Catalytic Deasphalting Process for Low-Solvent Crude Oil Upgrading
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Solution Overview
Problem
Conventional asphaltenes separation processes, such as Solvent Deasphalting (SDA), require large amounts of expensive paraffinic solvents and are energy-intensive, while asphaltenes precipitation and deposition cause operational issues in crude oil refining.
Innovation Solution
A catalytic upgrading process using a first catalytic deasphalting reactor with a solid heteropolyacid compound catalyst to deasphalt crude oil, producing polymerized asphaltenes and deasphalted oil with reduced asphaltenes, followed by steam cracking and selective hydrogenation to produce valuable petrochemical substances, with a wash solvent regenerating the catalyst.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional Solvent Deasphalting (SDA) technology is used to separate asphaltenes, then asphaltenes can be removed from crude oil, but large amounts of expensive paraffinic solvents are required and the process becomes energy-intensive
Solution Approach 1:
The patent changes the fundamental parameter of the separation mechanism from solvent-based liquid-liquid extraction to catalyst-based selective polymerization. The catalyst selectively polymerizes asphaltenes at specific active sites, changing the chemical state of asphaltenes from soluble to insoluble polymerized form, enabling separation without requiring large amounts of paraffinic solvents
Solution Approach 2:
The patent replaces the mechanical/physical separation process (SDA using paraffinic solvents) with a chemical process using solid acid catalysts. The catalyst provides selective polymerization of asphaltenes through chemical reactions at active sites, substituting the need for mechanical solvent extraction and subsequent separation equipment
2Reliability
If conventional Solvent Deasphalting (SDA) technology is used to separate asphaltenes, then asphaltenes can be removed from crude oil, but the separation and recovery of paraffinic solvents from DAO require considerable energy
Solution Approach 1:
The patent replaces the energy-intensive solvent recovery process with a catalytic chemical process. The solid acid catalyst enables selective polymerization of asphaltenes through chemical reactions, eliminating the need for thermal energy input required to evaporate and recover large volumes of paraffinic solvents from deasphalted oil
Solution Approach 2:
The patent extracts and removes the need for paraffinic solvents from the deasphalting process entirely. By using catalyst-based selective polymerization, the process directly converts asphaltenes to polymerized form that can be separated through filtration or decantation, eliminating the solvent addition and recovery steps that consume considerable energy
3Quantity of substance
If asphaltenes are present in crude oil, then the crude oil contains natural high molecular weight compounds, but asphaltenes precipitation and deposition cause operational issues and may poison refining catalysts
Solution Approach 1:
The patent converts the harmful asphaltenes into beneficial products. The solid acid catalyst selectively polymerizes asphaltenes to produce high-value aromatic compounds and carbonaceous materials that can be used as fuels or chemical feedstocks. This transforms the harmful substance that causes deposition and catalyst poisoning into valuable products, eliminating the harmful effects while creating economic value
Solution Approach 2:
The patent introduces a solid acid catalyst as an intermediary substance that mediates the transformation of asphaltenes. The catalyst provides selective active sites that facilitate polymerization reactions, acting as a bridge between the asphaltenes and the final aromatic products. This intermediary enables controlled conversion without requiring harsh conditions that could damage equipment or other process components
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
Reduces asphaltenes concentration in deasphalted oil to less than 1%, decreases solvent use, and enhances refining efficiency by recycling solvents, thereby lowering costs and ecological impact.
Implementation Method 1
The first catalytic deasphalting reactor comprises a catalyst having a solid heteropolyacid compound. The process includes introducing a feed comprising crude oil to the first catalytic deasphalting reactor to deasphalt the feed, thereby producing polymerized asphaltenes and deasphalted oil having a reduced concentration of asphaltenes.
Implementation Method 2
A wash solvent may be introduced to the first catalytic deasphalting reactor after deasphalting to remove the polymerized asphaltenes, thereby regenerating the catalyst in the first catalytic deasphalting reactor
Implementation Method 3
The deasphalted oil may then be introduced to the steam cracking unit, thereby producing pyrolysis gasoline.
Implementation Method 4
This pyrolysis gasoline may then be introduced to a selective hydrogenation unit, thereby producing an olefin-free product
Data Source
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AI summary
A catalytic upgrading process includes introducing a feed comprising crude oil to a first catalytic deasphalting reactor to deasphalt the feed, thereby producing polymerized asphaltenes and deasphalted oil (DAO). The DAO is introduced to a steam cracking unit, thereby producing pyrolysis gas (PG), which is introduced into a selective hydrogenation unit, thereby producing an olefin-free product, which can then be introduced to a separation unit. The resulting benzene-toluene-xylenes (BTX)-containing stream and liquid petroleum gas (LPG) are separated, and the BTX-containing stream is introduced to a BTX complex to produce refined BTX. After deasphalting, a wash solvent may be introduced into the first catalytic deasphalting reactor to remove the polymerized asphaltenes, regenerate the catalyst, and produce a mixture comprising the wash solvent and the polymerized asphaltenes. The wash solvent is separated from the polymerized asphaltenes.