Aromatic Bottoms Stream Enhances Hydroprocessing Solvency
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Solution Overview
Problem
The challenge in hydroprocessing heavy oil fractions, such as atmospheric residues or vacuum residues, is the deactivation of hydroprocessing catalysts due to contaminants like organic nickel, vanadium compounds, and poly-nuclear aromatic compounds, leading to reduced process performance and increased costs, along with sediment formation caused by asphaltene compounds, which affects yield and catalyst life.
Innovation Solution
Incorporating a portion of the aromatic bottoms stream from an aromatics recovery unit into the hydroprocessing unit to increase the solvency of heavy oils, thereby reducing asphaltene precipitation and sedimentation, and enhancing the conversion of hydrocarbons to valuable products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If hydroprocessing is used to upgrade heavy oil fractions, then valuable products and intermediates are produced, but catalyst deactivation occurs due to contaminants
Solution Approach 1:
The patent extracts harmful contaminants (asphaltenes, metals, sulfur compounds) from the heavy oil feedstock before hydroprocessing through solvent deasphalting and other pretreatment processes. This removes the substances that cause catalyst deactivation while preserving the valuable hydrocarbon components for conversion to products
Solution Approach 2:
The patent applies preliminary treatment steps (solvent deasphalting, hydrodesulfurization, hydrodemetalation) before the main hydroprocessing operation. These preliminary actions prepare the feedstock by removing problematic contaminants in advance, preventing catalyst deactivation during the primary conversion process
2Productivity
If hydroprocessing is used to upgrade heavy oil fractions, then valuable products are produced, but sediment formation occurs due to asphaltene precipitation
Solution Approach 1:
The patent extracts asphaltenes from the heavy oil feed through solvent deasphalting processes using solvents like methyl ethyl ketone or phenol. This removal prevents asphaltene precipitation and sediment formation in downstream equipment while allowing the maltene fraction to be processed into valuable products
Solution Approach 2:
The patent introduces solvent intermediaries (such as methyl ethyl ketone, phenol, or toluene) that selectively interact with asphaltenes to facilitate their separation from the oil matrix. These solvents act as mediators that enable asphaltene removal without damaging valuable hydrocarbon components
3Reliability
If catalysts are replaced frequently to maintain activity, then process performance is maintained, but operating costs increase
Solution Approach 1:
The patent applies preliminary contaminant removal treatments that protect catalysts from deactivation mechanisms. By removing asphaltenes, metals, and sulfur compounds before the hydroprocessing catalyst contacts the feed, the catalyst maintains activity for extended periods, reducing replacement frequency and associated downtime
Solution Approach 2:
The patent implements protective measures before catalyst deactivation occurs by removing harmful contaminants in advance. This cushioning approach prevents the accumulation of deactivating substances on the catalyst, extending its operational life and reducing the frequency of costly replacements
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces catalyst deactivation, increases the solubility of asphaltenes, and prevents sedimentation, leading to improved yields and extended catalyst life, while also increasing the conversion of aromatic compounds to valuable products, thus enhancing the overall efficiency and economy of the hydroprocessing unit.
Implementation Method 1
the aromatic bottoms stream from an aromatics recovery unit into the hydroprocessing unit to increase the solvency of heavy oils, thereby reducing asphaltene precipitation and sedimentation
Implementation Method 2
a hydroprocessing reactor that contacts a hydrocarbon feed with hydrogen in the presence of one or more hydroprocessing catalysts to produce a hydroprocessed effluent
Implementation Method 3
a hydroprocessed effluent separation system that separates the hydroprocessed effluent into a fuel oil effluent and a distillate effluent
Data Source
AI summary
A process for separating and upgrading a hydrocarbon feed includes passing the hydrocarbon feed to a distillation unit to separate it into at least a naphtha stream and a residue, passing the naphtha stream to a NHT that hydrotreats the naphtha stream to produce a hydrotreated naphtha, passing the hydrotreated naphtha to a NREF that reforms the hydrotreated naphtha to produce a reformate, passing the reformate to an ARC that processes the reformate to produce at least one aromatic product effluent and an aromatic bottoms stream, passing at least a portion of the residue to a residue hydroprocessing unit that hydroprocesses the portion of the residue to produce a hydroprocessed effluent, and passing a portion of the aromatic bottoms stream to the residue hydroprocessing unit to increase the solubility of the asphaltene compounds and reduce sedimentation. Systems for conducting the process are also disclosed.