Kinetic modeling of deep vacuum residue hydroconversion in a pilot scale continuous slurry reactor with recycle

Abstract

Slurry phase hydroconversion is a developing technology with the potential to completely upgrade Vacuum Residues (VR). In this work we use data from a continuous pilot plant with recycle to test and extend an existing distributed lumped kinetic model. The new data includes results from 134 steady state experiments with a Heavy Iran VR, including some at very high conversion, and allows sediment production rates to be quantified as well as sulphur removal in the form of H2S. The purpose of the work is to study the impact of the deep conversion reaction conditions and feedstock on the reaction kinetics. The model uses nineteen distributed lumps to represent the heavy hydrocarbons undergoing hydroconversion and hydrodesulphurisation with VR defined as the boiling range > 525°C. Reaction rates are based on molar concentrations. Hydrogen consumption and sediment production are taken into account in the model, as well as vapour liquid mass transfer resistances and vapour-liquid equilibrium. Parameter estimation has been carried out and the model provides a good fit with the experimental data. The modelling exercise found that, at very high conversions, thermal reactions give way to a cascade of catalytic reactions. The model gave a moderate fit for hydrogen consumption rates, which are strongly dependent on feedstock. Accumulation of sediment at high conversions was identified and well represented and the description of hydrodesulfurisation rates as proportional to cracking rates was validated.