing device, to a dispersant and to a separation apparatus, after which the NKF and VKF obtained after the separation apparatus are sent as described above.

Both parts of the separation (NKF and VKF) can be sent to the mixing device to obtain synthetic oil with an increased potential content of light fuel products and significantly lower density and viscosity compared to the feedstock, which is then sent for further in-depth processing, and the mixing device VKF and NKF may be built into the separation apparatus. After the unit for producing heavy commercial products (coke, bitumen, bitumen emulsions, coatings, oils and others), a light distillation is usually obtained, which is returned to the beginning of the process for reprocessing together with the raw material to obtain an additional amount of light target products. The bottom (heavy) residue after the unit for producing light commercial products (such as liquefied gas, gasoline, kerosene, diesel fuel, petrochemicals), for example, this is the bottom residue after the distillation column, is returned to the beginning of the process for reprocessing together with raw materials to obtain additional quantities light target products. Depending on the task and the raw materials can be preheated in recuperative heat exchangers due to the heat of commercial products. During the cracking process, coke particles and other mechanical impurities can be formed, the ingress of which is undesirable into the circulating VKF and further into the pump and heater, therefore, a device for cleaning VKF from harmful impurities, solids and coke particles is built into the circulation circuit of the VKF part. Together with liquid hydrocarbon feedstocks, gaseous hydrocarbons, which are also hydrocarbon feedstocks, such as associated or natural gas, gas fractions obtained during the refining process, in particular according to this invention, and solid hydrocarbons in the form of a fine powder can also be sent for advanced processing. The positive effect is also provided by the fact that the feedstock and / or circulating high boiling fractions of the FCF are subjected to mechanical and wave processing and / or thermomechanical (non-catalytic) cracking in front of the mixing device.

Directly the apparatus for the separation of hydrocarbons into the light vapor-gas separation part (low boiling fractions of NKF) and the heavy liquid part of separation (high boiling fractions of VKF) is a capacitive apparatus that contains a housing, fittings for input and output of working and product media, fittings and devices for monitoring the technological parameters of the apparatus (temperature, pressure). In addition, in the separation apparatus through additional fittings and nozzles are integrated: a device for mixing raw materials with a heated heavy high molecular weight liquid separation part (circulating VKF), a thermomechanical cracking device in which a mixture of raw materials and VKF is heated to a certain subcritical temperature to initiate a controlled process of breaking bonds molecules (thermomechanical cracking) are subjected to mechanical and wave effects of a different nature and a wide range of frequencies, for example, cavitation radiation, sound, ultrasonic vibrations, a device for spraying (dispersing) the mixture into the apparatus to increase the interfacial surface of the separated media and to more effectively and quickly separate them. A separation device (filter, droplet separator) of the vapor-gas separation part (NKF) is built into the upper part of the apparatus, after which the purified NKF leaves the apparatus and is sent to obtain marketable products, and the filtrate by gravity enters the lower part of the apparatus and mixes with VKF. In the process of cracking the feed and HCF, unsaturated hydrocarbons are formed. To reduce the number of unsaturated ones in the NKF and in the final products, a block or device with a catalyst is built into the separator, for example, in the form of a basket with catalyst granules filled in it. By analogy with catalytic cracking, there is a decrease in unsaturated compounds and an increase in isomers, i.e. Improving the quality of NKF and final products. At if necessary, molecular hydrogen, light hydrogen-containing media enriched with hydrogen, for example, natural or associated gas, light shoulder straps of gasoline fractions and others, are fed into the block with the catalyst. The temperature in the separation device corresponds to the maximum temperature of the end of boiling fractions of light target commercial products, for example 350-360 ⁰ C for a diesel fraction. The separation level of the combined-cycle phase of the NKF and the liquid phase of the VKF is lower than half the height of the separation apparatus, and a fitting is built into the device’s body for controlling the level of the phase separation and maintaining it in the set value by the flow rate of the VKF sent to the production units of heavy commodity products with the given other values technological process parameters. In the lower part of the apparatus, a VKF separation device is built into parts, a part of the VKF is sent for the production of heavy commercial products (such as coke, bitumen and others), and the other part returns to the beginning of the process and circulates in a closed circuit - a separation apparatus, a heating furnace (heater), separation apparatus. The number of devices for mixing raw materials and VKF, processing and spraying (dispersing) the mixture built into the device can be more than one of each type and depends on the productivity of the processing industry. Besides. A separator is installed in the lower part of the apparatus - a sump for separating from VKF the part necessary for circulation and for cleaning the circulating part of VKF from coke particles and other mechanical impurities. In order to optimize gas-vapor and liquid flows in the apparatus and the separator, to more clearly separate the liquid phase from the gas-vapor and rectification of the latter, internal devices such as distillation plates of various designs, Rashig rings, nets are built into the apparatus and separator. For carrying out commissioning The separation apparatus has built-in heat exchangers or a steam-heated jacket. The structural dimensions of the separation apparatus, separator and other elements depend on the productivity of the processing complex, the composition of the raw materials and the task for its processing.

The device for mechanical and wave processing is combined with the device for mixing and dispersing the mixture and can be called as “Tyrbodinoamichesky Disintegrator)) (TDD). Its task is to carry out direct heating of the raw material (medium 1) due to the heat of the superheated VKF (medium 2), cavitation and acoustic treatment of the mixture of raw materials (medium 1) and VKF (medium 2) and dispersing (spraying) the treated mixture into the separation apparatus.

As mentioned above, the phenomenon of cavitation occurs during the flow around obstacles and poorly streamlined bodies, especially with sharp edges and edges. There is a disruption of the flow with the appearance of a zone of low pressure and the formation of caverns, i.e. cavitation bubbles. When the bubbles collapse, shock pulses of high pressure (hundreds of atmospheres and more), local areas of a strong increase in temperature (hundreds and thousands of degrees) arise. Because Since bubbles are formed in different sizes, when the bubbles collapse, waves of a wide spectrum of frequencies appear, i.e. there is a mechanical and acoustic impact on the medium being treated. The cavitation phenomenon is widely used in various fields of technology, in particular, for the intensification of various chemical reactions and transformations.

Since tiny bubbles of gas or vapor are always present in a real liquid, moving with the flow and falling into the region of low pressure, they lose stability and acquire the ability to grow unlimitedly. After going to the zone increased pressure and exhaustion of the kinetic energy of the expanding fluid, the growth of the bubble stops and it begins to contract. If the bubble contains a lot of gas, then when it reaches the minimum radius, it is restored and performs several cycles of damped oscillations, and if there is little gas, then the bubble completely closes in the first period of life. Therefore, near the streamlined body (obstacle), a rather clearly defined “cavitation zone” is created, filled with moving bubbles.

The contraction of the cavitation bubble occurs at high speed and is accompanied by a sound pulse (water hammer), the stronger, the less gas the bubble contains. If the degree of cavitation development is such that many bubbles appear and collapse at random times, then the phenomenon is accompanied by strong noise with a continuous spectrum from several hundred Hz to hundreds and thousands of kHz. An increase in the flow rate after the onset of cavitation causes a rapid increase in the number of cavitation bubbles, after which they are combined into a common cavitation cavity. If the cavitation cavity is slammed close to the streamlined body, then repeatedly repeated impacts lead to the destruction (to the so-called cavitation erosion) of the surface of the streamlined body, therefore, the velocity of the processed medium should be sufficiently high (based on the experience of more than 5 m / s) so that the bubbles do not managed to slam close to the body, and slam away from the streamlined body, then cavitation will be voluminous and will not lead to the destruction of the streamlined body.

Cavitation more easily occurs in real liquids, as low tensile strength of real liquids is associated with the presence of so-called cavitation nuclei in them: poorly wetted areas solid body, solid particles with cracks filled with gas, microscopic gas bubbles that are protected from dissolution by monomolecular organic shells, ionic formations that arise under the influence of cosmic rays. If atmospheric air or another gas is introduced into the cavity through the body near which cavitation occurs, then the size of the cavity increases. Cavitation flows resulting from the supply of gas into the cavity are called artificial cavitation. In the case of artificial cavitation during the movement of a body in a fluid (or fluid near a streamlined body) at a speed of b ÷ 10 m / s, the same effects of its flow around can be obtained as at speeds of about 100 m / s. In the case of processing a heated hydrocarbon liquid according to the present invention and during its cracking, a gas phase always occurs, which is the nucleation of cavitation. The amount of the gas phase can be controlled by pressure in the processing device so that the amount of the gas phase does not exceed 25% by mass. (Kornfeld M., Elasticity and Strength of Liquids, M. - L., 1951; Birkhoff G., Saarantonello E., Sprays, Traces and Caverns, Per. English, M., 1964: Pernik A. D., Problems cavitation, 2nd ed., L., 1966.).

The acoustic and cavitation processing device (turbodynamic disintegrator) is equipped with two inlet pipes for two inlet media (medium 1 is raw material, medium 2 in this case, VKF), two vortex inserts (swirlers) for two inlet media, and a cylindrical mixing chamber for input media installed directly after the input swirls. The diameter of the mixing chamber is chosen so that the speed of the mixture is greater than 0.1 m / s, usually from the range 0.1 - 10 m / s, but this speed may be greater. The specific speed value is determined by the analysis of fractions obtained as a result of processing and products i.e. determined experimentally depending on the feedstock and the task. Partial cavitation and acoustic treatment of the input media and their mixtures occurs already in swirls when the media move at high speeds, and in the mixing chamber, when raw materials and VKF are heated to a high temperature, but the effect is enhanced when the main cavitators are installed. The cylindrical chamber can be interspersed with confuser and diffuser inserts, which leads to an increase in the velocity of the transverse motion of the media, an increase in the amplitude of the transverse vibrations and an increase in the process of mixing the two media (the parameters of the inserts are determined empirically depending on the composition of the raw material and the task). The cavitator is installed after the mixing chamber and is made in the form of a flat, concave or convex (as one of the options - in the form of a cone) along the movement of the mixture of two input media of the figure, installed across the flow and closing the entire flow cross section. To increase the number of cavitation and acoustic treatment zones formed on the entire surface of the cavitator, through round holes with diameters from 0.1 to 100 mm were made as nodes for the formation of cavitation zones. To worsen the streamlining, the holes can be made with sharp jagged edges. The diameter and number of holes depend on the flow rate of the processed mixture, the diameter and number of holes is chosen so that the speed of the mixture in the holes exceeds 5 m / s. After the cavitator, an outlet swirler is located for a mixture of input media (to improve dispersion of the mixture) and a nozzle. The swirls and nozzle are designed so that the flow velocity in the channels of the swirls and nozzle is higher than 5 m / s. The specific value of the velocities in the holes of the cavitator and the channels of the swirler is determined by the results of the analysis obtained as a result of processing fractions and products, i.e. determined experimentally depending on the feedstock and the task. The swirl channels are made in the form of two-start or multi-start (the number of channels is at least two, optimally 2 ÷ 3) tangential channels or channels in the form of Archimedes spirals (linear function in polar coordinates, easy to manufacture), screw or screw spirals, twisting channels of another shape . The ratio of the height of the channel (spiral) to its width is in the range from 1 to 10. The rotation of the medium in the channels can be either left or right, the direction of rotation of the two media can coincide and / or be multidirectional, this does not give a big difference in the results. The location of the cavitator between the mixing chamber and the output swirl for the mixture of input media and the nozzle is selected from the condition of maximum intensity of cavitation and acoustic effects on the mixture of input media, which is also determined experimentally. The holes in the cavitator can be in the form of rectangles, asterisks, ellipses and other flat figures (as one of the options with sharp jagged edges), and the shape and dimensions of the figures are chosen so that the ratio of the perimeter of the figure to its area is maximum to increase the zone of flow stall. The dimensions of the holes (the minimum and maximum distances between the two points of the perimeter of each hole) are in the range from 0.1 to 100 mm, and the medium velocity in each hole exceeded 5 m / s. The device can be installed 2 or more cavitators, which leads to an increase in the nodes and zones of formation of cavitation. The distance between the cavitators, as well as the distance between the mixing chamber, cavitators and the nozzle, is selected from the condition of maximum intensity of cavitation and acoustic impact on the mixture of input media, determined empirically. Instead of holes to increase the number of cavitation and acoustic treatment zones formed, the cavitator can be made in the form of filling balls, cylinders, parallelepipeds, sprockets, tori, dumbbells, Raschig rings and other rigid volumetric figures. Dimensions of volumetric figures are in the range from 0.1 to 100 mm, the velocity of the medium in all the gap between the backfill elements must exceed 5 m / s. The filling can be inserted into a container, for example, mesh, for the convenience of changing elements of various filling and moving the cavitator (container) along the axis of the processing device to find the optimal location to create maximum intensity of cavitation and acoustic effects on the mixture of input media. The number of containers may be more than one, and with various filling. The gas part of the mixture at operating pressure should not exceed 25% (otherwise the cavitation effect worsens) mass and is regulated by the pressure in the device. The nozzle is made in the form of a cylinder, cone or Laval nozzle, as well as another shape based on the goal of better atomization of the mixture.

If a plant is used in which the raw materials and circulating VKF are mixed before the VKF heating furnace, and the heated mixture is further supplied to the acoustic and cavitation processing device (turbodynamic disintegrator), then a mixture of raw materials and VKF is fed to each inlet pipe of the processing device, and the number of inlet pipes may be more than two.

In order to achieve 100% processing depth and reduce unsaturated hydrocarbons to almost zero level, fittings or nozzles for introducing molecular hydrogen and / or light hydrogen-containing media and / or active hydrogen and / or light radicals into the mixing chamber and / or into the treatment zone in front of and / or behind the cavitator, or the device (unit) for producing active hydrogen and / or light radicals is integrated into the processing device. One of the simplest options that was used in the experiments is that the cavitator is made in the form of a cone or a convex along the flow of the figure in the form of a cone or a truncated cone with an angle at the apex of the cone of more than 10 degrees, and on the entire surface of the cavitator as the nodes of the formation of cavitation zones made through holes with an effective diameter of from 0.1 to 100 mm At high consumption of raw materials for processing, so as not to reduce the quality of spraying the mixture, the number of outlet swirlers and / or nozzles built into the processing device can be more than one of each type. Not only the cylindrical sections of the mixing chamber, but also the cylindrical sections of the motion of both media before mixing can be interspersed with confuser and / or diffuser inserts. With a large gas part and high pressure in the device, the output swirl may not be used.

Raw materials heated by circulating VKF to subcritical temperature (vibrational levels of molecules are already excited, but avalanche-like breaking of molecules due to this excitation still does not occur) is sent to a processing device in which the raw materials are subjected to mechanical (for example, cavitation) and wave effects of various nature (sound, ultrasonic , cavitation, electromagnetic, light, radiation, etc.) and a wide range of resonant frequencies. A wide range of frequencies is needed because the number of combinations of compounds of carbon atoms, hydrogen and other elements, especially in polyatomic molecules the raw material is very large, and has not yet been studied in detail; therefore, the number of different vibrational levels excited by preheating is also very large. The application of mechanical and wave action on the raw material heated to a subcritical temperature by a thermal method allows initiating and activating the thermomechanical cracking process, i.e. the process of breaking bonds of already excited molecules, in this case, in contrast to conventional thermal cracking, the initiated process of breaking bonds by applying a resonant action is controlled by the intensity and nature of the applied effect. The thermomechanical cracking process becomes controllable rather than avalanche-like, which leads to a decrease in coking of equipment, an increase in its overhaul mileage, the process is continuous. Because the raw materials are already heated almost to a critical state, processing it with any type of exposure does not require large energy costs, i.e. initiating resonant action allows you to control the process. The products of thermomechanical initiated cracking are better than the products of thermal cracking, they have fewer gases and unsaturated compounds, and the yield of light products is 1.5-15 times higher than their potential content in raw materials depending on the composition of the raw materials (heavy oil, fuel oil, etc.). d.). Because the wave action is applied to activate the breaking of bonds already in the excited molecules, its energy is spent only on the activation and control of the thermomechanical cracking process, then the energy costs are low. Chemical reagents and catalysts are not used in the process. Thus, cracking can occur in three devices: in a circulating VKF heating device, in a raw material and VKF mixing device, and in a processing device (thermomechanical cracking). Depending on the composition and properties of the raw materials, the technological parameters of the process and the task, cracking can occur in only one device, in any two or all three.

For cavitation treatment of oil heated up to subcritical temperature (or other liquid hydrocarbon raw materials) and acoustic impact on it, various devices are used in the implementation of the invention: hydrodynamic devices, rotary-pulsation apparatuses (RPA), etc. In the framework of the present invention, it is most optimal to use such special devices, the action of which is based on the hydrodynamic effects of medium movement with a high (more than 5 m / s) velocity along channels with obstacles and turns of various shapes, which leads to the appearance of local zones of reduced pressure in which the process the evaporation and separation of the light cracking phase proceeds more intensively, and at sufficiently high temperatures, thermomechanical cracking of the feedstock occurs with the receipt of an additional amount of light fra ktsy. With this approach, the cavitation and acoustic treatment process occurs in the entire volume of the treatment zone, and not only in the near-surface zones, as when using, for example, rotary-pulsation apparatuses (RPA).

After processing and carrying out the thermomechanical cracking process, the raw materials are sent to the evaporation and separation apparatus, in which the vapor-gas part (low boiling fractions of NKF) is separated from the liquid (high boiling fractions of VKF). As the most optimal option, the heated mixture of raw materials and VKF is dispersed (sprayed) into a separation apparatus to increase the interfacial surface and more efficiently separate the gas-vapor part from the liquid. As a result, after the separation apparatus, two main products are obtained: the light part of the gas-vapor separation (low boiling fractions of NKF), with a boiling point predominantly up to 350-360 ⁰ C, which can be called very light oil or gas condensate, and a heavy high molecular weight part or liquid separation residue (high-boiling fraction of VKF separation). NKF consists mainly (80-90% due to non-ideal separation) of fractions with a boiling point up to 350-360 ⁰ C. Upon further processing by known methods, fuel products such as gasoline are produced from NKF (boiling range: boiling point - 180- 200 ⁰ C), kerosene (boiling range: 180-200 ⁰ C - 230-240 ⁰ C), diesel (boiling range: 230-240 ⁰ C - 350-360 ⁰ C), petrochemicals such as toluene benzene and others. In the future - light commercial products. VKF consists of heavy fractions with a boiling point predominantly above 350-360 ⁰ C. With further processing by known methods, VKF can produce heavy commercial products, such as coke, bitumen, bitumen emulsions, coatings. In the future - heavy commercial products. The boundary separation temperature of 350-360 ⁰ C is chosen because the end of boiling of diesel fuel is 350-360 ⁰ C. If the guests and requirements for fuel products change over time, the boundary separation temperature can be changed accordingly. Units for the production of commercial products usually include the following well-known processes: hydrotreating, reforming, platforming and other well-known processes (for producing gasoline, kerosene, diesel fuel), processes of the petrochemical and chemical industries, or at the first stage compounding, bitumen block for the production of oxidized bitumen or bitumen block, combined with a vacuum block for the production of non-oxidized bitumen, as well as equipment for the production of bitumen coatings, emulsions, boiler fuel, coke and other commercial products (Petrochemical Handbook. Two volumes. Volume 1, edited by Ogorodnikov CK. L. Chemistry, 1978, pp. 53-55).

When implementing the present invention, it is proposed, as one of the simplest and best options, to heat the raw material to subcritical temperature, use the heavy residue of the separation of liquid hydrocarbon raw materials (liquid phase separation VKF), obtained directly during the implementation of the invention, the necessary part of which returns to the beginning of the process. The use of VKF for heating the liquid phase (it does not need to be specially prepared or purchased, it appears during the implementation of the invention) with a boiling point predominantly above 360 ⁰ C allows you to increase the operating temperature in the separation apparatus, to intensify thermal and / or thermomechanical cracking and, accordingly, increase the depth of processing and the yield of light products above their potential content in the feedstock, as well as simplify and reduce the cost of equipment and reduce energy and operational costs, and also allows optimal and rational use of raw materials, because with in-depth processing, a smaller amount of oil or other liquid hydrocarbon feedstock is required to obtain a certain amount of marketable products. Direct contact of VKF, heated to a high temperature (for example, up to 400 ⁰ C and higher, depending on the process conditions), and colder oil or other liquid hydrocarbon feedstocks (for example, at a temperature of 200 ⁰ C) leads to an explosive nature of the heating of the feedstock, the occurrence oscillations and local cavitation zones, which in turn initiates thermomechanical cracking of heavy oil molecules already in the device for mixing raw materials and VKF and leads to an increase in the yield of light fractions (gasoline, kerosene, diesel, petrochemical products) by 1.5-15 times, depending on composition of raw materials (heavy oil, fuel oil, etc.). The circulating VKF must be heated not lower than 300 ⁰ C, and the preliminary heating of the raw material before mixing it with the VKF should be no higher than 450 ⁰ C in order to avoid coking. At the same time, part of the VKF necessary for heating the raw material to a subcritical temperature circulates in a closed circuit: the separation apparatus — the heating furnace (heater) VKF — the separation apparatus, and the ratio of the circulating VKF to the raw material is in the range of l ÷ SO. It should be borne in mind that VKF must be heated before it is mixed with raw materials (in contrast to the method according to copyright certificate SU 1558879, in which a mixture of raw materials and a heavy separation residue is heated, which leads to an increase in pressure in the coil due to the presence of light fractions in the raw material, plugs, coking, etc., while the heating temperature cannot be raised above 380 ⁰ C, which ultimately leads to only 69-78% of light petroleum products from their potential content in the feedstock and to speak here about increasing depth foreman edema, i.e. obtaining light light products above their potential content in raw materials, is not necessary). Raw materials and VKF can be heated in the same furnace or heater, but in separate coils. A device for heating raw materials by direct contact with VKF to a subcritical temperature, devices for processing, dispersing and separating raw materials into combined-cycle and liquid phases are combined in one apparatus, which leads to a decrease in the amount of equipment and lower capital and operating costs. The vapor-gas part of the NKF separation, due to the intensively conducted process of evaporation and separation, contains, in addition to light fractions in a gaseous form, and liquid droplets containing heavy high-boiling components with a boiling point above 350 - 360 ⁰ C. Therefore (if necessary, t. to. depends on the properties of the raw materials and the task) first NKF sent to the separation device (drop separation, filtration or rectification), usually built into the separation apparatus, then sent for further use and receipt of goods ny products, since NKF contains mainly gas, gasoline, kerosene and diesel fractions, petrochemical products. The filtrate after separation devices is sent for re-treatment to obtain an additional amount of light target fractions and increase the depth of processing. It is advisable to direct the vapor phase of the NFC to, for example, rectification and further production of light commercial fuel products or petrochemicals on the spot, or, after cooling, to realize for further advanced processing as high-grade oil, similar in composition to gas condensate (the content of light products - gasoline, kerosene and diesel fractions - up to 90% or more in the combined cycle gas condensate fraction). The liquid part of the VKF after the separation apparatus is fed, for example, to a bitumen reactor with a vacuum column to obtain marketable bitumen or other heavy products such as bitumen emulsions, coatings, etc. on site, or, after cooling, they are sold as intermediates for further processing. Because the liquid part of the separation (VKF) due to non-ideal separation contains some small amount of light fractions with a boiling point below 360 ⁰ C, then upon receipt of heavy commercial products (bitumen in a vacuum plant and others) there may be a slight distillation, which is returned, if necessary (depending on the properties of the raw materials and the task), at the beginning of the process for reprocessing and obtaining an additional amount of light target products.

In the process of cracking the feed, unsaturated hydrocarbons are formed, which can subsequently condense, which leads to a limitation of the processing depth. For the most complete and deep processing and increase the yield of light target products and fractions, the processing unit should be supplemented with a device that allows saturating open bonds with atomic hydrogen and / or light radicals with minimal costs. The problem can be solved by such a process organization in which the feed and the catalyst do not contact, as a result of which the catalyst is practically not poisoned by harmful impurities and does not coke, which leads to an increase in the durability of the catalyst and the absence of the need for regeneration processes. To achieve a high processing depth, the raw material or part thereof is subjected to the processing process according to this invention repeatedly. For this, molecular hydrogen and / or light hydrogen-containing media enriched with hydrogen, for example, associated gas, natural gas, including gas obtained during preparation and advanced processing, pentane fractions, xylene, toluene, some light fractions, including obtained in the process of preparation and deep processing, etc., if necessary, they are heated and sent to produce active atomic hydrogen and / or light radicals to a reactor with a catalyst heated to the required temperature (atomic hydrogen production unit ode), after which the active hydrogen and / or light radicals are sent to the cracking devices for the reaction, to the heating device and VKF cracking, into a device for mixing heated VKF and raw materials, into a thermomechanical cracking device, in which a mixture for initiating a controlled process of breaking bonds of molecules (thermomechanical cracking) is subjected to mechanical and wave effects of a different nature and a wide range of frequencies, for example, cavitation, sound, ultrasonic vibrations moreover, atomic hydrogen and / or light radicals can be directed only to one of the cracking devices, to any two devices and to all three cracking devices, as well as between these devices. In addition, atomic hydrogen and / or light radicals can be introduced into the separation device for reaction with NKF, in which there are radicals cracking raw materials and VKF. This will lead to a decrease in unsatisfactory in the NKF and improve the quality of the final products. It is also useful to introduce atomic hydrogen and / or light radicals in NKF and VKF after the separation apparatus to improve their quality. It is also useful to introduce molecular hydrogen and / or light hydrogen-containing media into all of the above devices and between them, but the effect will be much weaker, because the probability of the formation of atomic hydrogen and / or light radicals under the influence of cavitation and acoustic vibrations is much less than in a reactor with a catalyst. The pressure in the reactor with the catalyst should be greater than the pressure in the cracking devices. At the same time, atomic hydrogen and / or light radicals saturate open bonds of unsaturated hydrocarbons to obtain light target fractions, and with repeated re-treatment of VKF, almost 100% of the processing depth and yield of light target products can be achieved. The reaction products are sent to the units for obtaining marketable products, or sent to the separation apparatus, light target reaction fractions after the separation apparatus, mainly with an end temperature boiling up to 350-360 ⁰ C, sent to the unit for obtaining the target marketable products such as liquefied gas, gasoline, kerosene, diesel fuel, petrochemical products at the place of preparation and deep processing of raw materials according to this invention or transported to a remote processing site to obtain light marketable products.

At the same time, such expensive processes as hydrotreating, rimming, etc. in the blocks for the production of light commercial products may not be used, because open bonds of the cracking radicals of the raw material are saturated to the unit for obtaining marketable products, and the properties and composition of the obtained fractions are adjusted by changing the mode and process parameters. In addition, in the processing of raw materials according to this invention, the amount of harmful impurities, such as sulfur compounds, is reduced, because during the processing, the bulk of the sulfur is transferred to hydrogen sulfide and then removed from the process by known methods with the further production of, for example, atomic sulfur and other useful by-products.

If the production of molecular hydrogen is currently a rather expensive process, the use of natural or associated gas, which in many cases is flared, for the production of atomic hydrogen and / or light radicals, minimizes the cost of the downstream process.

The heavy residue after the separation apparatus (VKF), mainly with a boiling point of 350-360 ⁰ C, is sent to the block for the production of heavy commodity products such as bitumen, coke, or partially or completely sent for re-processing according to this invention at the beginning of the process. Solid hydrocarbon feedstocks (e.g., coal, shale, vegetable products) are sent to a fine grinding unit and they are introduced into the feedstock and / or a heavy separation residue before it is processed again, gaseous hydrocarbons are also introduced into the feedstock and / or a separation residue before it is processed, liquid, solid and gaseous hydrocarbons can be processed in the proposed installation simultaneously, individually or in pairs. Part of the gaseous and / or light products (they are enriched with hydrogen and can replace the original hydrogen-containing media) separation can be returned to the beginning of the process in a reactor with a catalyst to produce active atomic hydrogen and light radicals.

Heavy raw materials do not come into direct contact with the catalyst, poisoning and coking do not occur, there is no need for catalyst regeneration, the process is simplified and becomes more reliable, the cost of the process and equipment is significantly reduced, i.e. there is a decrease in capital and operating costs, the processing depth can be increased to 100%. At the same time, there is a saving of raw materials in the development of the required number of target commodity products, in other words, the optimal and rational use of raw materials in their further processing. In addition, various residues and wastes that accumulate in the process, for example, oil production and refining, lead to environmental degradation, and their processing according to this invention with the production of highly liquid products allows solving environmental problems, as well as making additional profit.

To obtain atomic hydrogen and / or light radicals, the use of catalysts is most optimal. For this, gaseous molecular hydrogen, hydrogen-containing media and / or the reactor with the catalyst is heated to a temperature of 300 - 500 ⁰ C, and sometimes even higher (although over time more efficient catalysts can be found that will allow the formation of hydrogen and / or light radicals at lower temperatures, for example, at 20 - 100 ⁰ C and below). The processes of catalytic decomposition of hydrocarbons are widely known. At the same time, during the interaction of hydrogen and hydrogen-containing media with molybdenum, cobalt, zinc, vanadium, nickel, aluminosilicate, zeolite-containing and other catalysts, for example, based on aluminum oxide, or other types of catalysts, atomic hydrogen and / or light radicals are formed, which effectively interacts with hydrocarbon molecules and saturates open bonds of light radicals obtained as a result of the cracking reaction of hydrocarbons, resulting in the formation of saturated light targets good quality fraction. These light radicals, together with the light cracking radicals of the feed, form a light target product molecule. It also happens with other light hydrogen-containing media. Light radicals obtained by detaching active atomic hydrogen from used hydrogen-containing media also attach to light cracking radicals of the feed, saturate their open bonds and form target fractions. If they (or atomic hydrogen) are attached to the heavy radicals of the cracking of the feed, then after the separation apparatus the heavy reaction residue (VKF) is sent partially or completely to the reprocessing according to this invention, or partially or completely to obtain heavy commercial products such as coke, bitumen ( depending on the task). However, much more light radicals are formed during cracking of raw materials, than heavy because most likely, a long raw material molecule breaks in about the middle, and with a much lesser probability is a very small and very large radical. This is evidenced, for example, by thermal cracking processes, as a result of which lighter fractions in larger quantities are obtained from heavy raw materials than heavy ones. Therefore, a significantly smaller amount of separation residue is sent for reprocessing than raw materials. In this case, the separation residue can be sent for re-treatment at the beginning of the process together with the feedstock, or separately for an additional processing unit according to this invention. With repeated reprocessing of the heavy separation residue (VKF), the feedstock will be processed into light target products with an efficiency of up to 100%.

The reactor with the catalyst is made in the form of a cylinder, ball, annular cylinder, parallelepiped (plate) or other volumetric figure, for example, in the form of a tubular coil, with the catalyst placed in it in the form of granules of arbitrary size and shape, the surface of the reactor is permeable to hydrogen atoms and / or light radicals, or holes of arbitrary shape are made on the surface of the reactor, the holes being smaller than the size of the catalyst granules. Or, the walls of a reactor with a catalyst are made of porous material with various pore sizes, for example, in the nanometer range. The reactor with the catalyst may not contain granules or powder of the catalyst, while the shell of the reactor or the entire reactor is made entirely of material that is a catalyst for carrying out the process of producing atomic hydrogen and / or light radicals from molecular hydrogen and / or hydrogen-containing media. Multiple reactors with catalyst (reactor bags). Reactors or reactor packages can be located along the movement of raw materials, across or at an angle. The catalyst body has a collector for distributing hydrogen and / or hydrogen-containing media. The number of hydrogen atoms and / or light radicals produced in the reactor with the catalyst must exceed the number of open bonds of the cracking radicals of the feedstock, and the ratio of the surface of the reactor (reactor pack) with the catalyst to the volume of the heating and / or cracking zone is increased so as to maximize the reaction raw materials and atomic hydrogen and / or light radicals.

Distinctive features of this installation and devices for the preparation and processing of hydrocarbon raw materials allow several processes to be carried out: heat transfer, cavitation and acoustic treatment, evaporation, separation, separation, initiated thermomechanical cracking intensively and simultaneously in one apparatus with minimal capital and operating costs with an increase in the depth of further processing and obtaining high-quality intermediates for further use.

Figures 1 to 5 show enlarged schematic diagrams of a hydrocarbon feed preparation and processing unit.

In FIG. 1 - 5 are indicated: 1 - a device for heating or heating and thermal cracking of VKF; 2 - a device for mixing heated VKF and raw materials and heating the raw materials to subcritical temperature; 3 - a processing and thermomechanical cracking device in which a mixture of raw materials and VKF to initiate a controlled process of breaking bonds of molecules (thermomechanical cracking) is subjected to mechanical and wave effects of a different nature and a wide range of frequencies, for example, cavitation, sound, ultrasonic vibrations; 4 - device for spraying (dispersing) the mixture into the apparatus separation; 5 - separation apparatus; 6 - separation device (filtration, droplet separation, rectification) NKF; 7 - a device for isolating the circulating part of VKF with a sump for cleaning from mechanical impurities and coke particles; 8, 9 - recuperative heat exchangers for preheating of raw materials; 10 - unit for the preparation of light target commercial products (gasoline, kerosene, diesel fuel, petrochemical products - reforming, platforming, etc.); 11 - unit for the preparation of heavy commercial products (bitumen, bitumen emulsions, coatings, coke); 12 - a separate heater for preheating or heating and cracking of raw materials; 13 is a block for the production of atomic hydrogen and / or light radicals. The unit for preliminary purification of raw materials (degassing, dehydration, desalination, purification from mechanical and other harmful impurities) is not shown in the figures for simplicity, nor are the final cooling and condensation units of NKF and VKF in case of their transportation to a remote place of production of marketable products. Units for the production of commercial products usually include the following known processes: hydrotreating, reforming, platforming and others, processes of the petrochemical and chemical industries, or at the first stage a compounding unit, a bitumen block for the production of oxidized bitumen or a bitumen block combined with a vacuum block for the production of non-oxidized bitumen, as well as equipment for the production of bitumen coatings, emulsions, boiler fuel, coke and other commercial products (Handbook of Petrochemistry. In two volumes. Volume 1, under edited by Ogorodnikov CK. L., Chemistry, 1978, p. 53-55).

If the raw materials are not supposed to be used at the place of in-depth processing to obtain marketable products, then it is advisable use the installation option shown in FIG. 1. The circulating high-boiling fractions of the VKF after the separation apparatus are fed to the heating and cracking device of the VKF (Fig. 1, position 1), then to the mixing and heating device of the raw materials (Fig. 1, position 2). Prepared raw materials after preheating in recuperative heat exchangers (Fig. 1, item 8, 9) are also fed to the mixing device with VKF (Fig. 1, item 2). Then the mixture of raw materials and VKF is fed into the processing device (thermomechanical cracking) (Fig. 1, position 3), then the mixture is dispersed (sprayed) (Fig. 1, position 4) with a decrease in pressure to increase the interfacial surface of the separated media in the separation apparatus (Fig. . 1, position 5). After the separation apparatus, the NCP are sent to the separation device (Fig. 1, position 6), after the separation device, light reaction fractions, mainly with a boiling point up to 350-360 ⁰ C, are sent (transported) after partial cooling on a recuperative heat exchanger (Fig. 1 , item 8) and final cooling and condensation (not shown on the installation diagram for simplicity) to the unit for producing light commercial products (such as liquefied gas, gasoline, kerosene, diesel fuel, petrochemical products), the filtrate after the separator for I receive an additional amount of light target products returned for reprocessing at the beginning of the process along with the circulating part of the VKF. Part of the high boiling VKF fraction after the separation apparatus after the circulating VKF separation device (Fig. 1, position 7) is returned for reprocessing (recycling) according to this invention to the beginning of the process to increase the yield of light products and the processing depth, and the returned part of the VKF is circulated in a closed circuit - separation apparatus (Fig. 1, position 5), furnace heating (heater) (Fig. 1, position 1) is a separation apparatus. The other part of the HCF is sent (transported) after partial cooling on a recuperative heat exchanger (Fig. 1, item 9) and final cooling (not shown in the installation diagram for simplicity) to the unit for producing heavy commercial products (such as coke, bitumen, bitumen emulsions, coatings, oils).

If commercial products are produced at the processing site according to this invention, such an installation is shown in FIG. 2. NKF after partial cooling on a recuperative heat exchanger (Fig. 2, position 8) is sent to the unit for obtaining light commercial products (Fig. 2, position 10), and VKF after partial cooling on a recuperative heat exchanger (Fig. 2, position 9) is sent in the block receiving heavy commercial products (Fig. 2, position 11). The bottom residue after the block for the preparation of light commercial products, as well as the light distillation after the preparation of heavy commercial products to increase the depth of processing and yield the target light products, are returned for reprocessing at the beginning of the process together with raw materials or circulating HCFs.

If, for technological reasons, the heat of NKF and VKF is not used for preheating the raw materials, or it is not necessary to cool them for supplying commercial products to the preparation units at the place of application of the invention, then the raw materials are preheated on a separate heater (Fig. 3, item 12), or in the same heater (furnace) in which the circulating VKF is heated, but in a separate coil (Fig. 4, position 1). In these embodiments, the raw materials can not only be heated, but also subjected to thermal cracking. If necessary, you can use separate heaters in conjunction with recuperative heat exchangers to preheat raw materials. For Preheating can also use the heat of commercial products.

In the process of cracking the feed, unsaturated hydrocarbons are formed, which can subsequently condense, which leads to a limitation of the processing depth. For the most complete and deep processing and increase the yield of light target products and fractions, the processing unit is supplemented (Fig. 5) with a device for producing atomic hydrogen and / or light radicals from molecular hydrogen and / or light hydrogen-containing media enriched with hydrogen, for example, natural or associated gas , in particular gas and light shoulder straps of gasoline fractions obtained during processing, which are sent to cracking devices — to the heating and cracking device VKF (Fig. 5, position 1), to the mixing device heated VKF and raw materials (Fig. 5, position 2), into the thermomechanical cracking device (Fig. 5, position 3), and atomic hydrogen and / or light radicals can be sent only to one of the cracking devices, to any two devices and to all three cracking devices. At the same time, atomic hydrogen and / or light radicals saturate open bonds of unsaturated hydrocarbons with obtaining light target fractions, and with repeated reprocessing of VKF (VKF is completely sent for reprocessing and is not used for the production of heavy commodity products, as shown in Fig. 5) almost 100% of the processing depth and yield of light target products can be achieved.

In FIG. 6 shows a separation apparatus. Heated to the required temperature VKF and heated raw materials are fed into the mixing device (Fig. 6, position 2), in which the raw material is heated to subcritical temperature. Then the mixture of raw materials and VKF is sent to the device thermomechanical cracking (Fig. 6, position 3), in which a mixture to initiate a controlled process of breaking bonds of molecules (thermomechanical cracking) is subjected to mechanical and wave effects of a different nature and a wide range of frequencies, for example, cavitation, sound, ultrasonic vibrations, Then the mixture is dispersed ( spray) (Fig. 6, position 4) with a decrease in pressure to increase the interfacial surface of the separated media in the separation apparatus. Moreover, the mixing, processing and spraying devices are combined in one apparatus, which can be called a turbodynamic disintegrator (TDD). The number of built-in TDD in the separation apparatus depends on the performance of one TDD and the total productivity of the processing industry. NKF formed in the gas-vapor form are sent to the separator (Fig. 6, position 6) located in the upper part of the separation apparatus. Separated (filtered) NKF are sent to the unit for the preparation of light commercial products, and the filtrate by gravity enters the lower part of the apparatus and mixes with VKF. All obtained VKF using a device for isolating the circulating part of the VKF (Fig. 6, position 7) are divided into 2 parts. One part is sent to the blocks for obtaining heavy commodity products, the other is sent to heating and then to the mixing device with raw materials and reprocessing (for recycling), and this part circulates in a closed circuit: separation apparatus - VKF heater - separation apparatus. The device for isolating circulating HCFs is made with a sump for purification of mechanical impurities and coke particles so that cleaner HCFs are selected for recycling. In addition, various filtering devices can be provided in the VKF circulation loop, for simplicity on figures not shown. Fittings for input-output of working and product media, fittings and devices for monitoring the technological parameters of the apparatus (temperature, pressure, phase separation level) are built into the body of the separation apparatus. The temperature in the separation device corresponds to the maximum boiling point of the fractions of light target commodity products, for example 350-360 ⁰ C for the diesel fraction and is maintained automatically, the level of separation of the vapor-gas phase of the NKF and the liquid phase of the VKF is lower than half the height of the separation apparatus. The temperature of the phase interface 350-360 ⁰ C is chosen because at present the temperature of the end of boiling of diesel fuel is in this range. If the requirements change, then this temperature will also be changed in the right direction. Distillation plates, Raschig rings can be built into the separator. Then, in the separator, not only the process of droplet separation and filtration will occur, but also the rectification process, which will lead to an improvement in the quality of NKF supplied for the production of light commercial products. Devices for mixing raw materials and VKF, processing (thermomechanical cracking) the mixture, dispersing (spraying), and also separating the gas-vapor part of the separation of NKF are built into the separation apparatus, i.e. make up one whole with it, which leads to a decrease in capital and operating costs, for example, to a decrease in metal consumption and heat loss. If a distillation column is used as a separation apparatus, then a spraying device may not be used, then the bottom residue after the column is VKF, and all light fractions in total comprise NKF.

The processing device — turbodynamic disintegrator TDD — is shown in FIG. 7 to 9. FIG. 7 - 9 indicated: 14 - swirl for medium 1 (in this case, for raw materials); 15 - swirl for medium 2 (in this case, for heavy high-boiling fractions of VKF); 16 - mixing chamber; 17 - cavitator in the form of a truncated cone with holes; 18 - output swirl for a treated mixture of input media; 19 - nozzle. In FIG. 8 shows a device with alternating cylindrical, confuser and diffuser inserts for moving medium 1, two cavitators with holes and a nozzle in the form of a cone. In FIG. 9 shows a device with alternating cylindrical, confuser and diffuser inserts for moving medium 1 and a mixture of media 1 and 2, a cavitator in the form of a mesh basket with filling in the form of balls and a cylindrical nozzle. The device operates as follows. Preheated raw materials (medium 1) are sent to a swirler for raw materials (Fig. 7-9, position 14), heated to high temperature VKF (raw materials 2) are sent to a swirler for VKF (Fig. 7-9, position 15). As a result of direct contact of the feed and VKF in the mixing chamber (Fig. 7-9, item 16), the feed and the entire mixture are heated to a critical temperature. Then the heated mixture of raw materials and VKF is sent to the cavitator (Fig. 7-9, position 17), in which the mixture is subjected to mechanical and wave action of a different nature and a wide range of frequencies, for example, cavitation, to initiate a controlled process of breaking bonds of molecules (thermomechanical cracking), sound, ultrasonic vibrations. The treated mixture is sent to the outlet swirler (Fig. 7-9, position 18) to improve further spraying and dispersed through a nozzle (Fig. 7-9, position 19) with a decrease in pressure into the separation apparatus to increase the interfacial surface and more efficient separation of the mixture into NKF and VKF. The speeds in the channels of all swirlers, cavitator (cavitators) and nozzle (s) should be quite high, at least above 5 m / s. Specific values of speeds are taken empirically based on the composition and properties of the raw materials and the task. The confuser and diffuser inserts increase the transverse component of the speed of the mixture and intensify the mixing process. The parameters of the mixing chamber and inserts are determined empirically.

The present invention is implemented in a pilot plant for the separation of oil and other liquid hydrocarbon feeds with a capacity of up to 30 kg / h, in which all processes and devices for implementing the invention are implemented. In addition, the installation is equipped with various capacitive equipment for storing raw materials and collecting the resulting products, heat exchange equipment for heating the raw materials, heating circulating HCFs and cooling products, pumping equipment and instrumentation. The layout of the bench installation is shown in FIG. 1, the separation apparatus — in FIG. 6, a turbodynamic disintegrator - in FIG. 7. The feedstock used was the oil of the Vishenskoye deposit in the Ulyanovsk Region (Ratov AH, Nemirovskaya GB. Problems of oil development in the Ulyanovsk Region. "Chemistry and Technology of Fuels and Oils", N ° 4, 1995). Oil contains many tarry compounds and impurities. Used oil and other fields, such as NGDU "Nurlatneft", with a different composition, as well as various bottoms, waste oils and other raw materials. The pressure of raw materials and circulating HCFs in bench experiments was up to 1.0 MPa and higher, the temperature of circulating VKFs was up to 450 ⁰ C and higher, the temperature of raw materials was up to 200 ÷ 250 ⁰ C, the ratio of flowing circulating VKF and raw materials was in the range up to 30 and more. At these pressures and temperatures, the linear feed rates of the feed and circulating VKF were more than 5 m / s With an increase in the feed rate and feedstock feed rate, the separation and processing efficiency increases nonlinearly. The choice of the value of the feed rates for a particular technological process depends on the properties of the raw materials, the task at hand and is optimized for several factors, including the economic factor.

Before starting the process of separation of liquid hydrocarbon feedstock, VKF is prepared. VKF, which is essentially a heavy separation residue, can be prepared in various ways, for example, using a simple process of single evaporation of a mixture of hydrocarbons. The simplest method, which was used when working on a bench installation, is as follows. The required amount of liquid hydrocarbon feed is poured into the separation apparatus. From the separation apparatus (Fig. 1, 6, position 5), the mixture is pumped to an electric heater - an analog of an industrial furnace (Fig. 1, position 1) and returned. At the same time, light fractions are continuously removed, accumulating the liquid phase of VKF. With continuous circulation and a certain temperature, a heavy residue (VKF) after a certain time (process parameters depend on the composition of the initial mixture of hydrocarbons) acquires all the necessary properties. Control of the end of the process is carried out by determining the physico - chemical properties and composition of the liquid phase VKF.

Preheated raw materials and heated to the required temperature (Fig. 1, position 1) circulating VKF pumps are fed to swirlers (Fig. 7, position 14, 15), then to the mixing device (Fig. 1, 6, position 2, Fig. 7 , position 16). A mixture of raw materials and VKF is fed to a mechanical and wave processing device (Fig. 1, 6, position 3, Fig. 7, position 17), in which thermomechanical hydrodynamic cracking of raw materials, then the treated mixture is sent to the outlet swirler (Fig. 7, position 18) and dispersed through the nozzle (Fig. 1, 6, position 4, Fig. 7, position 19) into the separation apparatus (Fig. 1, position 5). After the separation apparatus, the circulating VKF is again sent to the heating device (Fig. L, position 1), i.e. for recycling. The gas-vapor part (NKF) after the separation apparatus (FIG. 1, position 5) is sent to the separation device (droplet separation, filtration or rectification), (FIG. 1, 6, position 6), after which the filtrate returns to the beginning of the process together with circulating VKF for reprocessing and additional obtaining of light products above their potential content. The gas-vapor part after the separation device (Fig. 1, 6, item 6) is sent for cooling and condensation and is analyzed. The liquid separation part (VKF) after the separation apparatus (Fig. 1, position 5) and separation from the VKF of the circulating part (Fig. L, 6, position 7) is sent for cooling and analyzed. Devices for mixing and heating raw materials by circulating VKF, mechanical and wave treatment, evaporation and separation into gas-vapor and liquid phases, and the separation device for NKF are combined in one apparatus. This reduces the amount of equipment and, accordingly, capital and operating costs.

The following are some of the results of the separation process. In all cases, mass percent is used.

Example 1

Raw materials - oil deposits of the Ulyanovsk region.

Separation effect: NKF - 78.5% by mass, VKF - 20% by mass, gas yield - 1.5% by mass. The enlarged fractional composition of oil and NKF after processing according to the invention (in terms of oil taking into account the separation coefficient) and some characteristics are shown in table 1.

Table 1

Example 2

Raw materials - oil NGDU "Hyplatneft" (Tatarstan). Separation effect: HKF-77% by mass, BKF-21.5% by mass, losses 1.5% by mass. The enlarged fractional composition of oil and NKF after processing according to the invention (in terms of oil, taking into account the separation coefficient) and some characteristics are shown in table 2. table 2

In tables 1 and 2, the amount of obtained NCP was 77-78.5% by weight, and the total number of fractions up to 350-360 ⁰ C is 70.3-71, 7% by weight. This is due to the fact that the separation process for NKF and VKF is not ideal (even on a distillation column), therefore a small fraction of heavy fractions with a boiling point above 350-360 ⁰ C also get into the NKF catalytic cracking.

If you use the installation option, in which the raw materials and VKF are mixed before heating, and then the heated mixture is fed into processing device and further into the separation apparatus, the results are slightly worse. The number of obtained NKF, as well as the total number of fractions up to 350-360 ⁰ C is 3-5% less than in the tables.

Example 3

Atmospheric - vacuum distillation of the bottoms of Ulyanovsk oil after an atmospheric column (fuel oil) showed the absence of a gasoline fraction in it, the content of the kerosene fraction (240 - 360 ⁰ C) amounted to 2.9% of the mass, diesel fraction (240 - 360 ⁰ C) - 11, 8% of the mass. After processing the investigated bottoms according to the invention, the following results were obtained: the number of low boiling fractions (NKF - the easy part of the separation) was 74 - 79% by weight, depending on the process parameters. The NKF content of the target fuel compositions was 88 - 90% mass, of which gasoline (NK - 180 ⁰ C) fractions - 20.8% mass, kerosene (180 - 240 ⁰ C) - 17.4% mass, diesel (240 - 360 ⁰ C) - 61, 8% of the mass. The total content of the target products with a boiling point up to 360 ⁰ C increased from 14.7% by mass to 71% by mass in terms of the initial product.

Example 4

Atmospheric - vacuum distillation of unused oil M - 8B (universal motor oil) showed the absence of gasoline and kerosene fractions in it, the content of the diesel fraction was 5.2%, the bulk of the oil was distilled in the boiling range 380 - 500 ⁰ C. After processing the test oil 22% of gasoline, 9% of kerosene and 46% of diesel fractions are obtained according to this invention, i.e. the content of the target products with a boiling point up to 360 ⁰ C during the processing according to the invention increased from 5.2 to 77%, i.e. about 15 times. Thus, the principal possibility of thermomechanical cracking of high-boiling (above 360 ⁰ C) oil components into the target products with a boiling point up to 360 ⁰ C was shown. A study of the composition of the used oil M-8B, which underwent processing according to this invention, showed the presence of 19% gasoline in it , 15% kerosene and 38% diesel fractions. In general, the content of the target components with a boiling point up to 360 ^° C during the thermomechanical cracking of used oil was 72%.

Example 5

In the process of cracking the feed, unsaturated hydrocarbons are formed, therefore, for the most complete and deep processing and increase the yield of light target products and fractions, open bonds must be saturated with atomic hydrogen and / or light radicals. The unit is complemented by a unit with a catalyst for producing atomic hydrogen and / or light radicals and is shown in FIG. 5. Hydrogen from the cylinder is heated, fed to the unit for producing atomic hydrogen and / or light radicals (Fig. 5, position 13), then sent to the cracking device for heavy oil (Fig. 5, position 1, 2, 3), the reacted mixture is dispersed (Fig. 5, position 4) with decreasing pressure in the separation apparatus (Fig. 5, position 5). After the separation apparatus (Fig. 5, position 5), the VKF completely returns to the beginning of the process for repeated multiple processing, and the NFC is fed to the separation device (Fig. 5, position 6), after which the NFC is cooled and analyzed. The process is continuous. Some results are shown in table 4. The processing depth reaches 97-98 % Given the generated non-condensed gases, we can confidently talk about almost 100% depth of processing of raw materials using this invention. Unsaturated hydrocarbons within the measurement error were not detected.

Table 3

To achieve practically the same results according to this invention, instead of hydrogen, you can use a propane - butane mixture from a balloon and other light products enriched with hydrogen or fractions. When using a propane - butane mixture from a cylinder instead of hydrogen, the total yield of light target fractions practically did not change and amounted to 97.3% by mass. At the same time, the number of gasoline fractions (with a boiling point up to 180 ⁰ C) decreased by 1.6% by weight, and the number of diesel fractions (with a boiling point from 240 ⁰ C to 360 ⁰ C) increased by 1.7% by weight, the number of kerosene fractions (with a boiling point from 180 ⁰ C to 240 ⁰ C) remained virtually unchanged. With the addition of a propane - butane mixture in the feedstock up to 3%, the yield of the gasoline fraction increased insignificantly (up to 1%). With the addition of up to 3% shale crushed to the size of 0.05-1 micrometer to the feedstock, the yield of light target fractions practically did not change, i.e. part of the solid hydrocarbons was processed into light liquid hydrocarbons.

If molecular hydrogen and / or light hydrogen-containing media, for example, propane - butane from a cylinder, are fed into the cracking devices, i.e. If you do not use a reactor with a catalyst, then the yield of light light fractions (processing depth) will be much lower, and reaches values of 75 - 78%.

Example 6

When conducting experiments on the processing of various raw materials without the use of a device with a catalyst placed in the separator, the amount of unsaturated hydrocarbons in the NKF after the separation apparatus was 27 - 31%, and with the use of a device with a catalyst in the separator (for simplicity in Fig. 6, the device with a catalyst shown) amounted to 18 - 20%. If molecular hydrogen or propane - butane is introduced from a balloon into a device with a catalyst in the separator, the unsaturated amount decreases to 10-12%, and when atomic hydrogen and / or light radicals are used after the reactor with the catalyst, the unsaturated amount decreases to less than 2% .

Example 7

A promising option is that in which the vapor-gas part of the NKF and the liquid part of the VKF obtained after the separation apparatus partially chilled if necessary, mixed again. The resulting “synthetic” oil contains about two or more times more fuel fractions than the original product. In addition, if the density of the initial oil is 950 kg / m ³ (API = 17), then the density of the “synthetic” oil decreases to 850 kg / m ³ (API = 35), and the kinematic viscosity, respectively, from 83 cSt to 6 cSt. As a result of such an operation, the cost of “synthetic” oil increases significantly; it is easier to transport and process. This approach is especially promising for enterprises remote from refineries and producing heavy and viscous oil, such as, for example, in South America, Canada, and in some regions of Russia. In the same way, relatively cheap fuel oil and still cheaper still bottoms, oil sludge can be processed into much more expensive high-potential oil. In this case, environmental problems are solved.

Thus, the present invention allows for industrial in-depth (at the same time there is an increase in the depth of further processing by 1.5-15 times depending on the feedstock - heavy oil, fuel oil, etc.) and highly cost-effective preparation and processing of oil, including heavy, residues of oil refining and petrochemical industries, oil sludge, waste oils, natural bitumen and other liquid and gaseous organic media to produce tested commercial products and can be used in the production of hydrocarbon fuels, petrochemicals, coke, bitumen, etc. Accordingly, the yield of the most valuable and expensive fuel compositions — gasoline, kerosene and diesel fractions, and petrochemical products — is also increasing. Almost 100% processing depth (it is considered by the yield of light target fractions and products) that can be achieved by repeated treatment of heavy fractions of VKF using a unit for producing atomic hydrogen and / or light radicals. In this case, solid hydrocarbons can also be processed efficiently. The proposed installation and devices are easy to operate and do not require large capital and operating costs.

Using the proposed method and installation, it is easy to build highly efficient new and modernize existing oil refining and petrochemical industries to increase the depth of processing and yield the most valuable light commercial products.

Claims

Claim 1. Installation for in-depth processing of hydrocarbon raw materials, including the preparation of raw materials (preliminary purification from water and harmful impurities), supply and heating of raw materials, characterized in that the processing plant contains a separation apparatus in which the hydrocarbon mixture is divided into two parts - a light vapor-gas separation part ( low boiling fractions NKF), mainly with a boiling point up to 350-360 ⁰ C and heavy high molecular weight liquid separation (high boiling fractions VKF), mainly with a boiling point above 350-360 ⁰ C, contains recuperative heat exchangers in which the raw materials are preheated due to the heat of one or all separation products (NKF and VKF), and / or contains a separate heater, in which the raw material is heated to a temperature above 20 ⁰ C or heated and subjected to thermal cracking, contains a furnace (heater) for heating VKF, in which a high molecular weight liquid separation part (high boiling fractions VKF) obtained after the separation apparatus, or its part l heated separately from raw materials to a temperature above 300 ⁰ C or heated and subjected to thermal cracking, the mass fraction of VKF subjected thermal cracking in a heating furnace or heater does not exceed 50%, the installation contains a device for direct mixing of raw materials with a heated high molecular weight liquid separation part (high boiling fractions of VKF), in which the raw materials are finally heated, and the mixture of raw materials and VKF is heated to a certain subcritical temperature, which is lower temperature of the onset of an avalanche-like uncontrolled thermal cracking, but not more than 300 ⁰ C (depending on the composition and properties of the feedstock), i.e. heated so that uncontrolled thermal cracking has not yet begun, contains a thermomechanical cracking device in which a mixture of raw materials and VKF to initiate a controlled process of breaking bonds of molecules (thermomechanical cracking) is subjected to mechanical and wave effects of a different nature and a wide range of frequencies, for example, cavitation, sound , ultrasonic vibrations, and for cavitation processing of raw materials heated to subcritical temperature and application of acoustic impact using such devices, the action of which is based on the hydrodynamic effects of the motion of multiphase media with velocities of more than 5 m / s through channels of various shapes, the apparatus contains a mixture dispersion (spraying) device, into which a mixture of raw materials and VKF processed in thermomechanical cracking is sent and dispersed (sprayed ) to increase the interfacial surface of the separated media and to more efficiently and quickly separate them into a separation apparatus with decreasing pressure, the installation is supplemented a device for producing heavy commercial products at the place of preparation and processing of raw materials according to this invention, to which part of the VKF is sent after the separation apparatus, or contains a cooling device for part of the VKF, after which the cooled VKF is transported to a remote place for receiving heavy commercial products, the remaining part of the VKF is returned to re- processing according to this invention at the beginning of the process (in the heater VKF) to increase the yield of light products and the depth of processing, and the return part of the VKF to the circulation t in a closed loop - separation apparatus, VKF heating furnace (heater), separation apparatus, in the circulation circuit of the VKF part a device for cleaning VKF from harmful impurities, mechanical particles and coke particles is built in, the ratio of the circulating VKF to raw material consumption is in the range l ÷ SO, the installation contains a separation device (filtration, droplet separation, distillation), into which the light steam-gas part of the NKF is sent after the separation apparatus, which contains both light fractions of the feedstock and light fractions of thermal products one cracking CCF and thermo-mechanical cracking and CCF feed mixture, wherein the temperature in the separation device corresponds to a maximum final boiling point temperature of the light ends targeted commercial products, for example 350-360 ⁰ C for a diesel fraction, supplemented installation device for producing light commercial products on site preparation and processing of raw materials according to this invention, to which the NKF is sent, or the installation contains a device for cooling and condensing the NKF, after which NKF is transported to a remote place of receipt of light commercial products, the filtrate after the separator to obtain an additional amount of light target products is returned to the reprocessing at the beginning of the process together with the circulating part of the VKF, and devices for mixing raw materials and circulating VKF, wave and mechanical processing of the mixture, dispersion, as well as the separation of the gas-vapor part of the separation of NKF are built into the apparatus for separating the mixture into liquid (VKF) and gas-vapor (NKF) parts, and the quality of the separation products and their ratio, depending on the properties of the feedstock, is controlled by the temperature and pressure of the circulating VKF at the outlet of the furnace (heater) and raw materials, the temperature and pressure of the mixture in the separation apparatus, the temperature of the NKF in the separator, the consumption of raw materials, the circulating liquid part of the VKF and their ratio, as well as the speeds of the raw materials, the circulating liquid part of the VKF and their mixture in the mixing, processing, dispersing devices, the separation level of the combined-gas phase of the NKF and the liquid phase of the VKF in the separation apparatus is maintained at specified values above of the technological parameters listed, the consumption value of part of the VKF directed to obtaining heavy commercial products, and the number of devices for mixing raw materials and VKF, processing and dispersing the mixture built into the apparatus can be more than one of each type depending on the productivity of the processing production, in addition, the processing unit is supplemented by devices molecular hydrogen and / or lung hydrogen-containing media and / or a reactor with a catalyst for producing atomic hydrogen and / or light radicals from molecular hydrogen and / or light hydrogen-containing media enriched with hydrogen, for example, natural or associated gas, in particular gas and light shoulder straps of gasoline fractions obtained during processing which are sent to cracking devices - to a heating and / or cracking device for circulating VKF and raw materials, to a device for mixing heated VKF and raw materials, to a thermomechanical cracking device or between devices and also to a separation device, wherein molecular hydrogen and / or light hydrogen-containing media and / or atomic hydrogen and / or light radicals can be sent to only one of the cracking devices, to any two devices and to all three cracking devices at the same time, and in the NKF and / or VKF after the separation apparatus, and in the circulation circuit of part of the VKF, a device for cleaning VKF from harmful impurities, mechanical particles and coke particles is built-in. 2. The apparatus according to claim 1, characterized in that a distillation column is used as the separation apparatus, while the heavy liquid part of the separation (high boiling fractions of VKF) is the bottom residue, and the sum of all light fractions after the column is low boiling fractions of NKF. 3. Installation according to claim 1, characterized in that the adjustment of the speeds of the raw materials, the circulating liquid part of the VKF and their mixtures in the mixing, processing and dispersing devices is carried out by changing the mechanical parameters of the design of these devices. 4. The apparatus according to claim 1, characterized in that rotary-pulsation apparatuses (RPA), devices of light, radioactive irradiation, sound and ultrasound exposure from various types of external sources (piezo-emitters, magneto-emitters) are used as raw material processing devices, VKF and their mixtures ), devices using reagents and catalysts. 5. Installation according to claim 1, characterized in that the installation is supplemented by a mixing unit, into which both parts of the separation of NKF and VKF are sent to produce synthetic oil with an increased potential content of light fuel products and a significantly lower density and viscosity in comparison with the feedstock, which then sent to further obtain marketable products, and the mixing device can be integrated into the separation apparatus. 6. Installation according to claim 1, characterized in that the light distillation after the block for producing heavy commercial products is returned to the beginning of the process for reprocessing together with raw materials and / or circulating HCFs to obtain an additional amount of light target products. 7. Installation according to claim 1, characterized in that the still (heavy) residue after the unit for producing light commercial products is returned to the beginning of the process for reprocessing together with raw materials and / or circulating HCFs to obtain an additional amount of light target products. 8. Installation according to claim 1, characterized in that the raw material is preheated in recuperative heat exchangers due to the heat of commercial products. 9. A plant according to claim I _5, characterized in that, together with liquid hydrocarbon raw materials and / or circulating HCFs, gaseous hydrocarbons, for example associated or natural gas, gas fractions obtained in the oil refining process, in particular according to this invention, are sent for advanced processing as well as solid hydrocarbons in the form of a fine powder. 10. The installation according to claim I _5, characterized in that the device has a built-in mixing device for preheated raw materials and circulating high boiling fractions of the VKF to the VKF heating furnace (heater), the VKF heating furnace is used to heat the mixture of raw materials and VKF or to heat and thermally crack the mixture raw materials and VKF, after the heating furnace, the mixture is sent to a thermomechanical cracking device (acoustic and cavitation treatment), to the dispersant and separation apparatus. 1 1. Apparatus for separating hydrocarbon feedstocks into a light vapor-gas separation part (low boiling fractions of NKF) and a high molecular weight liquid separation part (high-boiling fractions VKF), containing a housing, fittings for input and output of working and product media, fittings and devices for monitoring the technological parameters of the apparatus, characterized in that a device for mixing raw materials with a heated high-molecular liquid part is built into the separation apparatus through additional fittings and nozzles separation (circulating high-boiling fractions VKF), built-in thermomechanical cracking, in which a mixture heated to a certain subcritical temperature to initiate a controlled process of breaking bonds of molecules (thermomechanical cracking) is subjected to mechanical and wave effects of a different nature and a wide range of frequencies, for example, cavitation, sound, ultrasonic vibrations, a dispersion device (dispersion) of the mixture is built-in in the volume of the apparatus to increase the interfacial surface of the separated media and more efficient and faster separation, in the upper part of the device The separator (filter, droplet separator) of the gas-vapor separation part (NKF) is built-in, after which the purified NKF is sent to obtain light commercial products, and the filtrate by gravity enters the lower part of the apparatus and mixes with VKF, and the temperature in the separation device corresponds to the maximum temperature of the end of boiling fractions of light target commercial products, for example 350-360 ⁰ C for a diesel fraction, part of the VKF is sent for the production of heavy commercial products, and the other part is returned to the beginning process and circulating in a closed circuit separation apparatus, heating furnace (heater) VKF, separation apparatus, a fitting is built into the apparatus casing for a device for controlling the level of the phase separation and maintaining it in a given value by the amount of consumption of VKF sent to the production units of heavy commodity products at specified values other technological parameters of the process, the number of devices for mixing raw materials and VKF, processing and dispersion (spraying) of the mixture can be more than one of each type, depending on the productivity of the processing industry, and for commissioning, the separation apparatus has built-in heat exchangers or a jacket with steam heating, input devices of molecular and / or atomic hydrogen and / or light hydrogen-containing media and / or light radicals and / or reactors with a catalyst for producing atomic hydrogen and / or light radicals from molecular hydrogen and / or light x hydrogen-rich media enriched with hydrogen, and a device with a catalyst for improving the quality of NCPs is built into the separation device, which, if necessary, is supplied with molecular and / or atomic hydrogen and / or light hydrogen-containing media and / or light radicals, is integrated into the lower part of the separation apparatus separator - sedimentation tank for separating from VKF the part necessary for circulation and for cleaning the circulating part of VKF from coke particles and other mechanical impurities, and in order to optimize gas-vapor and liquid flows in the separation apparatus and separation device, to more clearly separate the liquid phase of the VKF from the vapor-gas phase of the NKF and rectification of the latter, internal devices such as distillation plates of various designs, Rashig rings, nets are built into the separation apparatus and separation device. 12. The device of acoustic and cavitation treatment (turbodynamic disintegrator), including a pipe for inputting the medium to be treated, a cavitator, pipe for output treated medium, characterized in that the device is equipped with two inlet nozzles for two inlet media, two vortex inserts (swirlers) for two inlet media, a cylindrical mixing chamber of the input media, and partial cavitation and acoustic processing of the input media and their mixtures takes place in the swirls and chamber mixing chamber mixing is installed directly after the input swirls, the cavitator is installed after the mixing chamber and is made in the form of a flat, concave or convex (for example, in the form of nusa) along the flow of the mixture of two input media of the figure, installed across the flow and closing the entire cross section of the flow, through the round holes (as one of the options with sharp jagged edges) with a diameter of 0.1 to 100 mm, the diameter and number of holes depending on the flow rate, the diameter and number of holes selected so that the speed of the mixture in the holes x exceeded 5 m / s, after the cavitator there is an output swirl for a mixture of inlet media and a nozzle, and all swirls (inlet and outlet) and a nozzle are made so that the flow velocity in the channels of swirls and nozzles is higher than 5 m / s, the swirl channels in the form of two-start or multi-start tangential channels or channels in the form of Archimedes spirals, screw or screw spirals, twisting the flow of channels of another shape, and the ratio of the height of the channel (spiral) to its width is in range from 1 to 10, the rotation of the medium in the channels can be either left or right, the direction of rotation of the two media can coincide and / or be multidirectional, the location of the cavitator between two vortex inserts (swirlers) for two input media and an output swirl for a mixture of input media and nozzle is selected from the condition of maximum intensity of cavitation and acoustic effects on the mixture of input media, and in the device’s body there are fittings or nozzles for introducing molecular hydrogen and / or light hydrogen-containing environment and / or active hydrogen and / or light radicals into the mixing chamber and / or into the treatment zone in front of and / or behind the cavitator, or a reactor for producing active hydrogen and / or light radicals is integrated into the processing device. 13. The device according to p. 12, characterized in that the holes in the cavitator are in the form of rectangles, asterisks, ellipses and other flat figures (as one of the options with sharp jagged edges), and the shape and dimensions of the figures are chosen so that the ratio of the perimeter of the figure to its area was maximum, the size of the holes (the minimum and maximum distance between the two points of the perimeter of each hole) are in the range from 0.1 to 100 mm, and the velocity of the medium in each hole exceeds 5 m / s. 14. The device according to p. 12, characterized in that the device has 2 or more cavitators, the distance between them, as well as the distance between two vortex inserts (swirlers) for two input media, cavitators and an output swirl for a mixture of input media and a nozzle is selected from the condition of maximum intensity of cavitation and acoustic effects on the mixture of input media. 15. The device according to p. 12, characterized in that to increase the number of cavitation and acoustic treatment zones formed, the cavitator is made in the form of filling balls, cylinders, parallelepipeds, stars, tori, dumbbells, Rashig rings and other rigid volumetric figures, and the dimensions of volumetric figures are in the range from 0.1 to 100 mm, the velocity of the medium in all the gaps between the backfill elements exceeds 5 m / s, and the backfill can be inserted into a container, for example, mesh, for the convenience of changing elements of different backfill and moving the cavitator (container nera) along the axis of the processing device to find the optimal location to create the maximum intensity of cavitation and acoustic effects on the mixture of input media, and the number of containers can be more than one. 16. The device according to p. 12, characterized in that the gas part of the mixture in the device does not exceed 25% by mass and is regulated by the pressure in the device. 17. The device according to p. 12, characterized in that the nozzle is made in the form of a cylinder, cone or Laval nozzle. 18. The device according to p. 12, characterized in that the cavitator is made in the form of a cone or a convex along the flow of the figure in the form of a cone or a truncated cone with an angle at the apex of the cone more than 10 degrees, and on the entire surface of the cavitator as nodes of the formation of zones cavitation holes are made through (as one of the options - with sharp jagged edges) with sizes from 0.1 to 100 mm. 19. The device according to p. 12, characterized in that the number of inlet pipes and swirls, output swirls, nozzles built into the processing device, more than one of each type. 20. The device according to p. 12, characterized in that the cylindrical sections of the mixing chamber, as well as the cylindrical sections of the motion of both media, are mixed with confuser and / or diffuser inserts before mixing. 21. The device according to p. 12, characterized in that if the installation is used, in which the raw materials and circulating VKF are mixed before the VKF heating furnace, and the heated mixture is further supplied to the acoustic and cavitation processing device (turbodynamic disintegrator), then to each inlet pipe of the device processing feed a mixture of raw materials and VKF, and the input pipes may be more than two.