By-passable Hydrocracking Reactors for Low Sediment Fuel

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Solution Overview

Problem

Conventional refining processes for heavy hydrocarbon fractions, such as those used in maritime fuels, face challenges in achieving low sulfur and sediment content, particularly for bunker fuels, due to the formation of sediments during high-temperature conversion processes, which degrade fuel quality and fail to meet stringent ISO and MARPOL standards.

Innovation Solution

A novel process incorporating by-passable reactors for hydrocracking, allowing for higher conversion temperatures without sediment formation, coupled with hydrodemetallization and fixed bed hydrotreatment steps, to produce heavy fractions with low sulfur and sediment content, specifically targeting a sediments content of 0.1% or less after aging.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If high temperature conversion processes are used to increase conversion yields, then productivity is improved, but sediments content increases causing harmful effects

Engineering Contradiction:

Improveconversion yieldsVSAvoidsediments content

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The conversion process is divided into two separate reactor sections: a fixed bed hydrotreatment section operating at lower temperatures to minimize sediments, and a by-passable hydrocracking section operating at higher temperatures to maximize conversion. This segmentation allows each section to optimize its operating parameters independently, achieving high overall conversion while controlling sediments formation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The by-passable reactor section can be dynamically taken offline when sediments formation becomes excessive, allowing the process to adapt to changing conditions. This dynamic operation enables the system to maintain high conversion yields during optimal periods while preventing harmful sediments accumulation by bypassing the hydrocracking section when necessary.

Inventive Principle:

Principle #15Dynamics

2Productivity

If severe conversion conditions are applied to maximize distillate production, then productivity is improved, but product quality deteriorates due to increased sediments

Engineering Contradiction:

Improvedistillate productionVSAvoidproduct quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The process separates the conversion function into two specialized sections: fixed bed hydrotreatment for quality control and by-passable hydrocracking for maximum conversion. This segmentation enables the system to achieve both high distillate production and low sediments content by allowing each section to perform its specific function under optimized conditions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different operating parameters are applied in each section: lower temperature and pressure in the fixed bed hydrotreatment section to preserve product quality, and higher temperature and pressure in the by-passable hydrocracking section to maximize distillate production. The by-passable design allows dynamic adjustment of these parameters based on sediments formation rates.

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If fixed bed hydrotreatment is used to maintain simple operation, then ease of operation is improved, but conversion yields are limited

Engineering Contradiction:

Improveoperation simplicityVSAvoidconversion yields

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The process merges the operational simplicity of fixed bed hydrotreatment with the high conversion capability of by-passable hydrocracking in a single integrated flow scheme. The fixed bed section maintains ease of operation, while the added by-passable hydrocracking section enhances conversion yields without significantly complicating the overall process operation.

Inventive Principle:

Principle #5Merging (Combining)

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 effectively increases conversion yields of distillates and heavy fractions with low sulfur and sediment content, meeting stringent maritime fuel standards by optimizing reactor operation and temperature control, thereby enhancing fuel quality and compliance with regulatory requirements.

Implementation Method 1

an optional hydrodemetallization step in permutable reactors, in which the hydrocarbon feed is brought into contact with hydrogen over a hydrodemetallization catalyst

Methodology Applied

Scientific EffectHydrodemetallization: Catalysis

Implementation Method 2

a step for fixed bed hydrotreatment of the effluent obtained from step a)

Methodology Applied

Scientific EffectHydrotreatment: Catalysis

Implementation Method 3

a step for hydrocracking the effluent obtained from step b) in by-passable reactors

Methodology Applied

Scientific EffectHydrocracking: Catalysis

Data Source

PatentUS10266779B2Conversion process comprising at least one step for fixed bed hydrotreatment and a step for hydrocracking in by-passable reactors

Publication Date: 2019.04.23 IFP ENERGIES NOUVELLES

AI summary

The invention concerns a process for the treatment of a hydrocarbon feed in order to obtain a heavy hydrocarbon fraction with a low sulphur content, said process comprising the following steps: a) an optional step for hydrodemetallization carried out in permutable reactors, b) a step for fixed bed hydrotreatment of the effluent obtained from step a), c) a step for hydrocracking of the effluent obtained in step b) in by-passable reactors, d) a step for separation of the effluent obtained from step c).