In-line hydrotreatment process for low TAN synthetic crude oil production from oil sand

Abstract

A low cost and energy efficient process for manufacturing low TAN synthetic crude oils from oil sands, by selective removal of organic acids from carboneous distillates and or blends of carboneous distillates in a hydroprocessing unit integrated within the process flows of a bitumen Upgrader.

1 . A process for the manufacture of low TAN synthetic crude oil blending components from oil sand bitumen for the production of low TAN synthetic crude oils comprising the steps of: 
 i. providing a supply of hot bitumen distillate;    ii. mixing a charge gas containing hydrogen with the bitumen distillate;    iii. supplying the mixture under pressure to a hydro-deoxygenating reactor; and    iv. recovering the liquid portion of the effluent from the hydro-deoxygenating unit.    
     
     
         2 . The process of  claim 1  wherein the supply of hot bitumen distillate is a virgin bitumen distillate or a blend of virgin bitumen distillates produced by atmospheric or vacuum distillation of bitumen.  
     
     
         3 . The process of  claim 1  wherein the temperature of the supply of hot bitumen distillate is in the range of 400 to 530 degrees Fahrenheit.  
     
     
         4 . The process of  claim 2  wherein the temperature of the supply of hot bitumen distillate is in the range of 400 to 530 degrees Fahrenheit.  
     
     
         5 . The process of  claim 1  wherein the charge gas is supplied at a rate that provides hydrogen gas in the range of 250 to 1500 standard cubic feet per barrel of bitumen distillate.  
     
     
         6 . The process of  claim 1  wherein the charge gas is obtained from a source of hydrogen gas in a bitumen Upgrader.  
     
     
         7 . The process of  claim 6  wherein the source of hydrogen gas is a hydrotreater recycle bleed gas.  
     
     
         8 . The process of  claim 7  wherein the hydrogen gas portion of gas from the source of hydrogen gas is supplied at a rate in the range of 250 to 1500 standard cubic feet per barrel of bitumen distillate.  
     
     
         9 . The process according to  claim 1 , wherein the charge gas is a hydrogen rich gas, containing greater than 50% hydrogen, and 0% to 10% H2S.  
     
     
         10 . The process according to  claim 6 , wherein the charge gas is a hydrogen rich gas, containing greater than 50% hydrogen, and 0% to 10% H2S.  
     
     
         11 . The process according to  claim 7 , wherein the charge gas is a hydrogen rich gas, containing greater than 50% hydrogen, and 0% to 10% H2S.  
     
     
         12 . The process according to  claim 8 , wherein the charge gas is a hydrogen rich gas, containing greater than 50% hydrogen, and 0% to 10% H2S.  
     
     
         13 . The process of  claim 1  wherein the mixture supplied under pressure to the hydro-deoxygenating unit is supplied at a LHSV in the range of 0.5-5.0.  
     
     
         14 . The process according to  claim 2 , the hydro-deoxygenating reactor has one or more fixed catalyst beds.  
     
     
         15 . The process of  claim 1  wherein the hydro-deoxygenating reactor has a catalyst of nickel-molybdenum or cobalt-molybdenum deposited on an alumina carrier.  
     
     
         16 . The process of  claim 14  wherein the hydro-deoxygenating reactor has a catalyst of nickel-molybdenum or cobalt-molybdenum deposited on an alumina carrier.  
     
     
         17 . A process for removing naphthenic acids from bitumen products comprising the steps of: 
 i. supplying bitumen to an atmospheric or vacuum distillation unit to produce a hot gas oil supply;    iii. mixing a charge gas containing hydrogen with at least a portion of the hot gas oil supply;    iv. supplying the mixture under pressure to a hydro-deoxygenating reactor; and    v. recovering the liquid portion of the effluent from the hydro-deoxygenating reactor.    
     
     
         18 . The process of  claim 17  wherein the selected portion of the hot gas oil supply in the range of 400 to 530 degrees Fahrenheit.  
     
     
         19 . The process of  claim 17  wherein the charge gas is supplied at a rate that provides hydrogen gas in the range of 250 to 1500 standard cubic feet per barrel of bitumen.  
     
     
         20 . The process of  claim 17  wherein the charge gas is obtained from a source of hydrogen gas in a bitumen Upgrader.  
     
     
         21 . The process of  claim 20  wherein the source of hydrogen gas is a hydrotreater recycle bleed gas.  
     
     
         22 . The process of  claim 21  wherein the hydrogen gas portion of gas from the source of hydrogen gas is supplied at a rate in the range of 250 to 1500 standard cubic feet per barrel of bitumen.  
     
     
         23 . The process according to  claim 17 , wherein the charge gas is a hydrogen rich gas, containing greater than 50% hydrogen, and 0% to 10% H2S.  
     
     
         24 . The process according to  claim 19 , wherein the charge gas is a hydrogen rich gas, containing greater than 50% hydrogen, and 0% to 10% H2S.  
     
     
         25 . The process according to  claim 20 , wherein the charge gas is a hydrogen rich gas, containing greater than 50% hydrogen, and 0% to 10% H2S.  
     
     
         26 . The process according to  claim 21 , wherein the charge gas is a hydrogen rich gas, containing greater than 50% hydrogen, and 0% to 10% H2S.  
     
     
         27 . The process according to  claim 22 , wherein the charge gas is a hydrogen rich gas, containing greater than 50% hydrogen, and 0% to 10% H2S.  
     
     
         28 . The process of  claim 17  wherein the mixture supplied under pressure to the hydro-deoxygenating unit is supplied at a LHSV flow rate in the range of 0.5-5.0.  
     
     
         29 . The process of  claim 17 , wherein the hydro-deoxygenating reactor has one or more fixed catalyst beds.  
     
     
         30 . The process of  claim 17  wherein the hydro-deoxygenating reactor has a catalyst of nickel-molybdenum or cobalt-molybdenum deposited on an alumina carrier.  
     
     
         31 . The process of  claim 29  wherein the hydro-deoxygenating reactor has a catalyst of nickel-molybdenum or cobalt-molybdenum deposited on an alumina carrier.