Abstract: An integrated process for producing a hydrocarbon stream including C5-20 normal and iso-paraffins is disclosed. A de-sulfurized methane-rich stream and a natural gas condensate are isolated from the natural gas source. The methane-containing stream is converted into syngas, which is then subjected to a hydrocarbon synthesis process, for example, Fischer-Tropsch synthesis. One or more fractions from the hydrocarbon synthesis are blended with the natural gas condensate for co-hydroprocessing, where the blended stream includes less than about 200 ppm sulfur. Olefins and oxygenates are hydrotreated to form paraffins. Paraffins are subjected to hydroisomerization conditions to form isoparaffins. Hydrocarbons with chain lengths above a desired value, for example, C24, are hydrocracked. The hydrogenolysis that would otherwise form undesired C1-4 fractions is minimized by judicious selection of noble metal catalysts.

Abstract: An integrated process for producing a hydrocarbon stream, preferably including predominantly C5-20 normal and iso-paraffins, is disclosed. The process involves isolating a C4− stream and, optionally a C5+ stream (“natural gas condensate”) from a natural gas source. The C4− stream is converted to syngas, and the syngas used in a hydrocarbon synthesis process, for example, Fischer-Tropsch synthesis. In one embodiment, one or more fractions from the hydrocarbon synthesis are blended with one or more crude oil derived fractions, and, optionally, the natural gas condensate, such that the overall sulfur content of the blend is less than about 200 ppm. If necessary, the crude oil fractions and/or natural gas condensate can be treated to lower the sulfur content so that the blend has an acceptable sulfur level. The fraction from the hydrocarbon synthesis may include, for example, C5-20 hydrocarbons, C20+ hydrocarbons, or C5+ hydrocarbons.

Abstract: An integrated process for producing a hydrocarbon stream including C5-20 normal and iso-paraffins is disclosed. The process involves isolating a non-sulfur containing methane stream and a sulfur-containing C5+ stream from a natural gas source. The methane stream is converted to syngas and further reacted to form a higher molecular weight hydrocarbon product stream. The C5-20 hydrocarbons in that product stream are hydroprocessed along with at least a portion of the C5+ stream from the natural gas source. The presence of sulfur in the C5+ stream minimizes the hydrogenolysis that would otherwise occur if the C5-20 hydrocarbons were hydroprocessed without added sulfur-containing compounds or other hydrocracking suppressants. The result is an improved yield of C5-20 hydrocarbons relative to when the hydroprocessing step does not include hydrocracking suppressants.

Abstract: The present invention is directed to a method for hydroprocessing Fischer-Tropsch products. The invention in particular relates to an integrated method for producing liquid fuels from a hydrocarbon stream provided by Fischer-Tropsch synthesis. The method involves separating the Fischer-Tropsch products into a light fraction and a heavy fraction. The heavy fraction is subjected to hydrocracking conditions, preferably through multiple catalyst beds, to reduce the chain length. The products of the hydrocracking reaction following the last catalyst bed, optionally after a hydroisomerization step, are combined with the light fraction. The combined fractions are hydrotreated, and, optionally, hydroisomerized. The hydrotreatment conditions hydrogenate double bonds, reduce oxygenates to paraffins, and desulfurize and denitrify the products. Hydroisomerization converts at least a portion of the linear paraffins into isoparaffins.

Abstract: The present invention is directed to a method for hydroprocessing Fischer-Tropsch products. The invention in particular relates to an integrated method for producing liquid fuels from a hydrocarbon stream provided by Fischer-Tropsch synthesis. The method involves separating the Fischer-Tropsch products into a light fraction with normal boiling points below 700° F. and including predominantly C5-20 components and a heavy fraction with normal boiling points above 650° F. and including predominantly C20+ components. The heavy fraction is subjected to hydrocracking conditions, preferably through multiple catalyst beds, to reduce the chain length. The light fraction is used as all or part of a quench fluid between each catalyst bed.

Abstract: A method for hydroprocessing hydrocarbon products, preferably Fischer-Tropsch products, and a reactor useful for performing the method, are disclosed. The reactor includes one or more first catalyst beds comprising a catalyst useful for conducting relatively severe hydroprocessing and one or more second catalyst beds comprising a catalyst useful for conducting relatively mild hydroprocessing. The second catalyst beds are located at a position in the reactor where they can receive the products from the first catalyst bed(s), at least one of each of the first and second catalyst bed(s) comprises a catalyst grading scheme sufficient to remove at least a portion of any particulates from their respective feeds, and the reactor is set up to receive hydrocarbon feeds at a position above or within the first catalyst bed(s) and above or within the second catalyst bed(s).

Abstract: An integrated process for improved hydrocarbon recovery from a natural gas resource is disclosed. A methane-rich stream, an LPG stream and optionally a C5+ stream are isolated from a natural gas source in a first separation zone and desulfurized. The methane-rich stream is converted to syngas and subjected to hydrocarbon synthesis, for example, Fischer-Tropsch synthesis. The products from the hydrocarbon synthesis typically include a C4− fraction, a C5-C20 fraction, and a C20+ wax fraction. These fractions are isolated in a second separation zone. The C4− fraction is recycled through the first separation zone to provide methane for conversion to synthesis gas and an additional LPG fraction. The C4− fraction can be treated, for example, with hydrotreating or hydroisomerization catalysts and conditions before or after the separation.

Abstract: An integrated process for producing desulfurized hydroprocessed products from Fischer-Tropsch synthesis is disclosed. The process involves isolating and desulfurizing a methane-rich stream from a natural gas source in a first separation zone and a desulfurization zone. The methane-rich stream is converted to syngas and subjected to a hydrocarbon synthesis step, for example, a Fischer-Tropsch synthesis step. The products from the hydrocarbon synthesis step typically include a C4− fraction, a C5-20 fraction, and a C20+ wax fraction. These fractions are isolated in a second separation zone, typically via fractional distillation. The C4− fraction can be recycled through the first separation zone to provide a second methane-rich fraction for conversion to synthesis gas. The C4− fraction can optionally be treated, for example, with hydrotreatment or hydroisomerization catalysts and conditions before or after passage through the first separation zone.

Abstract: An integrated process for producing a liquid hydrocarbon stream from Fischer-Tropsch hydrocarbon product without having to remove particulate contaminants such as catalyst fines from hot Fischer-Tropsch wax is disclosed. The process involves performing Fischer-Tropsch synthesis, preferably under conditions which favor formation of wax and heavy products (i.e., using a catalyst with high chain growth probabilities), and obtaining a waxy heavy fraction including particulate contaminants. The fraction is subjected to hydroprocessing conditions, preferably upflow hydroprocessing conditions, using a catalyst bed which, through judicious selection of hydroprocessing catalysts and/or flow conditions, permits passage of the particulate contaminants. The particulates are then removed from the upgraded liquid product, for example by filtration, distillation and/or centrifugation.

Abstract: A physically intermixed catalyst system comprising two distinctly different catalytic particles, the first of which is a hydrodenitrification and/or hydrodesulfurization catalyst and the second of which is a relatively active hydrocracking catalyst, wherein the catalyst particles of both catalytic components are substantially the same size, that is the effective diameter of each catalyst component is substantially the same. The catalyst system of the present invention can be layered with unmixed catalysts. The novel systems of the present invention have been found to provide surprisingly good selectivity for liquid products and stability against catalyst fouling when used in combined hydrotreating and hydrocracking applications, and can therefore be used to provide a stable catalyst system which offers even heat distribution and reactor control in such applications.

Abstract: A physically intermixed catalyst system comprising two distinctly different catalytic particles, the first of which is a hydrodenitrification and/or hydrodesulfurization catalyst and the second of which is a relatively active hydrocracking catalyst, wherein the catalyst particles of both catalytic components are substantially the same size, that is the effective diameter of each catalyst component is substantially the same. The catalyst system of the present invention can be layered with unmixed catalysts. The novel systems of the present invention have been found to provide surprisingly good selectivity for liquid products and stability against catalyst fouling when used in combined hydrotreating and hydrocracking applications, and can therefore be used to provide a stable catalyst system which offers even heat distribution and reactor control in such applications.