Co-processing Diesel Biofeed and Kerosene Hydrocarbons
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Solution Overview
Problem
Producing ultra-low sulfur diesel fuel from biocomponent sources poses challenges, particularly in low-pressure hydroprocessing units, as biocomponent-based feeds can introduce heteroatoms that complicate processing and require significant capital investment for infrastructure modifications.
Innovation Solution
A multi-stage co-hydrotreating process is employed, blending biocomponent feedstocks with mineral hydrocarbon feedstocks to improve cold flow properties and reduce sulfur content, using hydrotreating conditions such as specific hydrogen partial pressures, temperatures, and catalysts to produce diesel fuel with sulfur levels of 10 ppm or less.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If biocomponent feedstocks are processed in low-pressure hydroprocessing units, then existing infrastructure can be used, but heteroatoms in the feed complicate processing and prevent ultra-low sulfur product achievement
Solution Approach 1:
The patent changes the operating parameters of the hydroprocessing unit from low-pressure conditions to high-pressure conditions (increasing hydrogen partial pressure to 100-500 psig). This parameter change enables the existing infrastructure to achieve ultra-low sulfur removal from biocomponent feedstocks by providing the necessary thermodynamic conditions for effective hydrodesulfurization and hydrodeoxygenation reactions
Solution Approach 2:
The patent applies preliminary treatment to the biocomponent feedstock by blending it with mineral hydrocarbon feedstocks before processing. This preliminary blending action modifies the feed composition to facilitate better processing performance and help achieve the desired ultra-low sulfur product specification
2Manufacturing precision
If processing pressure is increased to achieve ultra-low sulfur removal, then product quality improves, but capital investment for infrastructure modification is required
Solution Approach 1:
The patent makes the existing hydroprocessing unit multi-functional by operating it under high-pressure conditions that enable both the processing of biocomponent feedstocks and the achievement of ultra-low sulfur removal. This allows a single existing unit to perform multiple functions without requiring separate dedicated infrastructure for biocomponent processing
Solution Approach 2:
By changing the operating pressure parameters to high-pressure conditions, the patent enables existing infrastructure to achieve ultra-low sulfur removal capability. The parameter change transforms the unit's performance envelope to meet stringent product specifications without requiring complete infrastructure replacement
3Stability of the object's composition
If biocomponent feedstocks are blended with mineral hydrocarbon feedstocks, then cold flow properties improve, but feedstock complexity increases
Solution Approach 1:
The patent creates a composite feedstock by blending biocomponent feedstocks with mineral hydrocarbon feedstocks. This composite feed combines the renewable content of biocomponents with the favorable cold flow properties of mineral hydrocarbons, achieving improved overall product performance while managing feedstock complexity through controlled blending ratios
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 method allows for the production of ultra-low sulfur diesel fuel with improved cold flow properties without requiring significant new construction at refineries, enabling the use of biocomponent sources in existing hydroprocessing units while maintaining low sulfur levels.
Implementation Method 1
The blended feedstock is then hydrotreated under effective hydrotreating conditions including an LHSV of 0.5 to 1.5, a hydrogen partial pressure from about 100 to about 500 psig, a treat gas rate of about 2000-3000 scf/b of at least 80% hydrogen (remainder inert gas), and a temperature of from about 500-750° F., to produce a diesel fuel product
Implementation Method 2
hydrotreating the combined oil... to produce a diesel fuel product... ultra low sulfur diesel product
Data Source
AI summary
Processes are provided for producing a diesel fuel product having a sulfur content of 10 ppm by weight or less from feed sources that include up to 50% by weight of a biocomponent feedstock. The biocomponent feedstock is co-processed with a heavy oil feed in a severe hydrotreating stage. The product from the severe hydrotreatment stage is fractionated to separate out a diesel boiling range fraction, which is then separately hydrotreated.