Co-processing of biomass during fluidized coking with gasification

Abstract

Systems and methods are provided for integrated coking and gasification of a biomass feed in a three-vessel fluidized coking system under co-processing conditions so that biomass is co-fed with a conventional and/or mineral coker feed, such as a feed containing resid or heavy crude oil. It has been discovered that co-processing of a biomass feed can unexpectedly increase the reaction rate for coking of the conventional/mineral coker feed. This unexpected increase in reaction rate can allow for modification of how the three-vessel fluidized coking reaction system is operated. The resulting modification in operating conditions can allow for production of a modified and/or improved product slate from the fluidized coker. The modifications in the product slate can include an increase in total liquid products as well as a decrease in micro carbon residue and/or n-heptane insolubles in the total liquid products.

1 . A method for co-processing biomass in a fluidized coking system, comprising: exposing a feed comprising 1.0 wt % to 60 wt % of biomass and 40 wt % to 99 wt % of a mineral fraction having a T10 distillation point of 500° C. or higher, to a fluidized bed of particles under fluidized coking conditions in a reactor vessel to form i) a coker effluent comprising a liquid portion, ii) char, coke, or a combination thereof, at least a portion of the char, coke, or combination thereof being deposited on the particles to form particles comprising deposited char, coke, or a combination thereof, and iii) additional hydrocarbons associated with the particles comprising deposited char, coke, or a combination thereof; passing at least a portion of particles comprising deposited char, coke, or a combination thereof from the reactor vessel into a heater vessel, the at least a portion of particles comprising deposited char, coke or a combination thereof comprising 0.08 wt % or less of the associated additional hydrocarbons, relative to a weight of the feed; mixing the at least a portion of the particles comprising deposited char, coke, or a combination thereof with a portion of partially gasified particles in the heater vessel to form a heated particle mixture; passing a first portion of the heated particle mixture into the reactor vessel; passing a second portion of the heated particle mixture into a gasification vessel; introducing an oxygen-containing stream and steam into the gasification vessel; exposing the second portion of the heated particle mixture to oxidation conditions in the gasification vessel to form a gas phase product, and partially gasified particles; and passing at least a portion of the partially gasified particles from the gasification vessel to the heater vessel, wherein the liquid portion of the coker effluent comprises a micro carbon residue content of 0.5 wt % or less, an n-heptane insolubles content of 0.5 wt % or less, or a combination thereof. 
     
     
         2 . The method of  claim 1 , wherein the liquid portion of the coker effluent comprises a micro carbon residue content of 0.4 wt % or less, an n-heptane insolubles content of 0.4 wt % or less, or a combination thereof. 
     
     
         3 . The method of  claim 1 , wherein the oxidation conditions comprise partial oxidation conditions to form a gas phase product comprising CO and CO 2 . 
     
     
         4 . The method of  claim 1 , wherein the gas phase product further comprises H 2 . 
     
     
         5 . The method of  claim 1 , further comprising passing the gas phase product from the gasification vessel into the heater vessel, and exhausting at least a portion of the gas phase product from the heater vessel. 
     
     
         6 . The method of  claim 1 , wherein the biomass comprises 20 wt % or more of cellulose, or wherein the biomass comprises 30 wt % or less of lignin, or a combination thereof. 
     
     
         7 . The method of  claim 1 , wherein the feed comprises 10 wt % to 60 wt % of biomass. 
     
     
         8 . The method of  claim 1 , wherein the feed comprises 20 wt % or less of components with a boiling point of 350° C. or less. 
     
     
         9 . The method of  claim 1 , wherein the oxidation conditions comprise exposing the second portion of particles to an oxygen-containing stream comprising 45% to 75% of a stoichiometric amount of oxygen to combust the char, coke, or a combination thereof. 
     
     
         10 . The method of  claim 1 , wherein the liquid portion of the coker effluent comprises a weight ratio of naphtha boiling range components to light distillate boiling range components of 0.65 or less; or wherein the liquid portion of the coker effluent comprises 30 wt % to 50 wt % of naphtha boiling range components, 30 wt % to 50 wt % of heavy distillate boiling range components, 10 wt % to 25 wt % of light distillate boiling range components; and 5.0 wt % or less of vacuum resid boiling range components. 
     
     
         11 . The method of  claim 1 , wherein the liquid portion of the coker effluent comprises 0.9 wt % to 3.0 wt % of oxygen. 
     
     
         12 . A liquid product comprising: 30 wt % to 50 wt % of naphtha boiling range components; 30 wt % to 50 wt % of heavy distillate boiling range components; 10 wt % to 25 wt % of light distillate boiling range components; and 5.0 wt % or less of vacuum resid boiling range components, the liquid product comprising 0.9 wt % to 3.0 wt % of oxygen, the liquid product further comprising a) 0.05 wt % to 0.5 wt % of micro carbon residue content, b) 0.05 wt % to 0.5 wt % of n-heptane insolubles, or c) a combination of a) and b). 
     
     
         13 . The liquid product of  claim 12 , wherein the liquid product comprises 0.05 wt % to 0.4 wt % of micro carbon residue content. 
     
     
         14 . The liquid product of  claim 12 , wherein the liquid product comprises 0.05 wt % to 0.4 wt % of n-heptane insolubles. 
     
     
         15 . The liquid product of  claim 12 , wherein the liquid product comprises 0.05 wt % to 0.2 wt % of micro carbon residue content. 
     
     
         16 . The liquid product of  claim 12 , wherein the liquid product comprises 0.05 wt % to 0.2 wt % of n-heptane insolubles. 
     
     
         17 . The liquid product of  claim 12 , wherein the liquid product comprises 10 wt % to 40 wt % of oxygenated components. 
     
     
         18 . The liquid product of  claim 12 , wherein the liquid product comprises 15 wt % to 30 wt % of oxygenated components. 
     
     
         19 . The liquid product of  claim 12 , wherein the liquid product comprises 1.0 wt % or less of vacuum resid boiling range components. 
     
     
         20 . The liquid product of  claim 12 , wherein the liquid product comprises 0.9 wt % to 2.5 wt % of oxygen.