MARPOL Compliant Bunker Fuel Production via Aromatic Enrichment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The production of low sulfur bunker fuel oil with a pour point below +9°C is challenging due to the precipitation of asphaltenes when paraffinic cutter stock is added in excess, affecting the stability and flash point specifications of the fuel.
Innovation Solution
An integrated process involving mild thermal cracking of residue feedstock, followed by fractionation and in-situ aromatic enrichment of the 140-280°C boiling range stream with straight run kerosene, resulting in a low pour point and high flash point MARPOL compliant bunker fuel oil.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If paraffinic cutter stock is added in excess quantity to reduce pour point, then the pour point specification is improved, but asphaltenes precipitate and fuel oil stability deteriorates
Solution Approach 1:
The patent changes the chemical composition parameters of the cutter stock by using aromatic hydrocarbons instead of paraffinic hydrocarbons. This parameter change allows achieving the desired pour point reduction without causing asphaltene precipitation, as aromatics have different solubility characteristics with asphaltenes compared to paraffins.
Solution Approach 2:
The patent creates a composite fuel oil composition by blending aromatic hydrocarbons with the residual fuel oil. This composite approach allows the aromatic component to modify the physical properties (lowering pour point) while maintaining compositional stability, avoiding the harmful effects of pure paraffinic blends.
2Temperature
If paraffinic cutter stock is added in excess quantity to reduce pour point, then the pour point specification is improved, but flash point specification is affected
Solution Approach 1:
The patent changes the chemical type of cutter stock from paraffinic to aromatic hydrocarbons. This parameter change simultaneously achieves pour point reduction while preserving flash point integrity, as aromatic hydrocarbons have different volatility characteristics compared to paraffinic hydrocarbons.
3Manufacturing precision
If hydrogen based technology is used to produce low sulfur fuel, then sulfur content is reduced, but production cost increases
Solution Approach 1:
The patent extracts and removes sulfur from the residual fuel oil through hydrodesulfurization process, separating sulfur compounds from the hydrocarbon matrix. This extraction approach achieves low sulfur content without requiring expensive hydrogen-based refining processes, using instead catalytic hydrodesulfurization with hydrogen gas generated in-situ.
Solution Approach 2:
The patent implements a self-service sulfur removal system where hydrogen gas is generated within the same processing unit through catalytic reforming of the residual fuel oil itself. This eliminates the need for external hydrogen supply and reduces overall processing costs while achieving effective sulfur removal.
4Productivity
If thermal cracking process is used to produce bunker fuel, then fuel production is achieved, but meeting all required specifications becomes difficult
Solution Approach 1:
The patent segments the thermal cracking process into distinct functional units: cracking section, fractionation section, and blending section. This segmentation allows each unit to be optimized for its specific function, enabling better control over product specifications while maintaining high fuel production rates.
Solution Approach 2:
The patent incorporates feedback mechanisms in the blending section where the cracked products are blended with cutter stock and other fuels, with continuous monitoring of specifications. This feedback loop allows real-time adjustment of blend ratios to ensure compliance with MARPOL and other relevant specifications while maximizing fuel production.
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
The process produces bunker fuel oil with a pour point of +9°C, meeting stringent MARPOL specifications, enhancing stability and reducing the need for additional cutter stock, while maintaining low sulfur content and high flash point.
Implementation Method 1
mild thermal cracking of residue feed stock
Implementation Method 2
fractionation of products obtained by visbreaking
Implementation Method 3
in-situ aromatic enrichment of a stream generated from fractionation of products from thermal cracking
Data Source
AI summary
This invention relates to production of low sulfur MARPOL compliant bunker fuel oil and distillates using high sulfur residue, low sulfur residue and/or blend of high and low sulfur residue feed stock. The invention also describes a method for production of a cutterstock stream having a lower paraffin and higher aromatic content than a feed stream using a paraffin separation section and its blending to produce bunker fuel.