PROCESS FOR POLYMER MIXTURE HYDROCONVERSION

Abstract

There is a process for the hydroconversion of mixtures of polymers or plastics which comprises the pre-treatment of the mixtures through methods selected from mechanical methods, chemical methods, thermal methods, or combinations thereof forming a pre-treated charge. The pre-treated charge is mixed with a hydrocarbon vacuum residue, optionally pre-heated, to form a reactant mixture. The reactant mixture is fed to a hydroconversion section in slurry phase, together with a catalyst precursor containing Molybdenum, and a stream containing hydrogen, forming a reaction effluent. The effluent is separated into at least one high-pressure and high-temperature separator in a vapour phase and a slurry phase. The separate vapour phase is sent to a gas treatment section with the function of separating a liquid fraction from the gas containing hydrogen and hydrocarbon gases having from 1 to 4 carbon atoms; said liquid fraction comprising naphtha, atmospheric gas oil (AGO), vacuum gas oil (VGO). The slurry phase is then sent to a separation section that has the function of separating the fractions of the Vacuum Gas Oil (VGO), Heavy Vacuum Gas Oil (HVGO), Light Vacuum Gas Oil (LVGO), Atmospheric Gas Oil (AGO), from a stream of heavy organic products which contains asphaltenes, unconverted charge, catalyst and solid formed during the hydroconversion reaction. This stream of heavy organic products is partly recirculated to the hydroconversion section and partly forms a purge stream.

Claims

1. A process for polymer mixture hydroconversion which comprises the following steps: pre-treating a polymer mixture through methods selected from mechanical methods, chemical methods, thermal methods, or combinations thereof, forming a pre-treated charge; mixing said pre-treated charge with a vacuum hydrocarbon residue, optionally pre-heated, to form a reactant mixture; feeding to a hydroconversion section the reactant mixture in slurry phase, a precursor of the catalyst containing Molybdenum, and a stream containing hydrogen and carrying out a hydroconversion reaction producing a reaction effluent; separating the reaction effluent into at least one high-pressure and high-temperature separator in a vapour phase and a slurry phase; then sending the separated vapour phase to a gas treatment section with the function of separating a liquid fraction from the gas containing hydrogen and hydrocarbon gases having from 1 to 4 carbon atoms; said liquid fraction comprising naphtha, atmospheric gas oil (AGO), vacuum gas oil (VGO); then sending the slurry phase to a separation section that has the function of separating the fractions of Oil Vacuum (VGO), Heavy Vacuum Gas Oil (HVGO), Light Vacuum Gas Oil (LVGO), Atmospheric Gas Oil (AGO), from a stream of heavy organic products which contains asphaltenes, unconverted charge, catalyst and solid formed during the hydroconversion reaction; and recirculating a portion of said heavy organic products to the hydroconversion section, or mixing them with the pre-treated charge before being fed into the hydroconversion, and with the remainder forming a purge stream.

2. Process according to claim 1, wherein the mixture of polymers in solid phase comprises: one or more polymers selected from t he group consisting of: Ethylene polymers or copolymers and mixtures thereof; Propylene polymers or copolymers and mixtures thereof; Styrene polymers or copolymers and mixtures thereof; Polymers or copolymers of vinyl chloride or copolymers of vinilidene dichloride, and mixtures thereof; Polyesters; Polyamides; Polymers containing urethane bonds; Polymers deriving from cellulose; mixtures thereof; and optionally organic or inorganic source additives.

3. Process according to claim 2, wherein the ethylene polymers or copolymers are selected from high-density polyethylene (HDPE), low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), very low density polyethylene (VLDPE), ultra low density polyethylene (ULDPE), metallocene catalytic polyethylene (m-PE), ethylene-vinyl acetate (EVA) polymers, and mixtures thereof.

4. Process according to claim 2, wherein the propylene polymers or copolymers are selected from polypropylene (PP) or ethylene propylene diene monomer rubbers (EPDM), and mixtures thereof.

5. Process according to claim 2, wherein the styrene polymers or copolymers are selected from polystyrene (PS), expandable polystyrene (EPS), high impact polystyrene (HIPS), acrylonitrile-styrene-butadiene polymers (ABS), styrene-acrylonitrile copolymers (SAN), styrene-butadiene-styrene block copolymer (SBS), styrene-ethylene-butylene-styrene block copolymers (SEBS), and mixtures thereof.

6. Process according to claim 2, wherein the polymers or copolymers of vinyl chloride and vinylidene dichloride are selected from polyvinyl chloride (PVC), polyvinylchloride (PVDC) and its copolymers, and mixtures thereof.

7. Process according to claim 2, wherein the polyesters are selected from polycarbonate (PC), polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT), poly lactic acid (PLA), poly (L-lactic acid) (PLLA), poly (D-lactic acid) (PDLA), poly (D, L-lactic acid) (PDLLA), polyhydroxyalkanoate (PHA).

8. Process according to claim 2, wherein the polyamides are selected from nylon 6 (PA6), nylon 66 (PA66), nylon 46 (PA46), nylon 12 (PA12), and mixtures thereof.

9. Process according to claim 2, wherein the polymers containing urethane bonds are selected from polyurethanes (PU) containing aliphatic, or aromatic, or ester, or ether, or urea groups, and mixtures thereof.

10. Process according to claim 2, wherein the cellulose-derived polymers are selected from cellulose nitrate, cellulose acetate, cellulose acetate-butyrate, cellulose propionate, ethyl cellulose, carboxymethylcellulose, hydroxyethyl cellulose, benzyl cellulose and regenerated cellulose, and mixtures thereof.

11. Process according to claim 1, wherein the slurry phase hydroconversion reactor is a bubble reactor.

12. Process according to claim 1, wherein the reaction takes place in one or more hydroconversion reactors placed in parallel and similarly the separation of the effluent takes place in one or more high-pressure and high-temperature separators placed in parallel.

13. Process according to claim 1, wherein the vapour treatment section comprises heat exchangers interspersed with a washing column, a high-pressure and medium-temperature separator, a high-pressure and low-temperature separator.

14. Process according to claim 1, wherein said liquid separation section comprises a high-temperature and low-pressure separator which functions as an accumulator; a pre-flash column, possibly a stripper to separate the light, and finally a vacuum distillation column to recover the VGO fraction, the LVGO fraction, the HVGO fraction, the Wash Oil and the Vacuum residue.

15. Process according to claim 1, wherein the mechanical pre-treatment is selected from grinding and cryogenic grinding.

16. Process according to claim 1, wherein the chemical pre-treatment is selected the group consisting of: preparing the polymers mixture in an acid or basic atmosphere at room temperature; and preparing the polymers mixture with hydrocarbon compounds, at low or high molecular weight at room temperature.

17. Process according to claim 1, wherein the thermal pre-treatment involves heating the polymers mixture at a temperature greater than or equal to 200° C. in an inert atmosphere.

18. Process according to claim 1, wherein the pre-treatment is selected from the following methods: the polymer mixture is ground, then the ground polymer mixture is added to acids or bases at room temperature;or the polymer mixture is ground then the ground polymeric mixture is heated to a temperature T greater than or equal to 200° C. in an inert atmosphere; or the polymer mixture is heated to a temperature greater than or equal to 200° C. in an inert atmosphere.

19. Process according to claim 1, wherein the purge is treated as follows: heating to a temperature comprised between 185° C-220° C.; the hot purge is cooled by progressively and in a controlled manner lowering the temperature to the minimum temperature of 100° C. without stirring the purge, so as to form a light or clarified phase, and a heavy phase or cake depending on the density.

20. Process according to claim 19, wherein the controlled progressive lowering of the temperature can occur in different ways: by using an adequately sized and thermostated tank, or by mixing the heated purge with a cold stream considering the appropriate thermal balance of the process for calculating the flow rates.

21. Process according to claim 1, wherein the time necessary for the formation of a heavy phase or cake varies from 15 minutes to 2 hours.

22. Process according to claim 1, wherein the sedimentation speed is comprised between 85 mm/hour and 300 mm/hour.

23. Process according to claim 1, wherein the clarified is mixed with the pre-treated charge or is recycled to the hydroconversion section.

24. Process according to claim 1, wherein the purge is treated as follows: the purge is mixed, at a temperature greater than or equal to 100° C., with a mixture of hydrocarbons or flux that has a total aromatic content comprised between 50% and 70% by weight, and a starting boiling point equal to or greater than the temperature at which the mixing is conducted, so as to form a suspension with a content greater than or equal to 10% by weight of compounds having a boiling point T.sub.bp less than or equal to 350° C.; said suspension is then subjected to a liquid-solid separation stage, which operates at a temperature greater than or equal to 100° C., separating a solid phase containing a residual organic component and a solid component, cake, and a liquid phase containing solid residues; and cooling the solid phase (cake) thus obtained below 60° C., including the upper end, and maintaining a temperature lower than or equal to 60° C.

25. Process according to claim 24, wherein the liquid-solid separation is carried out by filtration or by using a centrifugal decanting device (centrifugation) which operates at temperature.

26. Process according to claim 1, wherein the catalyst precursor is Mo 2-ethylhexanoic acid (2-ethylhexanoate) solution, containing 15.5% by weight of Mo.

27. Process according to claim 1, wherein the hydroconversion reactors and high-pressure and temperature separators operate in a temperature range comprised between 420° C. and 440° C., at a pressure comprised between 155 atm and 160 atm.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0090] Further aims and advantages of the present disclosure will appear more clearly from the following description and from the accompanying figures, given purely by way of non-limiting example, which represent preferred embodiments of the present disclosure.

[0091] FIG. 1 shows a preferred embodiment of the process according to the present disclosure, in which the mixture of polymers (1) is fed to a pre-treatment section (G); then the pre-treated mixture is mixed in (F) with a vacuum residue (14) and catalyst precursors (2), together with the heavy product (12) and the clarified product (11) thus forming a reactant mixture (15). [0092] The reactant mixture (15) is then fed into a hydro-conversion reactor (A) together with a stream containing hydrogen. The reaction effluent is fed to a high-pressure and high-temperature separator (B) which forms a gaseous stream (5) and a slurry (7). The gas (5) is fed into the treatment section (C) where a gaseous stream containing hydrogen (4) is separated from naphtha, atmospheric gas oil (AGO) and Vacuum Gas oil (VGO) (liquid fraction) indicated with 6. Part of the gaseous stream containing hydrogen is purged (16), while the remaining part (4) is mixed with the hydrogen make-up (3) and the resulting stream is fed to the hydro-conversion reactor (A), at least one saturation gas (13) cut from gaseous recycling, which is fed to the bottom of the high-pressure and high-temperature separator (B).

[0093] The slurry (7) is fed into a separation section (D) to separate Vacuum Gas Oil (VGO) from a heavy product which partly recirculates to the mixing section (12, F) and partly forms a purge stream (9). The purge is subjected to a liquid-solid separation (E) where a heavy or dense phase (10) is separated from a light or clarified phase (11) which is recirculated to the mixing section (F).

[0094] FIG. 2 illustrates a preferred embodiment of the process according to the present disclosure, in which the catalyst precursors (2) are fed into the hydro-conversion section (A); a part of the heavy product recirculates to the hydro-conversion reactor (A), the clarified product (11) is recirculated to the hydro-conversion reactor (A). The rest of the process is similar to that described in FIG. 1.

DETAILED DESCRIPTION OF THE DISCLOSURE

Best Mode for Carrying Out the Disclosure

[0095] In the present patent application, slurry phase is meant as a mixture of liquid and solid.

[0096] In the present patent application the term “purging” is meant as slurry-phase organic streams which contain a quantity of hydrocarbons having a boiling point greater than or equal to 540° C. greater than 65% by weight, a quantity of asphaltenes greater than or equal to 20% by weight and characterised by the presence of solids contents greater than or equal to 4% by weight, the remainder being hydrocarbons having a boiling point comprised between 350° C. and 500° C. Purge solids contain carbonaceous residues and metal compounds which can contain sulphides of transition metals, such as for example molybdenum, iron, nickel and vanadium, and having sub-millimetre dimensions. For the purposes of this discussion, the term “solid” is meant as the insoluble fraction in tetrahydrofuran, indicated in this text by the acronym THF-i.

[0097] For the purposes of this discussion, the term “asphaltenes” is meant as the organic fraction soluble in tetrahydrofuran but insoluble in n-pentane.

[0098] Asphaltenes are classified according to their insolubility in n-paraffins (typically having 5 to 7 C5-C7 carbon atoms). Such compounds are generally constituted by nuclei of variously branched aromatic polycondensates and joined together through linear chains. These compounds can contain heteroatoms (S, N) therein which give them their polar nature.

[0099] In the present patent application the term “cake” is meant as a solid material at room temperature with glass-like characteristics (i.e. the appearance of the cake has the characteristics of glass) that make it easily grindable and consequently transportable even for long stretches without requiring a particular thermostatic control. This characteristic remains at temperatures ranging in the interval comprised between 50° C. and 60° C.

[0100] The cake is hard at room temperature with a softening point comprised between 80° C. and 100° C. and a degree of penetration from 2 dmm to 5 dmm (dmm indicates decimillimetres). The softening point is the temperature at which the solid cake becomes soft and indicates the dependence of the cake's consistency on the temperature. The degree of penetration is measured according to the method ASTM-D5-06 and expresses the penetration the material undergoes at room temperature by a needle of known weight, in decimillimetres.

[0101] The consistency of the cake is due to the presence of solids (THFi) in greater concentration than the other streams and to the presence of asphaltenic compounds.

[0102] The cake contains solids as previously defined in the text of the present patent application.

[0103] The cake solids contain carbonaceous residues and metal compounds which can contain sulphides of transition metals, such as for example molybdenum, iron, nickel and vanadium, and having sub-millimetre dimensions.

[0104] In the present patent application the term maltenes is meant as the set of those compounds soluble both in Tetrahydrofuran and in n-pentane.

[0105] In the present patent application the term “styrene residue” is meant as a by-product of industrial origin deriving from the production of styrene and ethylbenzene and/or production of styrene polymers/copolymers. In particular it can contain aromatic organic compounds such as for example benzene, ethylbenzene, styrene, toluene, xylenes, propylbenzenes, alpha methyl styrene, polyethylbenzenes, styrene oligomers, oligomers of the SAN copolymer (styrene-acrylonitrile), polycyclic aromatic hydrocarbon compounds (naphthalene, anthracene, fluorantene, etc.); both short-chain hydrocarbons, i.e. with less than or equal to 12 carbon atoms, and long-chain, i.e. with carbon atoms equal to or greater than 12, mineral oils with carbon atoms comprised between 10 and 40; other unsaturated compounds such as for example acrylonitrile, and mixtures of the components listed above.

[0106] In the present patent application the term “phenolic residue” is meant as a by-product of industrial origin deriving from the production of phenol and its derivatives such as cyclohexanone and cyclohexanol. In particular the phenolic residue can contain aromatic organic compounds such as phenol, cresols, acetophenonene, cumene, alpha-methyl styrene; both short-chain hydrocarbons, i.e. with less than or equal to 12 carbon atoms, and long-chain, i.e. with carbon atoms equal to or greater than 12, mineral oils with carbon atoms comprised between 10 and 40 and mixtures of the components listed above.

[0107] In the present patent application, all the operating conditions reported in the text must be understood as preferred conditions, even if not expressly declared. For the purposes of the present discussion the term “comprise” or “include” also comprises the term “consist in” or “essentially consisting of”.

[0108] For the purposes of the present discussion the definitions of the intervals always comprise the extremes unless otherwise specified.

[0109] Hydroconversion is usually carried out starting from heavy petroleum products and can be achieved by adopting different process schemes.

[0110] In the present patent application, heavy petroleum products is meant as crude oils, heavy crude oils, bitumen from bituminous sands, distillation residues, heavy distillation cuts, de-asphalting residues, synthetic oils produced by the Fischer Tropsch process, vegetable oils, coke-derived oils and oil shale, oils obtained by thermal decomposition of waste, polymers, biomass.

[0111] The method for the hydroconversion of polymer mixtures which is the object of the present patent application is now described in detail, also with reference to FIG. 1 and FIG. 2.

[0112] A mixture of polymers (1) is suitably pre-treated, then it is mixed with a vacuum residue (14). The catalyst precursors (2) can be fed to the mixer (F) or to the hydroconversion reactor (A). The mixture (15) is then subjected to a hydroconversion reaction producing hydrocarbons having a lower boiling temperature than the starting charge. In particular, a conversion of the mixture of polymers to hydrocarbon products is observed with boiling temperatures preferentially in the range from 65° C. to 170° C., also known as naphtha cut.

[0113] In the present patent application vacuum residue is meant as the residual stream of industrial origin which remains following a vacuum distillation of the pool of crude oils entering a refinery.

[0114] For the purposes of the present disclosure, the mixture of polymers mixed with the vacuum residue comprises polymeric waste deriving, for example, from the sorting cycle of differentiated solid urban plastic waste, from the selection from unsorted solid urban waste, from waste from industrial, craft, commercial and agricultural activities. The treated polymer mixtures are in solid phase and comprise: [0115] one or more polymers, preferably all the polymers, selected from the following classes: [0116] Ethylene polymers or copolymers, mixtures thereof; preferably selected from high-density polyethylene (HDPE), low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), very low density polyethylene (VLDPE), ultra low density polyethylene (ULDPE), metallocene catalytic polyethylene (m-PE), ethylene-vinyl acetate (EVA) polymers, and mixtures thereof; [0117] Propylene polymers or copolymers, mixtures thereof; preferably selected from polypropylene (PP) or ethylene propylene diene monomer rubbers (EPDM) and mixtures thereof; [0118] Styrene polymers or copolymers, mixtures thereof: preferably selected from polystyrene (PS), expandable polystyrene (EPS), high impact polystyrene (HIPS), acrylonitrile-styrene-butadiene polymers (ABS), styrene copolymers acrylonitrile (SAN), styrene-butadiene-styrene block copolymer (SBS), styrene-ethylene-butylene-styrene block copolymers (SEBS), and mixtures thereof; [0119] Vinyl chloride polymers or copolymers or vinylidene dichloride copolymers, mixtures thereof, preferably selected from polyvinyl chloride (PVC), polyvinylidene chloride (PVDC) and its copolymers and mixtures thereof; [0120] Polyesters, preferably selected from polycarbonate (PC), polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT), poly lactic acid (PLA), poly (L-acid lactic acid) (PLLA), poly (D-lactic acid) (PDLA), poly (D, L-lactic acid) (PDLLA), polyhydroxyalkanoate (PHA) and mixtures thereof; [0121] Polyamides, preferably selected from nylon 6 (PA6), nylon 66 (PA66), nylon 46 (PA46), nylon 12 (PA12); [0122] Polymers containing urethane bonds, preferably selected from polyurethanes (PU) containing aliphatic, or aromatic, or ester, or ether, or urea groups, and mixtures thereof; [0123] Cellulose-derived polymers, preferably selected from cellulose nitrate, cellulose acetate, cellulose acetate-butyrate, cellulose propionate, ethyl cellulose, carboxymethylcellulose, hydroxyethyl cellulose, benzyl cellulose and regenerated cellulose, and mixtures thereof; [0124] Mixtures thereof; [0125] Possibly additives of organic or inorganic origin, having for example the function of antioxidants, thermal stabilisers, antacids, nucleating agents, UV stabilisers, antiblocking, slip agents, antislip agents, plasticisers, external lubricants, releasing agents, flame retardants, polymer processing aids, dyes (organic and inorganic), antistatic agents, cross-linking agents, cross-linking aids, extender oils, vulcanisation accelerators, anti-ozonants and mixtures thereof.

[0126] The inorganic component of the polymeric mixture (consisting of ashes) and the unconverted polymers are instead concentrated in the fraction called THF-i (insoluble tetrahydrofuran).

[0127] A preferred mixture contains 35-60% by weight of polyethylene (PE) 15-40% by weight of polypropylene (PP); 0-25% weight of polystyrene (PS), 0-15% weight of polyethylene terephthalate (PET), 0-5% weight of polyvinyl chloride (PVC), 0-15% weight of inorganic charges. The polymer mixtures are mixed with the vacuum residue preferably at 5% by weight, more preferably at 20% by weight.

[0128] The process which is the object of the present patent application comprises several steps, among these a pre-treatment step of the polymer mixture (G) which has the purpose of making the polymer mixture miscible or suspendable in the vacuum residue (Vacuum Oil); and a hydro conversion step (A) of the reactant mixture to produce hydrocarbon products, among which preferably naphtha cuts. Naphtha is at the base of the petrochemical chain and thus allows valorising a waste product from the recycling of plastics or polymers.

[0129] A polymer mixture (1) can be pre-treated through methods selected from mechanical methods, chemical methods, thermal methods, or combinations thereof, in a pre-treatment section (G) forming a pre-treated charge. Among the preferred mechanical pre-treatments is grinding, also cryogenic, of the polymer mixture, in order to reduce the average dimension of the charge D.sub.50 itself to less than or equal to 1 mm.

[0130] The particle size distribution of the ground polymeric mixture was evaluated using Light Scattering measurements, performed with Mastersizer 2000 (Malvern Instruments). The dimension (MT50 or D.sub.50) is measured with a laser granulometer and is the diameter corresponding to 50% by weight of particles having a smaller diameter, and 50% by weight of particles having a larger diameter.

[0131] Among the preferred chemical pre-treatments are those selected from: [0132] preparing the polymers mixture in an acid or basic atmosphere at room temperature, preferably selected from an aqueous solution of H.sub.2SO.sub.4 at 10% w/w, an aqueous solution of NaOH at 10% w/w, an aqueous solution of Ca(OH).sub.2 at 10% w/w; [0133] preparing the polymers mixture with hydrocarbon compounds, at low or high molecular weight at room temperature; preferably selected from “styrene residues” and/or “phenolic residues”.

[0134] Among the preferred thermal pre-treatments is the method which involves heating the polymer mixture to a temperature T greater than or equal to 200° C. in an inert environment, possibly also through equipment such as extruders, thus allowing the intimate mixing of the polymeric components and the best subsequent mixing with Vacuum Oil. The pre-treatments can preferably be combined together in order to obtain the best stability of the final solution or suspension.

[0135] The pre-treatments can also be combined with each other, the preferred combinations being the following: [0136] the polymer mixture is ground, also with cryogenic grinding, in order to reduce the average dimension of the charge D.sub.50 itself to less than or equal to 1 mm; then the ground polymer mixture is added to acids or bases at room temperature, preferably selected from an aqueous solution of H.sub.2SO.sub.4 at 10% w/w, an aqueous solution of NaOH at 10% w/w, an aqueous solution of Ca(OH).sub.2 at 10% w/w, styrene residues and/or phenol residues; or [0137] the polymer mixture is ground, also with cryogenic grinding, in order to reduce the average dimension of the charge D.sub.50 itself to less than or equal to 1 mm; then the ground polymeric mixture is reheated to a temperature T greater than or equal to 200° C. in an inert environment; or [0138] the polymer mixture is heated to a temperature above or equal to 200 ° C. in an inert atmosphere, then the heated polymer mixture is added to acids or bases at room temperature, preferably selected from an aqueous solution of H.sub.2SO.sub.4 at 10% w/w, an aqueous solution of NaOH at 10% w/w, an aqueous solution of Ca(OH).sub.2 at 10% w/w, styrene residues and/or phenol residues.

[0139] Once the charge is pre-treated it can be mixed in a mixing section (F) with a vacuum hydrocarbon residue, optionally pre-heated, forming a reactant mixture which can be subsequently fed into a hydroconversion section in slurry phase (A). In this phase a catalyst precursor containing Molybdenum can also be added; otherwise said precursor can be added to the reactor.

[0140] The mixture thus formed, and possibly the precursors, are fed together with a stream containing hydrogen to the hydroconversion reactor (A) to conduct a hydroconversion reaction producing a reaction effluent.

[0141] Preferably the hydroconversion reactor in slurry phase is a bubble column. One or more hydroconversion reactors placed in parallel can be used; similarly, one or more high-pressure and high-temperature separators can be used in parallel.

[0142] Preferably a part of the hydrogen-containing recycling gas (13) is fed to the high-pressure and high-temperature separator.

[0143] The reaction effluent can be separated into at least one high-pressure and high-temperature separator (B) in a vapour phase and a slurry phase. The separated vapour phase can be subsequently sent to a vapour treatment section (C) with the function of separating a liquid fraction from the hydrogen-containing gas.

[0144] The vapour treatment section operates at gradually decreasing pressure and temperature. Said section can comprise heat exchangers interspersed with a washing column which uses VGO as a solvent, a high-pressure and medium-temperature separator, a high-pressure and low-temperature separator.

[0145] From the vapour treatment section, naphtha, atmospheric gas oil (AGO), vacuum gas oil (VGO) and a gaseous stream rich in hydrogen are recovered, which contains hydrocarbon gases having from 1 to 4 carbon atoms, and which is recycled to the hydroconversion section (4), except for a gaseous sample that can be fed into the high-pressure and high-temperature separator (B).

[0146] The slurry phase can be subsequently sent to a separation section (D) that has the function of separating the fractions of the Vacuum Gas Oil (VGO), Heavy Vacuum Gas Oil (HVGO) , Light Vacuum Gas Oil (LVGO) , Atmospheric Gas Oil (AGO), from a stream of heavy organic products which contains asphaltenes, unconverted charge, catalyst and solid formed during the hydroconversion reaction.

[0147] Said liquid separation section (D) can preferably comprise a series of devices of decreasing pressure and temperature. In a first step the slurry is fed to a high-temperature and low-pressure separator which acts as an accumulator; in a second step the separated vapour phase is fed into a pre-flash column, eventually the bottom current is fed to a stripper to separate the light oils, and finally in a third step the enriched stream leaving the stripper is fed to a vacuum distillation column; alternatively, the stripper is not present and the bottom stream is fed to a vacuum distillation column. The Vacuum Gas Oil (VGO) fraction, the Light Vacuum Gas Oil (LVGO) fraction, the Heavy Vacuum Gas Oil (HVGO) fraction, the Wash Oil and the vacuum residue are recovered from the vacuum column. The Vacuum residue leaves the bottom of the vacuum column and is rich in asphaltenes, solids, metals and catalysts and forms a stream of heavy products.

[0148] A part of the heavy products (12, FIG. 1) is recycled to the mixing section (F) or to the hydroconversion section in slurry phase (12, FIG. 2), while the remaining part forms a purge stream (9).

[0149] The described and claimed process can comprise a further purge processing step which provides a liquid-solid separation treatment selected from sedimentation, filtration or centrifugation.

[0150] In a first separation process the purging can be heated to a temperature greater than or equal to 185° C. and no greater than 220° C., preferably between 200° C. and 220° C.

[0151] Subsequently the hot purge can be cooled by progressively and in a controlled manner lowering the temperature to a minimum temperature of 100° C., preferably comprised between 100° C. and 170° C., more preferably comprised between 100° C. and 160° C., without stirring the purge, so as to form a light phase (clarified) and a heavy phase (cake) as a function of the density.

[0152] The controlled lowering of the temperature can occur in different ways: [0153] by using an adequately sized and thermostated tank, for example a hot-oil thermostated tank, or [0154] by mixing the warm stream to be decanted, for example the heated purge, with a cold stream, for example the clarified which can be at a temperature ranging from 200° C. to 80° C., considering the appropriate thermal balance of the system to calculate the flow rates thereof.

[0155] The controlled lowering of the temperature is of a value ranging from 3° C. per minute to 10° C. per minute, preferably from 5° C. per minute to 10° C. per minute, more preferably 10° C. per minute.

[0156] The cooled purge can be subjected to sedimentation, for example in a static sedimentation tank (E); during the static sedimentation, the temperature must be such as to make the asphaltenes insoluble and at the same time make the clarified part movable, allowing its extraction. In the temperature range comprised between 100° C. and 160° C. the separation of the dense phase (cake) is optimal. During the sedimentation phase the purge is not shaken. The sedimentation forms a light phase, called clarified, and a heavy phase, called cake, as a function of the density.

[0157] The time required for the formation of a heavy phase or cake can range from preferably 15 minutes to 2 hours, more preferably it ranges between 20 minutes and 1 hour. The sedimentation rate is preferably comprised between 85 mm/hour and 300 mm/hour.

[0158] The cake produced is “glassy” at room temperature with a softening point that can range from 80° C. to 100° C. and penetration 2 dmm.

[0159] The consistency of the cake is due to the presence of solids (THFi) in greater concentration than the other streams and to the presence of asphaltenic compounds. The clarified (11) thus obtained can preferably be recirculated into the mixing section (F) or into the hydroconversion section (A).

[0160] In an alternative separation process the purge is mixed, at a temperature greater than or equal to 100° C., with a mixture of hydrocarbons or flux which has a total aromatic compound content ranging from 50% to 70% by weight, and a starting boiling point equal to or greater than the temperature at which the mixing is conducted, so as to form a suspension with a content greater than or equal to 10% by weight of compounds having a boiling point T.sub.bp less than or equal to 350° C.

[0161] Said suspension is then subjected to a liquid-solid separation stage, which operates at a temperature greater than or equal to 100° C., separating a solid phase containing a residual organic component and a solid component, cake, and a liquid phase containing solid residues.

[0162] The liquid-solid separation is preferably carried out by filtration or by using a centrifugal decanting device (centrifugation) which operates at temperature. The separation is followed by cooling the solid phase (cake) thus obtained under 60° C., including the upper end, and maintaining it at a temperature lower than or equal to 60° C.

[0163] The catalyst used during the hydroconversion reaction is generated “in situ” by an oleosoluble precursor containing Mo, which can be fed to the hydroconversion reactor in liquid phase directly with the charge, or to the mixer together with the vacuum residue. The normally used precursor consists of Mo 2-ethylhexanoic acid (2-ethylhexanoate) solution, containing 15.5% by weight of Mo.

[0164] The catalyst precursor is liquid and reacts with the sulfide coming from the charge and the hydrogen present in the reactor forming MoS2 (solid molybdenite finely dispersed in the liquid phase) in lamellas.

[0165] The hydroconversion reactors can operate in a temperature range comprised between 420° C. and 440° C., at a pressure comprised between 155 atm and 160 atm.

[0166] The high-pressure and high-temperature separators operate in the same operating conditions as the hydroconversion reactors, except for the head losses and the heat losses along the line that connects the reactors to the separators.

[0167] Some application examples of the present disclosure are now described, which have a purely descriptive and non-limiting purpose and which represent preferred embodiments.

EXAMPLES

[0168] Description of polymeric charge

[0169] The polymeric charge used in the following examples, indicated with the term PLASMIX, is a mixture coming from the sorting of the separate collection of plastic packaging. These materials originate from industrial residues and/or post-consumer materials.

[0170] In particular, the unselected fraction output from the sorting process was tested, consisting of a mixture of heterogeneous plastics, mostly polyolefins.

[0171] The mixture consists of flakes with dimensions D.sub.50>1 cm and characterised by an apparent density of 200 kg/m.sup.3 measured according to the method ASTM D1895-96.

[0172] The described charge is insoluble in tetrahydrofuran.

[0173] In all the examples the mixture of polymers or plastics (polymeric charge) contains 35-60% weight of polyethylene (PE), 15-40% weight of polypropylene (PP); 0-25% weight of polystyrene (PS), 0-15% weight of polyethylene terephthalate (PET), 0-5% weight of polyvinyl chloride (PVC), 0-15% weight of inorganic charges.

[0174] The mixtures of polymers or plastics are mixed with the vacuum residue preferably at 5% by weight with respect to the vacuum residue.

Example 1

Mechanical Pre-Treatment by Grinding

[0175] For grinding, a Retsch Mill with a rotor diameter of 130 mm was used equipped with a 1.5 kW motor with the following operating conditions: [0176] RPM=1500 [0177] grinding times=10 minutes per 100 grams of product [0178] 2.5 mm “pass-through” mesh; the pass-through mesh can have “holes” of different sizes depending on the final granulometry to be obtained. Fine meshes impose longer times with the risk of the material overheating and the “kneading” of the entire mesh. 2.5 mm is the compromise we identified for this type of initial fluff. [0179] The grinding of the polymeric charge produced a particle size distribution characterised by D.sub.50<1 mm.

Example 2

Mechanical Pre-Treatment by Cryogenic Grinding

[0180] For grinding, a Retsch Mill ZM200 was used, an ultra-centrifugal rotor with annular screens, with current absorption of 1300 W and rotation speed between 6000 and 18000 rpm. Operating conditions: [0181] Material dosing through the Retsch DR100 sampler with slide speed 5 [0182] RPM=10000 [0183] grinding time=60 minutes per 15-20 grams of product [0184] 0.12 mm annular screen [0185] Addition of dry ice to the rotor for cooling [0186] Aspirated cyclone collection tank [0187] The grinding of the polymeric charge produced a particle size distribution characterised by D.sub.50<0.2 mm.

Example 3

Chemical Pre-Treatment

[0188] 100 ml of aqueous solution of NaOH at 10% w/w is prepared at room temperature in a glass flask. The polymeric charge at 5% w/w is added to this solution. This means that out of 100 grams of reactant mixture, 5 grams are the polymer mixture and 95 grams are the Vacuum residue. The system is initially stirred with a stirbar and subsequently the suspension thus obtained is left to rest for 12 hours.

Example 4

Chemical Pre-Treatment

[0189] 100 ml of aqueous solution of Ca(OH).sub.2 at 10% w/w is prepared at room temperature in a glass flask. The polymeric charge at 5% w/w is added to this solution. The system is initially stirred with a stirbar and subsequently the suspension thus obtained is left to rest for 12 hours.

Example 5

Chemical Pre-Treatment

[0190] 100 ml of aqueous solution of H.sub.2SO.sub.4 at 10% w/w is prepared at room temperature in a glass flask. The polymeric charge at 5% w/w is added to this solution. The system is initially stirred with a stirbar and subsequently the suspension thus obtained is left to rest for 12 hours. The pre-treatments reported in examples 2-3-4 were also repeated by adding 10% w/w and 20% w/w of polymeric charge to the different aqueous solutions.

Example 6

Chemical Pre-Treatment

[0191] 100 ml of aqueous solution of NaOH at 10% w/w is prepared at room temperature in a glass flask. The polymeric charge at 5% w/w is added to this solution. The system is initially stirred with a stirbar and subsequently the suspension thus obtained is left to rest for 12 hours. The suspension is filtered to remove the aqueous phase; the solid phase retained on the filter is dried in an oven at 120° C. for one night.

[0192] The pre-treatment reported in example 5 was also repeated using a solution of Ca(OH).sub.2 and H.sub.2SO.sub.4.

Example 7

Chemical Pre-Treatment

[0193] 45 grams of “styrene residue” are heated to 120° C., maintaining the stirring for 2 h, after which 15 grams of polymeric charge are added. The mixture is kept at 120° C. for 16 h in nitrogen storage.

Example 8

Chemical Pre-Treatment

[0194] 1 lt. of “styrene residue” is distilled obtaining a fraction containing the compounds with boiling temperatures greater than 350° C. This heavy fraction is then heated to 200° C., mechanically stirred and 5% of polymeric charge is added. The mixture is then cooled and placed in an ultrasonic bath at 50° C. for 2 h.

Example 9

Chemical Pre-Treatment

[0195] 1 lt. of “styrene residue” is distilled obtaining a fraction containing the compounds with boiling temperatures lower than 350° C. This heavy fraction is then heated to 120° C., mechanically stirred and 5% of polymeric charge is added.

[0196] The mixture is then cooled and placed in an ultrasonic bath at 50° C. for 2 h.

Example 10

Thermal Pre-Treatment

[0197] 20 g of polymeric charge is placed in a nitrogen vented oven at 200° C. for 16 h.

Example 11

Thermal Pre-Treatment

[0198] 20g of polymeric charge is placed in a nitrogen vented oven at 250° C. for 16 h.

Example 12

Thermal Pre-Treatment

[0199] 20g of polymeric charge is placed in a nitrogen vented oven at 350° C. for 16 h.

Example 13

Thermal Pre-Treatment

[0200] 2 kg of polymeric mixture is loaded into a co-rotating twin-screw extruder, equipped with a die plate having cylindrical holes. It is all extruded by operating at a constant temperature profile equal to 300° C., at a pressure upstream of the die plate equal to 50 bar, at a total flow rate equal to 10 Kg/h and at a screw rotation speed equal to 200 rpm. The material is extruded in the form of “spaghetti”, cooled in a water bath, air-dried and granulated using a cutter.

Example 14

Thermal Pre-Treatment

[0201] 2 kg of polymeric mixture is loaded into a co-rotating twin-screw extruder, equipped with a die plate. It is all extruded by operating at a constant temperature profile equal to 300° C., at a pressure upstream of the die plate equal to 15 bar, at a total flow rate equal to 10 Kg/h and at a screw rotation speed equal to 200 rpm. The material melted by the extruder is added to the vacuum residue.

Example 15

Combined Pre-Treatment

[0202] 5 grams of the pyrolysed material is taken at 200° C. (example 10) and mixed with 95 grams of acetone.

Example 16

Combined Pre-Treatment

[0203] 5 grams of the pyrolysed material is taken at 250° C. (example 11) and mixed with 95 grams of acetone.

Example 17

Combined Pre-Treatment 5 grams of the thermally-treated material is taken by extrusion (example 13) and pre-treated through the grinding process (example 1).

Example 18

Claimed Process

Mix Preparation

[0204] Case 1: The polymeric charge is treated as in Example 1, i.e. ground. 5 grams of pre-treated polymeric charge are taken, available at room temperature, and 95 grams of vacuum residue pre-heated to 200° C. are added. The mixture is kept warm at 200° C. for 2 h under mechanical stirring.

[0205] Case 2: The polymeric charge is treated as in Example 1, i.e. ground. 20 grams of pre-treated polymeric charge are taken, and 80 grams of vacuum residue pre-heated to 200° C. are added. The mixture is kept warm at 200° C. for 2 h under mechanical stirring.

[0206] Case 3: The polymeric charge is treated as in Example 1, i.e. ground. Subsequently, 5 grams of ground polymeric charge are taken and treated as in example 3, i.e. chemically pre-treated with a 10% w/w NaOH solution. The polymeric charge thus pre-treated is added to 95 grams of vacuum residue pre-heated to 200° C. The mixture is heated to 200° C. for 2 h under mechanical stirring.

[0207] Case 4: The polymeric charge is treated as in Example 2, i.e. ground. 5 grams of pre-treated polymeric charge are taken, available at room temperature, and 95 grams of vacuum residue pre-heated to 200° C. are added. The mixture is kept warm at 200° C. for 2 h under mechanical stirring.

REACTION

[0208] Several experiments were conducted using a 30 cc microautoclave reactor. The tests were conducted under the following operating conditions: [0209] 430° C.; [0210] 160 bar of hydrogen; [0211] 4 h; [0212] 3000 ppm of Molybdenum.

[0213] The mixtures tested in the various cases were characterised quantifying by precipitation the amount of insolubles in tetrahydrofuran (THF-i), the insolubles in n-pentane (Ins-C.sub.5, fraction normally considered as an asphaltenic fraction) and the characterisation of the fraction thus de-asphalted using the ASTM D2887 method. The reaction products are collected at the end of the test, quantified and characterised.

[0214] The gas phase is characterised by the ASTM D7833 Standard Refinery Gas Analysis method. Of the liquid phase, the insoluble in THF (THF-i) and the insoluble in n-pentane (Ins-C.sub.5) are quantified by precipitation and the de-asphalted fraction is analysed with the method D2887. The tables show the yields calculated according to the following formula:

[00001]$Yiel{d}_{\mathrm{Product},\%}=\frac{m_{\mathrm{product}\left(\mathrm{OUT}\right)}}{m_{mixt\mathrm{ure}\left(\mathrm{IN}\right)}}\%$

[0215] M.sub.product (OUT): mass of outgoing product (g)

[0216] M.sub.mixture (IN): mass of mixture loaded (g).

[0217] The outgoing products considered are gaseous products containing 1 to 4 carbon atoms (C1-C4), gaseous products containing 5 carbon atoms and liquid products with a boiling temperature comprised between 65° C. and 170° C. (65° C. (C.sub.5)-170° C.) considering the naphtha cut; liquid products with boiling temperature between 170° C. and 350° C. (170° C.-350° C.); liquid products with boiling temperature between 350° C. and 500° C. (350° C-500° C.); liquid products with a boiling temperature above 500° C. (500+° C.), products insoluble in n-pentane (Ins-C.sub.5) and products insoluble in tetrahydrofuran (THF-i).

TABLE-US-00001 TABLE 1 EST Base Case Case 1 Case 2 Characterisation Mixture IN IBP-350° C. wt % 1.8 2.8 1.4 350° C.-500° C. wt % 11.2 7.0 9.0 500° C.+ wt % 68.4 67.6 54.7 Ins-C.sub.5 wt % 18.5 17.5 14.8 THFi wt % 0.0 5.1 20.0 Yield Products OUT C.sub.1-C.sub.4 wt/wt.sub.FEED  7.8%  8.3% 10.7% 65° C.(C.sub.5)-170° C. wt/wt.sub.FEED 13.7% 17.0% 22.6% 170° C.-350° C. wt/wt.sub.FEED 28.2% 29.3% 26.9% 350° C.-500° C. wt/wt.sub.FEED 22.3% 21.4% 16.5% 500° C.+ wt/wt.sub.FEED 16.7% 13.0%  6.9% Ins-C.sub.5 wt/wt.sub.FEED  8.4%  7.8% 11.0% THF-i wt/wt.sub.FEED  2.9%  3.3%  5.4% Estimated   90%   85% conversion of PLASMIX

[0218] The EST base case represents the reactivity of the vacuum residue alone in hydroconversion conditions. The polymeric charge is insoluble in tetrahydrofuran and constitutes the THF-i fraction present in the charge.

[0219] In case 1 a vacuum residue charge was treated, added to 5% of mechanically pre-treated polymeric charge (see the Case 1 description of the mixture preparation) while in case 2 the quantity of polymeric charge introduced was increased from 5% to 20%. An increase in the yields of the fraction 65° C-170° C. is observed, along with the increase in the charge treated.

[0220] THF-i also increase from the base case to case 1 to case 2. This fraction consists of THF-i reaction products (see base case), THF-i deriving from the organic fraction of unconverted plastic material, accumulation, in THF-i, of the inorganic fraction (ashes of the polymeric charge).

TABLE-US-00002 TABLE 2 Case 1 Case 3 Characterisation Mixture IN IBP-350° C. wt % 2.8 1.1 350° C.-500° C. wt % 7.0 5.8 500° C.+ wt % 67.6 65.1 Ins-C.sub.5 wt % 17.5 22.7 THFi wt % 5.1 5.4 Yield Products OUT C.sub.1-C.sub.4 wt/wt.sub.FEED  8.3% 12.3% 65° C.(C.sub.5)-170° C. wt/wt.sub.FEED 17.0% 16.0% 170° C.-350° C. wt/wt.sub.FEED 29.3% 25.8% 350° C.-500° C. wt/wt.sub.FEED 21.4% 14.2% 500° C.+ wt/wt.sub.FEED 13.0%  6.9% Ins-C.sub.5 wt/wt.sub.FEED  7.8% 12.5% THFi wt/wt.sub.FEED  3.3% 12.3% Estimated   90% conversion of PLASMIX

[0221] In case 3 the reactivity is reported under the same operating conditions using a vacuum residue mixture with 5% w/w of Plasmix chemically pre-treated with NaOH. As can be seen, while maintaining the naphtha cut yield at 65° C.-170° C., the production of THF-i considerably increases, indicating how the presence of NaOH intervenes in the overly high production of solid carbonaceous compounds.

TABLE-US-00003 TABLE 3 Case 1 Case 4 Characterisation Mixture IN IBP-350° C. wt % 2.8 2.4 350° C.-500° C. wt % 7.0 7.1 500° C.+ wt % 67.6 67.9 Ins-C.sub.5 wt % 17.5 17.5 THFi wt % 5.1 5.1 Yield Products OUT C.sub.1-C.sub.4 wt/wt.sub.FEED  8.3%  9.8% 65° C.(C.sub.5)-170° C. wt/wt.sub.FEED 17.0% 18.3% 170° C.-350° C. wt/wt.sub.FEED 29.3% 29.5% 350° C.-500° C. wt/wt.sub.FEED 21.4% 18.6% 500° C.+ wt/wt.sub.FEED 13.0%  8.2% Ins-C.sub.5 wt/wt.sub.FEED  7.8% 11.6% THFi wt/wt.sub.FEED  3.3%  3.9%

[0222] In case 4 the reactivity is reported, under the same operating conditions, using a mixture of vacuum residue with 5% w/w of Plasmix pre-treated by grinding, obtaining a Plasmix with D50<0.2 mm. As can be seen, the naphtha cut yield 65-170° C., compared to Case 1 in which the Plasmix was more coarsely ground, slightly increases, as does the production of solids. The decrease in the diameter of the polymeric charge particles helps, in both the mixing and homogenisation of the polymeric charge with the vacuum residue in the preparation phase of the mixture, and, moreover, make the material more available for both the naphtha cut and carbonaceous solids reaction.

Example 19

Comparison

Mix Preparation

[0223] Case 5: The polymeric charge is treated as in Example 1, i.e. ground. 5 grams of pre-treated polymeric charge are taken, available at room temperature, and 95 grams of vacuum residue pre-heated to 200° C. are added. The mixture is kept warm at 200° C. for 2 h under mechanical stirring.

[0224] Case 6:

[0225] The polymeric charge is treated as in Example 2, i.e. ground. 5 grams of pre-treated polymeric charge are taken, available at room temperature, and 95 grams of vacuum residue pre-heated to 200° C. are added. The mixture is kept warm at 200° C. for 2 h under mechanical stirring.

Reaction

[0226] Several experiments were conducted using a 30 cc microautoclave reactor.

[0227] The tests were conducted under the following operating conditions: [0228] 400° C.; [0229] 1 h; [0230] 20 bar of nitrogen.

[0231] As described in example 18, the mixtures tested in the various cases and the reaction products were characterised quantifying by precipitation the amount of insolubles in tetrahydrofuran (THFi), the insolubles in n-pentane (Ins-C.sub.5, fraction normally considered as an asphaltenic fraction) and the characterisation of the fraction thus de-asphalted using the ASTM D2887 method. The gas phase produced is characterised by the ASTM D7833 Standard Refinery Gas Analysis method.

[0232] In the base case reported in the table below and in cases 5 and 6 the operating reaction conditions have been kept unchanged and represent the conditions of a thermal treatment process.

TABLE-US-00004 TABLE 4 THERMAL Base Case Case 5 Case 6 Characterisation Mixture IN IBP-350° C. wt % 1.8 2.7 2.4 350° C.-500° C. wt % 11.2 7.0 7.1 500° C.+-Ins-C.sub.5 wt % 86.9 85.3 85.4 THFi wt % 0.0 5.0 5.1 Yield Products OUT C.sub.1-C.sub.4 wt/wt.sub.FEED  4.5%  6.2%  3.6% 65° C.(C.sub.5)-170° C. wt/wt.sub.FEED  3.0%  2.4%  0.9% 170° C.-350° C. wt/wt.sub.FEED  9.9% 10.2% 10.2% 350° C.-500° C. wt/wt.sub.FEED 17.3% 17.2% 16.9% 500° C.+-Ins-C.sub.5 wt/wt.sub.FEED 64.9% 61.4% 65.0% THFi wt/wt.sub.FEED  0.5%  2.6%  3.4%

[0233] The THERMAL base case represents the reactivity of the vacuum residue alone in thermal conversion conditions. The polymeric charge is insoluble in tetrahydrofuran and constitutes the THF-i fraction present in the charge. In case 5 a vacuum residue charge was treated, added to 5% of mechanically pre-treated polymeric charge (see the Case 5 description of the mixture preparation) while in case 6 a vacuum residue mixture was prepared, added to 5% of mechanically pre-treated polymeric charge so as to obtain particles with D50<0.2 mm. From the comparison of the base case with the cases in which the polymeric charge is added, it can be observed that in thermal conversion process conditions the naphtha yield is in any case lower than in the base case. At the same time there is evidence of a decrease in the conversion of the polymeric charge, as the THF-i are much higher at the end of the test. Considering the THF-i at the end of the test as an unconverted polymeric charge, it can be observed that the conversion in Case 5 is greater than in Case 6. Comparing the two cases (5 and 6) the increase in gas yields (C1-C4) and naphtha cut in Case 5 can be observed, indicating that the polymeric charge converts to light products even in a thermal conversion process, but predominantly with C1-C4 gaseous compounds.