US 9,809,765 B2
Process for producing transportation fuels from oil sands-derived crude
Richard H. Schlosberg, Highland Park, IL (US); and Richard D. Jordan, Vienna, VA (US)
Assigned to Epic Oil Extractors, LLC, Ponchatoula, LA (US)
Filed by EPIC OIL EXTRACTORS, LLC, Ponchatoula, LA (US)
Filed on Sep. 26, 2014, as Appl. No. 14/498,151.
Claims priority of provisional application 61/883,781, filed on Sep. 27, 2013.
Prior Publication US 2015/0090634 A1, Apr. 2, 2015
Int. Cl. C10G 1/04 (2006.01); C10G 45/04 (2006.01); C10G 69/04 (2006.01); C10G 11/05 (2006.01); C10G 1/00 (2006.01); C10G 45/00 (2006.01); C10G 45/08 (2006.01); C10G 11/00 (2006.01)
CPC C10G 69/04 (2013.01) [C10G 1/002 (2013.01); C10G 1/045 (2013.01); C10G 11/00 (2013.01); C10G 11/05 (2013.01); C10G 45/00 (2013.01); C10G 45/08 (2013.01); C10G 2300/202 (2013.01); C10G 2300/206 (2013.01); C10G 2300/301 (2013.01); C10G 2300/44 (2013.01); Y02P 30/10 (2015.11); Y02P 30/446 (2015.11)] 8 Claims
 
1. A process for producing a naphtha stream from a deoxygenated oil sands-derived, deasphalted crude oil feedstock, comprising:
a) obtaining an oil sands-derived, deasphalted crude oil feedstock, wherein the oil sands-derived, deasphalted crude oil feedstock has an ASTM D7169 5% distillation point of from 400° F. to 700° F., an asphaltenes content of not greater than 10 wt %, a Conradson Carbon Residue (CCR) of not greater than 15 wt %, a nickel plus vanadium content of not greater than 150 wppm, a total acid number (TAN) of from 1-8, and a sulfur content of not greater than 4 wt %, with the oil sands-derived, deasphalted crude oil feedstock being obtained from a water-free process that includes steps of:
(i) pumping oil sands containing heavy bitumen tar through an extractor,
(ii) selectively extracting a crude oil composition from the heavy bitumen tar on the oil sand material pumped through the extractor by contacting the oil sands material with a solvent in a contacting zone of the extractor, wherein the solvent is comprised of at least 90 wt % of at least one of propane and butane, the contact zone is at a pressure and temperature in which at least 20 wt % of the solvent is in vapor phase during the contacting, and no water is employed in the contacting,
(iii) removing the selectively extracted crude oil composition and the solvent utilized in the selective extraction step (ii) from the contact zone of the extractor,
(iv) separating at least a portion of the solvent from the selectively extracted crude oil composition removed from the contact zone of the extractor in step (iii) to produce the oil-sands derived, deasphalted crude oil feedstock and solid tailings, and
(v) placing the solid tailings into the ground without producing tailings ponds;
b) deoxygenating at least a portion of the oil-sands derived, deasphalted crude oil feedstock to reduce the TAN of the oil-sands derived, deasphalted crude oil feedstock by mildly hydrotreating the oil-sands derived, deasphalted crude oil feedstock in the presence of a hydrotreating catalyst containing at least one Group VIB metal and at least one non-noble Group VIII metal at a H2/HC ratio of from 10-50 std m3/m3; and
c) catalytically cracking at least a portion of the deoxygenated, oil sands-derived, deasphalted crude oil feedstock to produce catalytically cracked product streams, wherein the catalytically cracked product streams comprise the naphtha stream, and the naphtha stream is ≧45 wt % of the total amount of cracked product streams produced.