SYSTEMS AND METHODS FOR PROCESSING HYDROCARBON FEEDSTOCKS

Abstract

Systems and methods for processing a hydrocarbon feedstock are provided. The method can include removing a portion of one or more impurities from a non-phenolic sour water to produce a treated sour water and a waste byproduct. The non-phenolic sour water can have a total concentration of impurities ranging from about 100 ppmw to about 125,000 ppmw. The treated sour water can have a total concentration of impurities ranging from about 1 ppmw to about 4,000 ppmw. The treated sour water can be heated to produce steam. A hydrocarbon feedstock can be contacted with the steam at conditions sufficient to separate the hydrocarbon feedstock into at least a first hydrocarbon product and a second hydrocarbon product.

Description

BACKGROUND

1. Field

Embodiments described herein generally relate to systems and methods for processing hydrocarbon feedstocks. More particularly, such embodiments relate to using steam comprising recycled non-phenolic sour water for separating the hydrocarbon feedstocks.

2. Description of the Related Art

Atmospheric distillation towers and/or vacuum distillation towers are typically used to separate hydrocarbon feedstocks such as crude oil into two or more fractions, which are then typically subjected to further processing, e.g., asphaltene separation, hydrocracking, hydrotreating, and/or fluidized catalytic cracking. These distillation processes, however, require a significant amount of steam in order to generate the necessary heat for the distillation of the hydrocarbon feedstock. Additionally, the subsequent processing of the hydrocarbon fraction(s) is frequently accompanied with the generation of large amounts of waste water such as phenolic sour water and non-phenolic sour water.

The waste water produced during the processing of hydrocarbons must be cleaned of impurities before the water can be disposed. The process equipment required to cleanup the waste water requires significant capital and operating expense. Additionally, a large amount of fresh water is required in order to operate the distillation towers and process the hydrocarbon feedstocks.

There is a need, therefore, for improved systems and methods for separating hydrocarbon feedstocks while generating a reduced amount of waste water that needs to be purified for disposal.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a schematic of an illustrative system for separating a hydrocarbon feedstock using dirty steam containing treated non-phenolic sour water recovered from one or more non-phenolic sour water sources, according to one or more embodiments described.

FIG. 2 depicts a schematic of another illustrative system for separating a hydrocarbon feedstock using dirty steam containing treated non-phenolic sour water recovered from one or more non-phenolic sour water sources, according to one or more embodiments described.

FIG. 3 depicts an illustrative system for treating non-phenolic sour water recovered from one or more sour water sources, according to one or more embodiments described.

DETAILED DESCRIPTION

Systems and methods for processing a hydrocarbon feedstock are provided. In one or more embodiments, the method can include removing a portion of one or more impurities from a non-phenolic sour water to produce a treated sour water and a waste byproduct. The non-phenolic sour water can have a total concentration of impurities ranging from about 100 ppmw to about 125,000 ppmw. The treated sour water can have a total concentration of impurities ranging from about 1 ppmw to about 4,000 ppmw. The treated sour water can be heated to produce steam. A hydrocarbon feedstock can be contacted with the steam at conditions sufficient to separate the hydrocarbon feedstock into at least a first hydrocarbon product and a second hydrocarbon product.

In one or more embodiments, non-phenolic sour water can be recovered, obtained, or otherwise acquired from any process, system, or combination of processes and/or systems that produce(s) or generate(s) non-phenolic sour water. The non-phenolic sour water can be free or substantially free of phenol and phenolic based or phenolic containing compounds, i.e., compounds containing one or more phenol groups. For example, the non-phenolic sour water can contain less than about 100 parts per million by weight (“ppmw”), less than about 90 ppmw, less than about 80 ppmw, less than about 70 ppmw, less than about 50 ppmw, or less than about 30 ppmw phenol and/or phenol containing compounds. In another example, the non-phenolic sour water can have a concentration of phenol and/or phenol containing compounds ranging from a low of about 1 ppmw, about 5 ppmw, or about 10 ppmw to a high of about 30 ppmw, about 50 ppmw, about 75 ppmw, or about 100 ppmw.

The non-phenolic sour water can contain one or more non-phenol containing impurities or simply “impurities.” The impurities present in the non-phenolic sour water can include, but are not limited to, sulfur containing compounds, nitrogen containing compounds, carbon dioxide, chloride containing compounds, thiocyanate compounds, cyanide compounds, dissolved hydrocarbons, insoluble hydrocarbons, or any combination thereof. Illustrative sulfur containing compounds can include, but are not limited to, mercaptans, disulfides, hydrogen sulfide, sulfates such as thiosulfate, or any combination thereof. Mercaptans can be represented by the symbol RSH, where R represents a normal or branched alkyl or aryl hydrocarbon, S represents sulfur, and H represents hydrogen. Illustrative mercaptans can include, but are not limited to, methanethiol, ethanethiol, 1-propanethiol, 2-propanethiol, 2-mercaptoethanol, heterocyclic sulfur compounds, or any combination thereof. Illustrative disulfides can include, for example, carbon disulfide. Illustrative heterocyclic sulfur compounds can include, but are not limited to, thiophenes, tetrahydrothiophenes, benzothiophenes, or any combination thereof. Illustrative nitrogen containing compounds can include, but are not limited to, ammonia, cyanides, or any combination thereof. Illustrative chloride containing compounds can include, but are not limited to, hydrogen chloride, ammonium chloride, chloride ions, or any combination thereof.

Depending, at least in part, on the particular source of the non-phenolic sour water, the particular make-up or composition of the non-phenolic sour water can widely vary. The non-phenolic sour water can have a total concentration of impurities ranging from a low of about 100 ppmw, about 500 ppmw, about 1,000 ppmw, or about 5,000 ppmw to a high of about 10,000 ppmw, about 15,000 ppmw, about 20,000 ppmw, about 30,000 ppmw, about 40,000 ppmw, about 50,000 ppmw, about 60,000 ppmw, or about 70,000 ppmw, about 75,000 ppmw, about 100,000 ppmw, or about 125,000 ppmw. For example, depending, at least in part, on the particular source or combination of sources of the non-phenolic sour water, the total concentration of impurities in the non-phenolic sour water can range from about 100 ppmw to about 125,000 ppmw.

The concentration of sulfur containing compounds in the non-phenolic sour water can range from a low of about 5 ppmw, about 50 ppmw, about 100 ppmw, about 500 ppmw, or about 1,000 ppmw to a high of about 1,500 ppmw, about 2,000 ppmw, about 3,000 ppmw, about 5,000 ppmw, about 10,000 ppmw, about 15,000 ppmw, about 20,000 ppmw, about 25,000 ppmw, about 40,000 ppmw, about 50,000 ppmw, about 60,000 ppmw, about 70,000 ppmw, or about 75,000 ppmw. The concentration of nitrogen containing compounds in the non-phenolic sour water can range from a low of about 1 ppmw, about 20 ppmw, about 50 ppmw or about 100 ppmw to a high of about 1,000 ppmw, about 3,000 ppmw, about 6,000 ppmw, about 12,500 ppmw, about 25,000 ppmw, or about 50,000 ppmw. The concentration of carbon dioxide in the non-phenolic sour water can range from a low of about 1 ppmw, about 10 ppmw, or about 50 ppmw to a high of about 100 ppmw, about 200 ppmw, or about 500 ppmw. The concentration of dissolved hydrocarbons in the non-phenolic sour water can range from a low of about 1 ppmw, about 10 ppmw, or about 50 ppmw to a high of about 100 ppmw about 200 ppmw, about 300 ppmw, or about 400 ppmw. The concentration of insoluble hydrocarbons in the non-phenolic sour water can range from a low of about 1 ppmw, about 50 ppmw, or about 100 ppmw to a high of about 250 ppmw, about 400 ppmw, or about 500 ppmw. The concentration of chloride containing compounds can range from a low of about 1 ppmw, about 5 ppmw, about 10 ppmw, or about 50 ppmw to a high of about 250 ppmw, about 1,000 ppmw, about 2,000 ppmw, or about 2,500 ppmw. For example, the concentration of chloride containing compounds can range from about 1 ppmw to about 2,500 ppmw, about 4 ppmw to about 250 ppmw, about 2 ppmw to about 50 ppmw, about 7 ppmw to about 2,000 ppmw, or about 5 ppmw to about 20 ppmw.

The concentration of hydrogen sulfide in the non-phenolic sour water can range from a low of about 1 ppmw, about 5 ppmw, about 100 ppmw, or about 200 ppmw to a high of about 1,000 ppmw, about 2,000 ppmw, about 5,000 ppmw, about 10,000 ppmw, about 15,000 ppmw, about 20,000 ppmw, about 25,000 ppmw, about 40,000 ppmw, about 50,000 ppmw, about 60,000 ppmw, about 70,000 ppmw, or about 75,000 ppmw. In at least one example, the concentration of hydrogen sulfide in the non-phenolic sour water can be at least 50 ppmw, at least 100 ppmw, at least 500 ppmw, at least 1,000 ppmw, at least 2,000 ppmw, or at least 2,500 ppmw. The concentration of ammonia in the non-phenolic sour water can range from a low of about 1 ppmw, about 20 ppmw, about 50 ppmw, or about 100 ppmw to a high of about 6,000 ppmw, about 12,500 ppmw, about 25,000 ppmw, or about 50,000 ppmw. In at least one example, the concentration of ammonia in the non-phenolic sour water can be at least 100 ppmw, at least 200 ppmw, at least 500 ppmw, at least 1,000 ppmw, or at least 2,000 ppmw. The concentration of dissolved hydrocarbons in the non-phenolic sour water can range from a low of about 1 ppmw, about 25 ppmw, or about 50 ppmw to a high of about 125 ppmw, about 175 ppmw, or about 200 ppmw. In at least one example, the concentration of dissolved hydrocarbons in the non-phenolic sour water can be at least 25 ppmw, at least 50 ppmw, at least 75 ppmw, or at least 100. The concentration of insoluble hydrocarbons in the non-phenolic sour water can range from a low of about 1 ppmw, about 25 ppmw, or about 50 ppmw to a high of about 200 ppmw, about 350 ppmw, or about 500 ppmw. In at least one example, the concentration of insoluble hydrocarbons in the non-phenolic sour water can be at least 50 ppmw, at least 100 ppmw, at least 150 ppmw, at least 200 ppmw, at least 250 ppmw, or at least 257 ppmw. In at least one example, the non-phenolic sour water can have a concentration of hydrogen sulfide of about 1,000 ppmw to about 75,000 ppmw and a concentration of ammonia of about 250 ppmw to about 50,000 ppmw.

In one or more embodiments, at least a portion of the non-phenolic sour water can be treated to remove a portion of the impurities contained therein to provide a treated non-phenolic sour water or “treated sour water” and a waste byproduct. For example, all or a portion of the non-phenolic sour water can be treated by contacting the non-phenolic sour water with steam, e.g., steam stripping, to produce the treated sour water and the waste byproduct. In another example, all or a portion of the non-phenolic sour water can be treated by passing the non-phenolic sour water through one or more reverse osmosis systems. In another example, all or a portion of the non-phenolic sour water can be treated by heat stripping, reboiling and fractionating, reboiling, fractionating, distilling, or any combination thereof.

Considering a treatment process that includes contacting the non-phenolic sour water with steam in more detail, the non-phenolic sour water can be at any desired pressure when contacted with steam. For example, the non-phenolic sour water can be at a pressure ranging from a low of about 101 kPa, about 150 kPa, about 200 kPa, or about 250 kPa to a high of about 350 kPa, about 600 kPa, about 1,000 kPa, about 1,500 kPa, or about 2,000 kPa. In another example, the non-phenolic sour water can be at a pressure ranging from a low of about 101 kPa, about 200 kPa, or about 300 kPa to a high of about 400 kPa, about 500 kPa, or about 600 kPa when contacted with steam. In another example, the non-phenolic sour water can be at a pressure of about 101 kPa to about 450 kPa, about 150 kPa to about 380 kPa, or about 250 kPa to about 360 kPa when contacted with the steam. The temperature of the sour water, when contacted with the steam can range from a low of about 100° C., about 110° C., or about 115° C. to a high of about 135° C., about 145° C., about 150° C., about 165° C., or about 185° C.

Treating the non-phenolic sour water can also include introducing one or more treatment additives or aids thereto. For example, it can be desirable to adjust the pH of the non-phenolic sour water, with the desired pH depending, at least in part, on the particular impurity composition of the non-phenolic sour water. Suitable acids can include, but are not limited to, hydrochloric acid, nitric acid, sulfuric acid, phosphoric acid, or any combination thereof. Suitable bases or alkaline compounds can include, but are not limited to, sodium hydroxide, potassium hydroxide, amines, or any combination thereof. Other additives that can be mixed or otherwise combined with the non-phenolic sour water in addition to or in lieu of and acid or base can include, for example, corrosion inhibitors.

Depending, at least in part, on the particular composition of the non-phenolic sour water all of the sour water or only a portion of the sour water can be subjected to treatment. For example, the non-phenolic sour water can be apportioned or split into a first portion and a second portion and the first portion of the non-phenolic sour water can be treated to produce a treated first portion and the second portion of non-phenolic sour water can bypass the treatment. All or a portion of the second portion and all or a portion of the treated first portion can be recombined to provide a re-combined treated sour water. If the non-phenolic sour water is split into a first portion and a second portion, with the first portion subjected to treatment and the second portion bypassing the treatment, the amount of the first portion can range from about 1 wt % to about 99 wt % and conversely the amount of the second portion can range from about 99 wt % to about 1 wt %. In at least one specific example, the non-phenolic sour water can be split into a first and second portion, where the first portion includes about 10 wt %, about 20 wt %, about 30 wt %, about 40 wt %, about 50 wt %, about 60 wt %, about 70 wt %, about 80 wt %, about 90 wt %, or about 95 wt % of the non-phenolic sour water and the first portion undergoes treatment while the second portion bypasses the treatment. In another example, all of the non-phenolic sour water can be treated to produce the treated sour water.

In another example, the non-phenolic sour water can be apportioned or split into the first portion and the second portion and both the first portion and the second portion can be treated. For example, the first portion of non-phenolic sour water can be treated or processed to remove at least a portion of one or more first impurities and the second portion can be treated or processed to remove at least a portion of one or more second impurities. In at least one specific example, the first portion can be treated to remove at least a portion of one or more sulfur containing impurities, e.g., hydrogen sulfide, to provide a first treated water and the second portion can be treated to remove at least a portion of one or more nitrogen containing impurities, e.g., ammonia, to provide a second treated water. At least a portion the first treated water and at least a portion of the second treated portion can be combined with one another to provide a re-combined treated sour water. Accordingly, the particular treatment or processing conditions for the first and second portions can be optimized to remove a particular impurity or a particular class of impurities relative to other impurities. For example, the optimized conditions for removing ammonia and hydrogen sulfide contained in a given non-phenolic sour water via steam stripping can differ, e.g., differing pH, and splitting the non-phenolic sour water into the first and second portions can provide for optimized separation of hydrogen sulfide from the first portion and ammonia from the second portion, for example. As such, the re-combined treated sour water can have a desired reduction in total impurities contained therein.

In another example, the non-phenolic sour water or the first portion and/or the second portion produced by splitting the non-phenolic sour water into the first portion and the second portion can be treated in two or more stages. Each treatment stage can be the same or different. For example, a first treatment stage can be optimized to remove at least a portion of one or more sulfur containing impurities and a second treatment stage can be optimized to remove at least a portion of one or more nitrogen containing impurities.

The treated sour water and/or the re-combined treated sour water can have a reduced concentration of at least one impurity relative to the non-phenolic sour water before treatment. The total concentration of impurities in the treated sour water and/or the re-combined treated sour water can range from a low of about 1 ppmw, about 25 ppmw, about 50 ppmw, or about 100 ppmw to a high of about 500 ppmw, about 800 ppmw, about 900 ppmw, about 1,000 ppmw, about 1,500 ppmw, about 2,000 ppmw, about 2,500 ppmw, about 3,000 ppmw, about 3,300 ppmw, about 3,500 ppmw, about 4,000 ppmw, about 4,500 ppmw, or about 5,000 ppmw. In at least one specific example, the total concentration of impurities in the treated sour water and/or the re-combined treated sour water can be less than about 3,500 ppmw, less than about 3,000 ppmw, less than about 2,500 ppmw, less than about 2,000 ppmw, less than about 1,500 ppmw, less than about 1,000 ppmw, less than about 700 ppmw, less than about 500 ppmw, less than about 200 ppmw, less than about 150 ppmw, or less than about 100 ppmw. In at least one other specific example, the total concentration of impurities in the treated sour water and/or the re-combined treated sour water can be at least 5 ppmw, at least 10 ppmw, at least 15 ppmw, at least 20 ppmw, at least 25 ppmw, at least 30 ppmw, at least 35 ppmw, at least 40 ppmw, at least 50 ppmw, at least 75 ppmw, at least 100 ppmw, at least 200 ppmw, at least 500 ppmw, or at least 1,000 ppmw. In another example, the concentration of impurities in the treated sour water can range from about 1 ppmw to about 10,000 ppmw, about 100 ppmw to about 7,000 ppmw, about 50 ppmw to about 9,000 ppmw, or about 1 ppmw to about 7,000 ppmw. In other words, a portion or “first” portion of at least one of the one or more impurities in the non-phenolic sour water can be removed, but at least a portion or “second” portion of the at least one of the one or more impurities can also remain in the treated sour water and/or the re-combined treated sour water.

The concentration of sulfur containing impurities in the treated sour water and/or the re-combined treated sour water can range from a low of about 1 ppmw, about 5 ppmw, about 8 ppmw, or about 10 ppmw to a high of about 15 ppmw, about 20 ppmw, about 25 ppmw, about 30 ppmw, about 40 ppmw, or about 50 ppmw. In another example, the concentration of sulfur containing impurities in the treated sour water and/or the re-combined sour water can range from a low of about 10 ppmw, about 50 ppmw, about 100 ppmw, or about 125 ppmw to a high of about 200 ppmw, about 225 ppmw, about 250 ppmw, about 275 ppmw, about 300 ppmw, about 325 ppmw, or about 350 ppmw. In at least one specific example, the total concentration of sulfur containing impurities in the treated sour water and/or the re-combined treated sour water can be at least 1 ppmw, at least 3 ppmw, at least 5 ppmw, at least 7 ppmw, at least 10 ppmw, at least 15 ppmw, at least 20 ppmw, at least 30 ppmw, at least 40 ppmw, at least 50 ppmw, at least 75 ppmw, at least 100 ppmw, or at least 125 ppmw. The total concentration of nitrogen containing compounds in the treated sour water and/or the re-combined treated sour water can range from a low of about 1 ppmw, about 5 ppmw, about 10 ppmw, or about 15 ppmw to a high of about 25 ppmw, about 35 ppmw, about 50 ppmw, about 100 ppmw, about 150 ppmw, or about 200 ppmw. In another example, the total concentration of nitrogen containing compounds in the treated sour water and/or the re-combined treated sour water can range from a low of about 10 ppmw, about 25 ppmw, about 50 ppmw, or about 100 ppmw to a high of about 500 ppmw, about 1,000 ppmw, about 1,500 ppmw, about 2,000 ppmw, about 2,500 ppmw, about 3,000 ppmw, or about 3,500 ppmw. In at least one specific example, the total concentration of nitrogen containing impurities in the treated sour water and/or the re-combined treated sour water can be at least at least 1 ppmw, at least 10 ppmw, at least 20 ppmw, at least 30 ppmw, at least 40 ppmw, at least 50 ppmw, at least 75 ppmw, at least 100 ppmw, at least 125 ppmw, at least 150 ppmw, at least 175 ppmw, at least 200 ppmw, at least 225 ppmw, at least 250 ppmw, at least 275 ppmw, at least 300 ppmw, or at least 350 ppmw. The concentration of carbon dioxide in the treated sour water and/or the re-combined treated sour water can range from a low of about 1 ppmw, about 5 ppmw, or about 10 ppmw to a high of about 15 ppmw, about 20 ppmw, or about 25 ppmw. In at least one specific example, the concentration of carbon dioxide in the treated sour water and/or the re-combined treated sour water can be at least 1 ppmw, at least 3 ppmw, at least 5 ppmw, at least 7 ppmw, at least 10 ppmw, at least 13 ppmw, at least 15 ppmw, at least 18 ppmw, at least 20 ppmw, or at least 22 ppmw. The concentration of dissolved hydrocarbons in the treated sour water and/or the re-combined treated sour water can range from a low of about 1 ppmw, about 10 ppmw, about 25 ppmw or about 50 ppmw to a high of about 100 ppmw, about 150 ppmw, about 175 ppmw, or about 200 ppmw. In at least one specific example, the total concentration of dissolved hydrocarbons in the treated sour water and/or the re-combined treated sour water can be at least 15 ppmw, at least 25 ppmw, at least 40 ppmw, at least 50 ppmw, at least 60 ppmw, or at least 75 ppmw. The concentration of insoluble hydrocarbons in the treated sour water and/or the re-combined treated sour water can range from a low of about 1 ppmw, about 25 ppmw, about 50 ppmw, or about 100 ppmw to a high of about 250 ppmw, about 350 ppmw, about 425 ppmw, or about 500 ppmw. In at least one specific example, the total concentration of insoluble hydrocarbons in the treated sour water and/or the re-combined treated sour water can be at least 15 ppmw, at least 30 ppmw, at least 50 ppmw, at least 75 ppmw, at least 100 ppmw, at least 125 ppmw, at least 150 ppmw, or at least 160 ppmw.

The concentration of hydrogen sulfide in the treated sour water and/or the re-combined treated sour water can range from a low of about 1 ppmw, about 10 ppmw, or about 15 ppmw to a high of about 25 ppmw, about 35 ppmw, about 40 ppmw, or about 50 ppmw. In another example, the concentration of hydrogen sulfide in the treated sour water and/or the re-combined treated sour water can range from a low of about 1 ppmw, about 10 ppmw, about 20 ppmw, or about 30 ppmw to a high of about 100 ppmw, about 150 ppmw, about 200 ppmw, about 250 ppmw, about 300 ppmw, or about 350 ppmw. In at least one specific example, the concentration of hydrogen sulfide in the treated sour water and/or the re-combined treated sour water can be at least 1 ppmw, at least 3 ppmw, at least 5 ppmw, at least 7 ppmw, at least 10 ppmw, at least 15 ppmw, at least 20 ppmw, at least 25 ppmw, at least 40 ppmw, at least 60 ppmw, at least 80 ppmw, at least 100 ppmw, at least 125 ppmw, or about least 150 ppmw. The concentration of ammonia in the treated sour water and/or the re-combined treated sour water can range from a low of about 1 ppmw, about 5 ppmw, or about 10 ppmw to a high of about 30 ppmw, about 50 ppmw, about 100 ppmw, or about 200 ppmw. In another example, the concentration of ammonia in the treated sour water and/or the re-combined treated sour water can range from a low of about 1 ppmw, about 25 ppmw, about 50 ppmw, or about 100 ppmw to a high of about 500 ppmw, about 1,000 ppmw, about 1,500 ppmw, about 2,000 ppmw, about 2,500 ppmw, about 3,000 ppmw, or about 3,500 ppmw. In at least one specific example, the concentration of ammonia in the treated sour water and/or the re-combined treated sour water can be at least 1 ppmw, at least 10 ppmw, at least 20 ppmw, at least 30 ppmw, at least 40 ppmw, at least 50 ppmw, at least 75 ppmw, at least 100 ppmw, at least 125 ppmw, at least 150 ppmw, at least 175 ppmw, at least 200 ppmw, at least 225 ppmw, at least 250 ppmw, at least 275 ppmw, at least 300 ppmw, or at least 350 ppmw. The concentration of chloride containing compounds can range from a low of about 1 ppmw, about 5 ppmw, about 10 ppmw, or about 50 ppmw to a high of about 250 ppmw, about 1,000 ppmw, about 2,000 ppmw, or about 2,500 ppmw. For example, the concentration of chloride containing compounds can range from about 1 ppmw to about 2,500 ppmw, about 4 ppmw to about 250 ppmw, about 2 ppmw to about 50 ppmw, about 7 ppmw to about 2,000 ppmw, or about 5 ppmw to about 20 ppmw.

The concentration of phenol and phenol containing compounds in the treated sour water and/or the re-combined treated sour water can range from a low of about 1 ppmw, about 3 ppmw, about 5 ppmw, or about 10 ppmw to a high of about 25 ppmw, about 40 ppmw, about 50 ppmw, about 75 ppmw, or about 100 ppmw. For example, the treated sour water and/or the re-combined treated sour water can have a total concentration of phenol and phenol containing compounds ranging from about 1 ppmw to about 50 ppmw, about 2 ppmw to about 30 ppmw, about 5 ppmw to about 35 ppmw, about 5 ppmw to about 90 ppmw, or about 5 ppmw to about 20 ppmw. In another example, the treated sour water and/or the re-combined treated sour water can have a total concentration of phenol and phenol containing compounds of at least 1 ppmw, at least 5 ppmw, at least 10 ppmw, at least 20 ppmw, at least 30 ppmw, at least 40 ppmw, at least 50 ppmw, at least 60 ppmw, at least 70 ppmw, or at least 80 ppmw.

In at least one example, the treated sour water and/or the re-combined treated sour water can have a concentration of hydrogen sulfide ranging from about 5 ppmw to about 15 ppmw and a concentration of ammonia ranging from about 20 ppmw to about 50 ppmw. In another example, the treated sour water and/or the re-combined treated sour water can have a concentration of hydrogen sulfide of at least 5 ppmw, at least 10 ppmw, at least 15 ppmw, or at least 20 ppmw and a concentration of ammonia of at least 10 ppmw, at least 20 ppmw, at least 30 ppmw, at least 35 ppmw, or at least 40 ppmw. In at least one other example, the treated sour water and/or the re-combined treated sour water can have a concentration of hydrogen sulfide ranging from about 5 ppmw to about 15 ppmw, a concentration of ammonia ranging from about 20 ppmw to about 50 ppmw, and a concentration of phenol and/or phenol containing compounds ranging from about 1 ppmw to about 30 ppmw. In another example, the treated sour water and/or the re-combined treated sour water can have a concentration of hydrogen sulfide of at least 5 ppmw, at least 15 ppmw, at least 25 ppmw, or at least 50 ppmw, a concentration of ammonia of at least 10 ppmw, at least 30 ppmw, at least 60 ppmw, at least 100 ppmw, or at least 250 ppmw, and a concentration of phenol and/or phenol containing compounds of at least 1 ppmw, at least 5 ppmw, at least 10 ppmw, at least 25 ppmw, at least 50 ppmw, at least 60 ppmw, at least 70 ppmw, at least 80 ppmw, or at least 90 ppmw. In at least one other example, the treated sour water and/or the re-combined treated sour water can have a concentration of hydrogen sulfide ranging from about 5 ppmw to about 15 ppmw, a concentration of ammonia ranging from about 20 ppmw to about 50 ppmw, a concentration of dissolved hydrocarbons ranging from about 20 ppmw to about 120 ppmw, and a concentration of insoluble hydrocarbons ranging from about 50 ppmw to about 100 ppmw.

At least a portion of the treated sour water and/or the re-combined treated sour water can be heated to produce steam or a steam product. As used herein, the term “dirty steam,” refers to steam containing the treated sour water and/or the re-combined treated sour water. The steam or dirty steam can be used to process hydrocarbon feedstocks. One suitable process the dirty steam can be used in can include, but is not limited to, a hydrocarbon separation process. For example, the hydrocarbon feedstock can be contacted with the dirty steam at atmospheric pressure, e.g., within an atmospheric distillation process, and the amount and/or temperature of the dirty steam contacted with the hydrocarbon feedstock can be sufficient to heat and fractionate, distill, or otherwise separate the hydrocarbon feedstock into two or more fractions or products, e.g., a first or light fraction and a second or heavy fraction. In another example, the hydrocarbon feedstock can be contacted with the dirty steam under a under vacuum, e.g., within a vacuum distillation process, and the amount and/or temperature of the dirty steam contacted with the hydrocarbon feedstock can be sufficient to heat and separate or distill the hydrocarbon feedstock into two or more fractions or products. In another example, a first hydrocarbon feedstock can be contacted with a first portion of the dirty steam at about atmospheric pressure to separate or distill the first hydrocarbon feedstock into two or more fractions and a second hydrocarbon feedstock can be contacted with a second portion of the dirty steam under a vacuum to separate or distill the second hydrocarbon feedstock into two or more fractions. Other processes in which the dirty steam can be used to process the hydrocarbon feedstock can include, but are not limited to, coker/fractionator, visbreaker, thermal cracker, or any combination thereof. In another example, the dirty steam can be used as purge steam within a catalytic cracker, a catalytic cracker fractionator, or other purging operations.

The treated sour water and/or the re-combined treated sour water can be heated using any suitable heating process or any combination of heating processes. For example, heat can be indirectly transferred to the treated sour water and/or the re-combined treated sour water from a heat transfer medium to produce the dirty steam. In another example, heat can be directly transferred to the treated sour water and/or the re-combined treated sour water from a heat transfer medium to produce the dirty steam. In another example, a fuel can be combusted and at least a portion of the heat generated by combusting the fuel can be transferred indirectly and/or directly to the treated sour water and/or the re-combined treated sour water to produce the dirty steam. In another example, an electric heater can be used to heat the treated sour water and/or the re-combined treated sour water to produce the dirty steam. In another example, heat can be transferred from one or more intermediate and/or final product streams within a hydrocarbon processing and/or production process. For example, heat from a syngas produced in a gasifier can be used to heat the treated sour water and/or the re-combined sour water to produce the dirty steam.

The dirty steam can be low pressure (“LP”) steam, medium pressure (“MP”) steam, high pressure (“HP”) steam, superheated steam, and/or superheated high pressure steam. Low pressure steam can have a temperature ranging from about 100° C. to about 160° C. and a pressure ranging from about 101 kPa to about 620 kPa. Medium pressure steam can have a temperature ranging from about 161° C. to about 195° C. and a pressure ranging from about 621 kPa to about 1,380 kPa. High pressure stream can have a temperature ranging from about 196° C. to about 252° C. and a pressure ranging from about 1,381 kPa to about 4,138 kPa. Superheated steam can have a temperature ranging from about 165° C. to about 250° C. and a pressure ranging from about 621 kPa to about 1,380 kPa. Superheated high pressure steam can have a temperature ranging from about 200° C. to about 310° C. and a pressure ranging from about 1,381 kPa to about 4,138 kPa.

In one or more embodiments, if the amount or quantity of dirty steam is lower than desired, a make-up steam or “fresh” steam can be mixed, combined, or otherwise added to the dirty steam to produce a desired amount of dirty steam. In another example, if the amount of dirty steam is lower than desired, a make-up water or “fresh” water can be mixed, combined, or otherwise added to the non-phenolic sour water, the treated sour water, and/or the re-combined treated sour water, and the mixture can then be heated to produce the dirty steam. As such, the dirty steam contacted with the hydrocarbon feedstock can be made up of about 1%, about 5%, about 10%, about 20%, about 30%, about 40%, about 50%, about 60%, about 70%, about 80%, about 90%, or about 100% of the treated sour water and/or the re-combined treated sour water. For example, the steam can contain from about 10 wt % to about 100 wt % of the treated sour water and/or the re-combined treated sour water.

The hydrocarbon feedstock can be contacted with an amount of dirty steam sufficient to separate the hydrocarbon feedstock into at least two fractions, e.g., a light fraction and a heavy fraction. The amount of dirty steam contacted with the hydrocarbon feedstock can range from a low of about 0.05 kg/hr, about 0.1 kg/hr, about 0.2 kg/hr, or about 0.3 kg/hr to a high of about 0.4 kg/hr, about 0.5 kg/hr, about 0.6 kg/hr, or about 0.7 kg/hr, where the amount of dirty steam is based on one barrel per day of the hydrocarbon feedstock. For example, about 0.25 kg/hr (per barrel per day) to about 0.5 kg/hr (per barrel per day) of medium pressure dirty steam can be contacted with the hydrocarbon feedstock at a pressure of about atmospheric pressure, e.g., 101 kPa to about 130 kPa, where the amount of dirty steam is based on one barrel per day of hydrocarbon feedstock. In another example, about 0.05 kg/hr (per barrel per day) to about 0.25 kg/hr (per barrel per day) of medium pressure dirty steam can be contacted with the hydrocarbon feedstock at a pressure less than atmospheric pressure, e.g., about 2 kPa to about 10 kPa, where the amount of dirty steam is based on one barrel per day of the hydrocarbon feedstock.

In one or more embodiments, the two or more hydrocarbon fractions or products separated from the hydrocarbon feedstock can include, but are not limited to, atmospheric tower bottoms, light, medium, and/or heavy atmospheric gas oils, straight run kerosene, straight run naphtha, off gases, vacuum distillation tower bottoms, light, medium, and/or heavy vacuum gas oils, diesels, kerosene, hydrocarbon gases, virgin gas oils, straight run gasoline, light, medium, and/or heavy cycle oils, other distillates, or any combination thereof.

Referring again to the non-phenolic sour water, the non-phenolic sour water can be acquired from inside battery limits (ISBL), outside battery limits (OSBL), or a combination thereof. Illustrative non-phenolic sour water sources can include, but are not limited to, hydrocarbon hydroprocessing systems, hydrocracking systems, or any combination thereof. Illustrative hydrocarbon hydroprocessing systems can include, but are not limited to, hydrodesulfurization, hydrotreating, hydrocracking, hydrogenation of aromatics, hydroisomerization, hydrodewaxing, metal removal, ammonia removal, and the like. Hydrotreating processes can be used to hydrotreat one or more hydrocarbons, fore example, such as naphtha, kerosene, gas oil, and the like.

Referring again to the hydrocarbon feedstock, the hydrocarbon feedstock can be or include any suitable hydrocarbon containing material. The hydrocarbon feedstock can include, but is not limited to, one or more whole crude oils, crude oils, oil shales, oil sands, tars, bitumens, kerogens, waste oils, or any combination thereof. In one or more embodiments, the hydrocarbon can be a mixture containing one or more hydrocarbons having a bulk API specific gravity (API @ 15.6° C.—ASTM D4052) of about 35° or less, about 25° or less, about 20° or less, about 15° or less, or about 10° or less. In one or more embodiments, the hydrocarbon can have a bulk API specific gravity (API @ 15.6° C.—ASTM D4052) of from about 6° to about 25°; about 7° to about 23°; about 8° to about 19′; or about 8° to about 15°. In one or more embodiments, the hydrocarbon can have a bulk normal, atmospheric, boiling point of about 10° C. to about 300° C. or more for crude processing and about 300° C. to about 550° C. or more for vacuum processing.

In one or more embodiments, the hydrocarbon feedstock can have a Conradson Carbon Residue (“CCR”) of from about 1 wt % to about 20 wt %. For a crude oil example, the CCR content of the hydrocarbon feedstock can range from a low of about 1 wt %, to a high of about 5 wt %. For a heavy (bitumen) example, the CCR content of the hydrocarbon feedstock can range from a low of about 5 wt %, to a high of about 15 wt %. The hydrocarbon feedstock can also include from about 5 ppmw to about 400 ppmw or more nickel and from about 5 ppmw to about 1,000 ppmw or more vanadium.

FIG. 1 depicts a schematic of an illustrative system 100 for separating a hydrocarbon feedstock 101 using dirty steam 127 containing treated non-phenolic sour water via line 106 recovered from one or more non-phenolic sour water sources 105, according to one or more embodiments. As noted above, the non-phenolic sour water source 105 can include any process or combination of processes that produce or generate non-phenolic sour water via line 106. All or a portion of the non-phenolic sour water in line 106 can be introduced via line 107 to one or more treatment units or systems (one is shown 110) to produce a waste byproduct via line 112 and a treated sour water via line 114. As illustrated, the treatment unit 110 can include a steam stripper or “non-phenolic sour water stripper.” Other suitable treatment systems 110 can include, but are not limited to, reverse osmosis systems, electric heating, re-boiling and fractionation, fractionation, re-boiling, distillation, or any combination thereof.

Steam or any other suitable heated medium via line 109 can be introduced to the treatment unit 110. The steam or other heated medium introduced via line 109 can heat and/or contact the non-phenolic sour water, which can remove at least a portion of one or more impurities contained in the non-phenolic sour water to produce the waste byproduct via line 112 and the treated sour water via line 114. For example, steam introduced via line 109 can heat the non-phenolic sour water a sufficient amount to cause at least a portion of the impurities to vaporize, thereby separating out of the non-phenolic sour water. The steam can contact the non-phenolic sour water co-currently, counter-currently, or a combination thereof.

The treatment unit 110 can include any treatment unit or system or combinations of treatment units and/or systems capable of separating or otherwise removing at least a portion of the one more impurities contained in the non-phenolic sour water in line 107. In at least one specific embodiment, the treatment unit 110 can include one or more strippers. With reference to strippers in particular, strippers can separate at least a portion of one or more impurities from the non-phenolic sour water by contacting the non-phenolic sour water with the a heated fluid, e.g., steam, introduced via line 109 thereto. The stripper can include one or more systems and/or devices suitable for separating at least a portion of one or more impurities from the non-phenolic sour water to provide the waste byproduct via line 112 and the treated sour water via line 114. For example, the stripper can include, but is not limited to, one or more internal structures including, but not limited to, one or more trays, e.g., perforated trays, bubble trays, floating valve trays, and the like; randomly packed elements, e.g., Nutter rings, I-rings, P-rings, R-rings, Raschig rings, saddle rings, A-PAK rings, Pall rings, U-rings, and the like; and/or structured packing elements, e.g., corrugated sheets, crimped sheets, gauzes, grids, wire mesh, monolith honeycomb structures, and the like. In another example, the stripper can be an open column with or without internals. The steam stripper can operate at a temperature ranging from a low of about 50° C., about 100° C., about 200° C., or about 300° C. to a high of about 400° C., about 500° C., about 550° C., or about 600° C. The steam stripper can operate at a pressure ranging from a low of about 101 kPa, about 150 kPa, about 200 kPa, or about 250 kPa to a high of about 350 kPa, about 600 kPa, about 1,000 kPa, about 2,500 kPa, or about 4,000 kPa. For example, the stream stripper can operate at a pressure of about 101 kPa to about 500 kPa, about 150 kPa to about 450 kPa, about 200 kPa to about 400 kPa or about 300 kPa to about 375 kPa.

In one or more embodiments, a first portion of the sour water in line 106 can be introduced via line 107 to the treatment unit 110 and a second portion of the treated sour water via line 108 can bypass the treatment unit 110. In one or more embodiments, at least a portion of the second portion in line 108 can be introduced via line 113 and mixed or otherwise combined with the treated sour water in line 114 and/or 116 (not shown) to provide a re-combined treated sour water in line 114 and/or 116. In one or more embodiments, at least a portion of the second portion via line 117 can be removed from the system 100 and further processed, introduced to one or more other processes or systems, disposed of, or any combination thereof.

The treated sour water via line 114 can be introduced to one or more steam generators (one is shown 125) to produce dirty steam via line 127. In at least one example, the treated sour water via line 114 can be introduced to one or more pumps (one is shown 120) to assist or aid in the introduction of the treated sour water in line 114 to the steam generator 125. In at least one embodiment the pump 120 can produce pressurized treated sour water via line 116. The pump 120 can increase the pressure of the treated sour water in line 114 to produce the treated sour water in line 116 having any desired pressure. The pressure of the treated sour water can range from about 101 kPa to about 600 kPa.

The dirty steam via line 127 can be low pressure steam, medium pressure steam, high pressure steam, superheated steam, or high pressure superheated steam. The particular temperature and pressure of the steam in line 127 can depend, at least in part, on the particular or intended use for the dirty steam. For example, the dirty steam in line 127 can be introduced to one or more atmospheric distillation units (ADU) (one is shown 140) where the dirty steam can be used to separate a hydrocarbon feedstock introduced via line 101 into two or more fractions (three are shown 141, 142, 143). The dirty steam in line 127 can be at a temperature ranging from about 110° C. to about 170° C. The dirty steam in line 127 can be at a pressure ranging from a about 137 kPa to about 593 kPa, about 101 kPa to about 600 kPa, or about 120 kPa to about 550 kPa.

The steam generator 125 can include one or more steam generating systems and/or devices capable of heating the treated sour water introduced thereto via line 114 (not shown) and/or 116 a sufficient amount to produce the dirty steam via line 127. The steam generator 125 can be an open column without internal structures. The steam generator 125 can include one or more internal structures such as trays, structured packing elements, and/or random packing elements. In one or more embodiments, a condensed waste water or “blowdown” via line 126 can be recovered from the steam generator 125. The blowdown via line 126 can be introduced to one or more waste water treatment units (not shown) for purification and further use and/or disposal.

In one or more embodiments, a heated heat transfer medium via line 121 can be introduced to the steam generator 125 and heat can be transferred indirectly and/or directly to the treated sour water introduced thereto via line 114 and/or 116. Illustrative heated heat transfer mediums can include, but are not limited to, steam, combustion gases, hot syngas, other heated gases, or any combination thereof. For example, steam via line 121 can be introduced to the steam generator via line 121 and can indirectly and/or directly transfer heat to the treated sour water to produce the dirty steam via line 127.

The steam generator 125 can also include one or more heat exchangers or “re-boilers” (one is shown 130) for further heating the treated sour water. Condensed water within the steam generator 125 can be introduced via line 128 to the heat exchanger 130 and heat can be directly and/or indirectly transferred to the condensed water to produce steam via line 131. The steam via line 131 can be reintroduced via line 131 to the steam generator 125. In one or more embodiments, one or more heated heat transfer mediums via line 129 can be introduced to the heat exchanger 130 to provide at least a portion of the heat transferred to the condensed water therein. Illustrative heated heat transfer mediums in line 129 can include, but are not limited to, steam, combustion gases, hot syngas, other heated gases, or any combination thereof.

The heat exchanger 130 can include one or more devices and/or systems suitable for transferring heat from the heated heat transfer medium in line 129 to the condensed water introduced via line 128. For example, the heated exchanger 130 can include, but is not limited to, single or multiple pass heat exchange devices such as shell and tube heat exchangers, plate and frame heat exchangers, spiral heat exchangers, bayonet type heat exchangers, U-tube heat exchangers, and/or any similar systems and/or devices. Other suitable heat exchangers 130 can include vessels or other containers having an internal volume or zone for combining the condensed water introduced via line 128 with the heated heat transfer medium introduced via line 129.

As noted above, the dirty steam via line 127 can be introduced to the atmospheric distillation unit 140 where the dirty steam can be used to separate a hydrocarbon feedstock introduced via line 101 into two or more fractions (three are shown 141, 142, and 143).

In one or more embodiments, make-up steam via line 133 can be mixed or otherwise combined with the dirty steam in line 127. For example, the make-up steam via line 133 can be used supplement the quantity or amount of steam recovered via line 127 from the steam generator 125. In another example, the make-up steam via line 133 can be used to replace the dirty steam in line 127 during periods of interruption. For example, a disruption in the process that produces the non-phenolic sour water via line 107 can cause a reduction or termination in the dirty steam produced via line 127 from the steam generator 125. Although not shown, make-up water can be introduced to the non-phenolic sour water in line 106, 107, 108, the treated sour water and/or the recombined treated sour water in lines 114 and/or 116, and/or directly to the steam generator 125.

FIG. 2 depicts a schematic of another illustrative system 200 for separating a hydrocarbon feedstock via line 101 using dirty steam via line 127 containing treated non-phenolic sour water recovered via line 106 from one or more non-phenolic sour water sources 105, according to one or more embodiments. The system 200 can include the one or more sour water sources 105, treatment units 110, pumps 120, steam generators, and atmospheric distillation units 140, which can be as discussed and described above with reference to FIG. 1. In one or more embodiments, the dirty steam in line 127 can be split into a first portion via line 203 and a second portion via line 205. The first portion via line 203 can be introduced to the atmospheric distillation unit 140 to separate the hydrocarbon feedstock introduced via line 101 thereto into the one or more hydrocarbon fractions or products (three are shown 141, 141, and 143). The second portion via line 205 can be introduced to one or more vacuum distillation units (one is shown 215) to separate a hydrocarbon feedstock (the third or heavy hydrocarbon fraction 143 as shown) into one or more hydrocarbon fractions (three are shown 217, 219, 221).

In one or more embodiments, the dirty steam or first portion of dirty steam in line 203 can be further split or divided into any number of portions or fractions. For example, a portion of the dirty steam in line 203 can be introduced via line 206 to one or more side strippers (one is shown 210) to produce further purified hydrocarbon product. As shown, the intermediate or second hydrocarbon fraction via line 141 recovered from the atmospheric distillation unit 140 can be introduced to the side stripper 210 where the dirty steam introduced via line 206 (or heat therefrom) can be used to further separate the second hydrocarbon into a lighter hydrocarbon fraction via line 242 and a heavier hydrocarbon fraction via line 241. As such, an intermediate or second hydrocarbon via line 241 having a higher purity can be recovered from the side stripper 210 as compared to the second hydrocarbon in line 141. The lighter hydrocarbon fraction via line 241 can be recovered as an additional product (not shown) or recycled back to the atmospheric distillation unit 140.

The atmospheric distillation unit 140 can include any number of side strippers 210. For example, the system 200 can include one side stripper 210 (as shown), two, three, four, five, six, seven, eight, nine, ten, or more than ten side strippers 210. Two or more side strippers 210 can be arranged in parallel with respect to one another, i.e., each side stripper 210 can receive a hydrocarbon from the atmospheric distillation unit. Two or more side strippers 210 can be arranged in series with respect to one another, i.e., a subsequent side stripper can receive a produce from a previous side stripper rather than from the atmospheric distillation unit 210. Although not shown, the vacuum distillation unit 215 can also include one or more side-strippers for improving the purity of one or more hydrocarbon fractions recovered therefrom.

The one or more side strippers 210 can include one or more systems and/or devices suitable for fractionating or purifying the second hydrocarbon in line 141. For example, the side stripper 210 can be or include an open column without internal structures. In another example, the side stripper 210 can be or include one or more internal structures such as trays, structured packing elements, and/or random packing elements. The particular composition of the second hydrocarbon in line 140 can, at least in part, determine the particular operating temperature, pressure, and other parameters of the side stripper 210. The particular composition of the second hydrocarbon in line 140 can, at least in part, determine the particular internal structure, e.g., the presence or absence of internal structures, the particular type of internal structures, if present, as well and the overall configuration of the internal structures, if present. Although not shown, the system 100 discussed and described above with reference to FIG. 1 can also include one or more side strippers 210.

The atmospheric distillation unit 140 can include one or more systems and/or devices suitable for fractionating or distilling the hydrocarbon feedstock introduced via line 101. For example, the atmospheric distillation unit 140 can include one or more trays, e.g., chimney trays, bubble cap trays, and the like. The atmospheric distillation unit 140 can also include one or more structured packing elements, randomly packed elements, or a combination thereof. The operating temperature within the atmospheric distillation unit 140 can vary. For example, the temperature can range from a low of about 35° C. to about 120° C. at the end where the first or light hydrocarbon fraction via line 141 can be recovered to a high of about 260° C. to about 380° C. at the end where the third or heavy hydrocarbon fraction via line 143 can be recovered. As the name implies, the pressure within the atmospheric distillation unit 140 can be about atmospheric pressure; however, the pressure can also be above atmospheric pressure. For example, the pressure with the atmospheric distillation unit 140 can range from about 101 kPa to about 150 kPa.

In one or more embodiments, one or more of the hydrocarbon fractions 141, 142, and/or 143 can be further processed. For example, the third or heavy hydrocarbon fraction via line 143 can be introduced to the vacuum distillation unit 215 for further separation. The third hydrocarbon fraction 143 can also be referred to as an atmospheric distillation bottoms product. The vacuum distillation unit can be operated at a pressure ranging from a low of about 1 kPa, about 10 kPa, about 20 kPa, or about 25 kPa, to a high of about 80 kPa, about 85 kPa, about 90 kPa, or about 100 kPa. The operating temperature within the vacuum distillation unit can range from about 25° C. to about 450° C.

As shown, the vacuum distillation unit 215 can be used to separate the atmospheric tower bottoms in line 143 into the three hydrocarbon fractions 217, 219, 221. The dirty steam via line 205 can be introduced to the vacuum distillation unit 215 where the dirty steam can directly and/or indirectly heat the atmospheric tower bottoms introduced via line 143 to separate the atmospheric tower bottoms into the hydrocarbon fractions 217, 219, 221. Although not shown, one or more side strippers 210 can be used to further purify or otherwise modify any one or more of the hydrocarbon fractions 217, 219, 221 recovered from the vacuum distillation unit 215.

The vacuum distillation unit 215 can include one or more systems and/or devices suitable for fractionating or distilling the hydrocarbon feedstock introduced via line 143. For example, the vacuum distillation unit 215 can include one or more trays, e.g., chimney trays, bubble cap trays, and the like. The vacuum distillation unit 215 can also include one or more structured packing elements, randomly packed elements, or a combination thereof.

FIG. 3 depicts an illustrative system 300 for treating a non-phenolic sour water via line 106 recovered from the one or more sour water sources 105, according to one or more embodiments. The one or more non-phenolic sour water sources 105 and treating units 110 can be as discussed and described above with reference to FIGS. 1 and 2. The non-phenolic sour water in line 106 can be split or apportioned into a first portion via line 107 and a second portion via line 108. The first portion via line 107 can be introduced to the treating unit 110 to produce the waste byproduct via line 112 and the treated sour water or “first” treated sour water via line 114. The second portion via line 108 can be introduced to a second treating unit 310 to produce a second waste byproduct via line 312 and a second treated sour water via line 314. The second treating unit 310 can be the same as or similar to the treating unit 110 discussed and described above with reference to FIGS. 1 and 2.

At least a portion of the first treated sour water in line 114 and at least a portion of the second treated sour water in line 314 can be combined with one another to provide a recombined treated sour water via line 320. The recombined treated sour water via line 320 can then be introduced to the steam generator 125 and heated to produce dirty steam via line 127, as discussed and described above with reference to FIGS. 1 and 2. The recombined treated sour water via line 320 can also be introduced to the pump 120 to provide a pressurized recombined treated sour water via line 116, which can be introduced to the steam generator 125, as discussed and described above with reference to FIGS. 1 and 2.

In one or more embodiments, the non-phenolic sour water in line 106 can be split or apportioned into the first and second portions 107, 108 at any desired ratio with respect to one another. For example, the amount of the first portion in line 107 can range from about 1 wt % to about 99 wt % and conversely the amount of the second portion in line 108 can range from about 99 wt % to about 1 wt %, based on a total weight of the non-phenolic sour water in line 106. In at least one specific example, the non-phenolic sour water in line 106 can be split into the first and second portion, where the first portion includes about 10 wt %, about 20 wt %, about 30 wt %, about 40 wt %, about 50 wt %, about 60 wt %, about 70 wt %, about 80 wt %, about 90 wt %, or about 95 wt % of the non-phenolic sour water in line 106.

In one or more embodiments, separating the non-phenolic sour water in line 106 into the first and second portions 107, 108 can improve operational flexibility, reduce costs, reduce the energy input required to treat the non-phenolic sour water, reduce equipment size, or any combination thereof. For example, the first portion in line 107 can be treated within the first treating unit 110 under process conditions that tend to promote the removal of at least one first impurity relative to at least one second impurity contained in the first portion of non-phenolic sour water. Conversely, the second portion 108 can be treated within the second treating unit 310 under process conditions that tend to promote the removal of the at least one second impurity relative to the at least one first impurity. As such, the first treated sour water in line 114 can contain less of the first impurity relative to the second treated sour water in line 314 and the second treated sour water in line 314 can contain less of the second impurity relative to the first treated sour water in line 114. For example, if a non-phenolic sour water in line 106 were to contain 60 ppmw ammonia and 20 ppmw hydrogen sulfide, the non-phenolic sour water could be split into two equal portions via lines 107 and 108. The first treating unit 110 could be operated at conditions sufficient to substantially remove the ammonia and produce a first treated sour water having a total concentration of ammonia of less than about 1 ppmw. The second treating unit 310 could be operated at conditions sufficient to substantially remove or otherwise neutralize the hydrogen sulfide and produce a second treated sour water having a total concentration of hydrogen sulfide of less than about 1 ppmw. As such, the amount of the ammonia and hydrogen sulfide in the recombined treated sour water in line 320 could be reduced by about 50% as compared to the non-phenolic sour water in line 106. Depending on the particular desired composition of the recombined treated sour water in line 320, the particular operating conditions, number of treating units, number of separate non-phenolic sour water portions separated and individually treated, or any combination thereof, can widely vary.

Embodiments of the present disclosure further relate to any one or more of the following paragraphs:

1. A method for processing a hydrocarbon feedstock, comprising: removing a portion of one or more impurities from a non-phenolic sour water to produce a treated sour water and a waste byproduct, wherein the non-phenolic sour water has a total concentration of impurities ranging from about 100 ppmw to about 125,000 ppmw, and wherein the treated sour water has a total concentration of impurities ranging from about 1 ppmw to about 4,000 ppmw; heating the treated sour water to produce steam; and contacting a hydrocarbon feedstock with the steam at conditions sufficient to separate the hydrocarbon feedstock into at least a first hydrocarbon product and a second hydrocarbon product.

2. The method of paragraph 1, wherein the portion of the one or more impurities is removed by contacting the non-phenolic sour water with steam, and wherein the waste byproduct comprises removed impurities and at least a portion of the steam.

3. The method according to paragraph 1 or 2, further comprising mixing one or more additives with the non-phenolic sour water to adjust at least one property of the non-phenolic sour water, wherein the one or more additives comprise one or more bases, one or more phosphate containing compounds, one or more acids, or any combination thereof.

4. The method according to any one of paragraph 1 to 3, wherein the impurities in the treated sour water comprise ammonia and hydrogen sulfide, and wherein the treated sour water has a concentration of ammonia of at least 10 ppmw and a concentration of hydrogen sulfide of at least 5 ppmw.

5. The method according to any one of paragraph 1 to 4, wherein the treated sour water is heated by indirectly transferring heat from a heat transfer medium to the treated sour water.

6. The method according to any one of paragraph 1 to 5, wherein the treated sour water is heated by directly contacting the treated sour water with a heated heat transfer medium.

7. The method according to any one of paragraph 1 to 6, wherein the non-phenolic sour water is recovered from a hydrocracking process, a hydrotreating process, or any combination thereof.

8. The method according to any one of paragraph 1 to 7, wherein the hydrocarbon feedstock comprises whole crude oil, crude oil, oil shales, oil sands, tars, bitumens, kerogen, waste oils, atmospheric tower bottoms, or any combination thereof.

9. The method according to any one of paragraph 1 to 8, wherein the one or more impurities comprise one or more nitrogen containing compounds, one or more sulfur containing compounds, or any combination thereof.

10. The method according to any one of paragraph 1 to 9, wherein the one or more impurities comprise ammonia and hydrogen sulfide, wherein a concentration of ammonia in the non-phenolic sour water ranges from about 1 ppmw to about 50,000 ppmw and a concentration of hydrogen sulfide ranges from about 1 ppmw to about 75,000 ppmw, and wherein a concentration of ammonia in the treated sour water ranges from about 1 ppmw to about 3,000 ppmw and a concentration of hydrogen sulfide ranges from about 1 ppmw to about 300 ppmw.

11. The method according to any one of paragraph 1 to 10, further comprising: apportioning the non-phenolic sour water into a first portion and a second portion; removing the portion of the one or more impurities from the first portion to produce the treated sour water and the waste byproduct; combining at least a portion of the treated sour water with at least a portion of the second portion to provide a re-combined treated sour water; and heating the re-combined treated sour water to produce the steam.

12. The method according to any one of paragraph 1 to 11, further comprising: apportioning the non-phenolic sour water into a first portion and a second portion; removing the portion of the one or more impurities from the first portion to produce the treated sour water and the waste byproduct; removing a portion of one or more other impurities from the second portion to produce a second treated sour water and a second waste byproduct; combining at least a portion of the first treated portion with at least a portion of the second treated portion to provide a re-combined treated sour water; and heating the re-combined treated sour water to produce the steam.

13. The method of paragraph 12, wherein removing the portion of the one or more impurities from the first portion is carried out under conditions sufficient to separate more nitrogen containing impurities as compared to sulfur containing impurities, and wherein removing the portion of the one or more other impurities from the second portion is carried out under conditions sufficient to separate more sulfur containing impurities as compared to nitrogen containing impurities.

14. A method for processing a hydrocarbon feedstock, comprising: acquiring a non-phenolic sour water from one or more non-phenolic sour water sources, wherein the one or more non-phenolic sour water sources comprise at least one of a hydrotreating processes, and a hydrocracking process; removing a portion of one or more impurities from the non-phenolic sour water to produce a treated sour water and a waste byproduct, wherein the non-phenolic sour water has a total concentration of impurities ranging from about 1,000 ppmw to about 125,000 ppmw, and wherein the treated sour water has a total concentration of impurities ranging from about 15 ppmw to about 4,000 ppmw; heating the treated sour water to produce steam; and contacting a hydrocarbon feedstock at a pressure ranging from about 101 kPa to about 150 kPa with the steam to separate the hydrocarbon feedstock into at least a first hydrocarbon product and a second hydrocarbon product, wherein the amount of steam contacted with the hydrocarbon feedstock ranges from about 0.05 kg/hr per barrel of hydrocarbon feedstock per day to about 0.5 kg/hr per barrel of hydrocarbon feedstock per day.

15. The method of paragraph 14, further comprising: apportioning the steam into at least a first portion and a second portion, wherein the hydrocarbon feedstock is contacted with the first portion of steam; and contacting a second hydrocarbon feedstock at a pressure of less than about 101 kPa with the second portion of steam to separate the second hydrocarbon feedstock to produce at least a third hydrocarbon product and a fourth hydrocarbon product.

16. The method of paragraph 15, wherein the second hydrocarbon feedstock comprises the second hydrocarbon product.

17. The method according to any one of paragraphs 14 to 16, wherein the portion of the one or more impurities is removed by contacting the non-phenolic sour water with steam, and wherein the waste byproduct comprises removed impurities and at least a portion of the steam, wherein the one or more impurities comprise hydrogen sulfide and ammonia, and wherein the treated sour water contains at least 5 ppmw hydrogen sulfide and at least 20 ppmw ammonia.

18. The method according to any one of paragraphs 14 to 17, wherein the one or more impurities comprise ammonia and hydrogen sulfide, wherein a concentration of ammonia in the non-phenolic sour water ranges from about 20 ppmw to about 50,000 ppmw and a concentration of hydrogen sulfide ranges from about 5 ppmw to about 75,000 ppmw, and wherein a concentration of ammonia in the treated sour water ranges from about 10 ppmw to about 3,000 ppmw and a concentration of hydrogen sulfide ranges from about 5 ppmw to about 300 ppmw.

19. A system for processing a hydrocarbon feedstock, comprising: one or more treatment units for removing a portion of one or more impurities from a non-phenolic sour water to produce a treated sour water and a waste byproduct, wherein the non-phenolic sour water has a total concentration of impurities ranging from about 1,000 ppmw to about 125,000 ppmw, and wherein the treated sour water has a total concentration of impurities ranging from about 1 ppmw to about 3,300 ppmw; one or more steam generators for heating the treated sour water to produce steam; and one or more distillation units for contacting a hydrocarbon feedstock with the steam at conditions sufficient to separate the hydrocarbon feedstock into at least a first hydrocarbon product and a second hydrocarbon product.

20. The system of paragraph 19, further comprising one or more hydrotreaters, hydrocrackers, or any combination thereof, from which the non-phenolic sour water is recovered, and wherein the one or more distillation units comprise at least one atmospheric distillation unit and at least one vacuum distillation unit.

Certain embodiments and features have been described using a set of numerical upper limits and a set of numerical lower limits. It should be appreciated that ranges from any lower limit to any upper limit are contemplated unless otherwise indicated. Certain lower limits, upper limits and ranges appear in one or more claims below. All numerical values are “about” or “approximately” the indicated value, and take into account experimental error and variations that would be expected by a person having ordinary skill in the art.

Various terms have been defined above. To the extent a term used in a claim is not defined above, it should be given the broadest definition persons in the pertinent art have given that term as reflected in at least one printed publication or issued patent. Furthermore, all patents, test procedures, and other documents cited in this application are fully incorporated by reference to the extent such disclosure is not inconsistent with this application and for all jurisdictions in which such incorporation is permitted.

While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.

Claims

1. A method for processing a hydrocarbon feedstock, comprising:

removing a portion of one or more impurities from a non-phenolic sour water to produce a treated sour water and a waste byproduct, wherein the non-phenolic sour water has a total concentration of impurities ranging from about 100 ppmw to about 125,000 ppmw, and wherein the treated sour water has a total concentration of impurities ranging from about 1 ppmw to about 4,000 ppmw;

heating the treated sour water to produce steam; and

contacting a hydrocarbon feedstock with the steam at conditions sufficient to separate the hydrocarbon feedstock into at least a first hydrocarbon product and a second hydrocarbon product.

2. The method of claim 1, wherein the portion of the one or more impurities is removed by contacting the non-phenolic sour water with steam, and wherein the waste byproduct comprises removed impurities and at least a portion of the steam.

3. The method of claim 1, further comprising mixing one or more additives with the non-phenolic sour water to adjust at least one property of the non-phenolic sour water, wherein the one or more additives comprise one or more bases, one or more phosphate containing compounds, one or more acids, or any combination thereof.

4. The method of claim 1, wherein the impurities in the treated sour water comprise ammonia and hydrogen sulfide, and wherein the treated sour water has a concentration of ammonia of at least 10 ppmw and a concentration of hydrogen sulfide of at least 5 ppmw.

5. The method of claim 1, wherein the treated sour water is heated by indirectly transferring heat from a heat transfer medium to the treated sour water.

6. The method of claim 1, wherein the treated sour water is heated by directly contacting the treated sour water with a heated heat transfer medium.

7. The method of claim 1, wherein the non-phenolic sour water is recovered from a hydrocracking process, a hydrotreating process, or any combination thereof.

8. The method of claim 1, wherein the hydrocarbon feedstock comprises whole crude oil, crude oil, oil shales, oil sands, tars, bitumens, kerogen, waste oils, atmospheric tower bottoms, or any combination thereof.

9. The method of claim 1, wherein the one or more impurities comprise one or more nitrogen containing compounds, one or more sulfur containing compounds, or any combination thereof.

10. The method of claim 1, wherein the one or more impurities comprise ammonia and hydrogen sulfide, wherein a concentration of ammonia in the non-phenolic sour water ranges from about 1 ppmw to about 50,000 ppmw and a concentration of hydrogen sulfide ranges from about 1 ppmw to about 75,000 ppmw, and wherein a concentration of ammonia in the treated sour water ranges from about 1 ppmw to about 3,000 ppmw and a concentration of hydrogen sulfide ranges from about 1 ppmw to about 300 ppmw.

11. The method of claim 1, further comprising:

apportioning the non-phenolic sour water into a first portion and a second portion;

removing the portion of the one or more impurities from the first portion to produce the treated sour water and the waste byproduct;

combining at least a portion of the treated sour water with at least a portion of the second portion to provide a re-combined treated sour water; and

heating the re-combined treated sour water to produce the steam.

12. The method of claim 1, further comprising:

apportioning the non-phenolic sour water into a first portion and a second portion;

removing the portion of the one or more impurities from the first portion to produce the treated sour water and the waste byproduct;

removing a portion of one or more other impurities from the second portion to produce a second treated sour water and a second waste byproduct;

combining at least a portion of the first treated portion with at least a portion of the second treated portion to provide a re-combined treated sour water; and

heating the re-combined treated sour water to produce the steam.

13. The method of claim 12, wherein removing the portion of the one or more impurities from the first portion is carried out under conditions sufficient to separate more nitrogen containing impurities as compared to sulfur containing impurities, and wherein removing the portion of the one or more other impurities from the second portion is carried out under conditions sufficient to separate more sulfur containing impurities as compared to nitrogen containing impurities.

14. A method for processing a hydrocarbon feedstock, comprising:

acquiring a non-phenolic sour water from one or more non-phenolic sour water sources, wherein the one or more non-phenolic sour water sources comprise at least one of a hydrotreating processes, and a hydrocracking process;

removing a portion of one or more impurities from the non-phenolic sour water to produce a treated sour water and a waste byproduct, wherein the non-phenolic sour water has a total concentration of impurities ranging from about 1,000 ppmw to about 125,000 ppmw, and wherein the treated sour water has a total concentration of impurities ranging from about 15 ppmw to about 4,000 ppmw;

heating the treated sour water to produce steam; and

contacting a hydrocarbon feedstock at a pressure ranging from about 101 kPa to about 150 kPa with the steam to separate the hydrocarbon feedstock into at least a first hydrocarbon product and a second hydrocarbon product, wherein the amount of steam contacted with the hydrocarbon feedstock ranges from about 0.05 kg/hr per barrel of hydrocarbon feedstock per day to about 0.5 kg/hr per barrel of hydrocarbon feedstock per day.

15. The method of claim 14, further comprising:

apportioning the steam into at least a first portion and a second portion, wherein the hydrocarbon feedstock is contacted with the first portion of steam; and

contacting a second hydrocarbon feedstock at a pressure of less than about 101 kPa with the second portion of steam to separate the second hydrocarbon feedstock to produce at least a third hydrocarbon product and a fourth hydrocarbon product.

16. The method of claim 15, wherein the second hydrocarbon feedstock comprises the second hydrocarbon product.

17. The method of claim 14, wherein the portion of the one or more impurities is removed by contacting the non-phenolic sour water with steam, and wherein the waste byproduct comprises removed impurities and at least a portion of the steam, wherein the one or more impurities comprise hydrogen sulfide and ammonia, and wherein the treated sour water contains at least 5 ppmw hydrogen sulfide and at least 20 ppmw ammonia.

18. The method of claim 14, wherein the one or more impurities comprise ammonia and hydrogen sulfide, wherein a concentration of ammonia in the non-phenolic sour water ranges from about 20 ppmw to about 50,000 ppmw and a concentration of hydrogen sulfide ranges from about 5 ppmw to about 75,000 ppmw, and wherein a concentration of ammonia in the treated sour water ranges from about 10 ppmw to about 3,000 ppmw and a concentration of hydrogen sulfide ranges from about 5 ppmw to about 300 ppmw.

19. A system for processing a hydrocarbon feedstock, comprising:

one or more treatment units for removing a portion of one or more impurities from a non-phenolic sour water to produce a treated sour water and a waste byproduct, wherein the non-phenolic sour water has a total concentration of impurities ranging from about 1,000 ppmw to about 125,000 ppmw, and wherein the treated sour water has a total concentration of impurities ranging from about 1 ppmw to about 4,000 ppmw;

one or more steam generators for heating the treated sour water to produce steam; and

one or more distillation units for contacting a hydrocarbon feedstock with the steam at conditions sufficient to separate the hydrocarbon feedstock into at least a first hydrocarbon product and a second hydrocarbon product.

20. The system of claim 19, further comprising one or more hydrotreaters, hydrocrackers, or any combination thereof, from which the non-phenolic sour water is recovered, and wherein the one or more distillation units comprise at least one atmospheric distillation unit and at least one vacuum distillation unit.