Crude Oil Refining via Hydroconversion and Nanocatalysts
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Solution Overview
Problem
Traditional oil refining processes are complex and energy-intensive, struggling to efficiently convert heavy crude oils into distillates while minimizing the production of heavier fractions and reducing environmental impact, due to changes in demand and crude oil quality.
Innovation Solution
Substituting the sub-atmospheric distillation section with a hydroconversion step using nanodispersed hydrogenation catalysts and specific hydroconversion processes, such as those in the Eni Slurry Technology (EST), to achieve total conversion of crude oil into gas, naphtha, and gasoil with reduced byproducts and improved operational simplicity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional complex cycle refining schemes with multiple distillation columns and conversion units are used, then conversion efficiency increases, but device complexity and energy consumption increase
Solution Approach 1:
The invention extracts and removes the sub-atmospheric distillation column from the traditional refining scheme, replacing it with a hydroconversion unit. This extraction eliminates the need for vacuum distillation operations and associated equipment while achieving equivalent or better conversion results through hydrocracking and hydroprocessing technologies.
Solution Approach 2:
The invention merges the functions of sub-atmospheric distillation and heavy fraction conversion into a single hydroconversion unit. This consolidation integrates separation and conversion operations, reducing the number of discrete equipment items and simplifying the overall process flow while maintaining high conversion efficiency.
2Productivity
If traditional complex cycle refining schemes with multiple distillation columns and conversion units are used, then conversion efficiency increases, but energy consumption increases
Solution Approach 1:
By removing the sub-atmospheric distillation column which operates under vacuum and requires significant energy for pumping and heating, the invention eliminates a major energy consumer while maintaining conversion efficiency through the hydroconversion unit's optimized processing.
Solution Approach 2:
The invention changes the operating parameters from vacuum distillation conditions to hydroconversion conditions (higher pressure, presence of hydrogen, catalytic conditions). This parameter transformation allows achieving equivalent conversion results with different energy characteristics, ultimately reducing total energy consumption.
3Manufacturing precision
If sub-atmospheric distillation column is used to separate heavy distillates from vacuum residue, then separation is achieved, but device complexity increases
Solution Approach 1:
The invention merges the separation function of the sub-atmospheric distillation column with the conversion function of the hydroconversion unit. The hydroconversion process simultaneously handles heavy fraction conversion and product separation, eliminating the need for dedicated vacuum distillation equipment while achieving equivalent separation results.
Solution Approach 2:
The hydroconversion unit performs multiple functions: it converts heavy fractions, separates products by boiling point range, and prepares distillates for further processing. This multi-functionality replaces what previously required separate dedicated units, simplifying the overall装置 complexity.
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 simplifies refinery operations, reduces energy consumption, and increases refining margins by achieving total conversion of crude oil with a modest amount of tar as a byproduct, while lowering environmental emissions and operational complexity.
Implementation Method 1
the use of nanodispersed hydrogenation catalysts and specific hydroconversion processes
Implementation Method 2
nanodispersed hydrogenation catalysts and specific hydroconversion processes
Implementation Method 3
the atmospheric distillation column only, the sub-atmospheric distillation column being substituted with a hydroconversion step
Data Source
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AI summary
A process for the refining of crude oil, comprising a separation unit of the crude oil, consisting of at least one atmospheric distillation unit for separating the various fractions, a unit for the conversion of the heavy fractions obtained, a unit for improving the quality of some of the fractions obtained by actions on the chemical composition of their constituents, and units for the removal of undesired components, characterized in that the heaviest fraction, the atmospheric distillation residue, is sent to the conversion unit comprising a hydroconversion reactor in slurry phase or of the ebullated bed type, into which hydrogen or a mixture of hydrogen and ¾S is introduced in the presence of a suitable nanodispersed hydrogenation catalyst.