Hydrocarbon Upgrading via DAO Segmentation and Cracking

Solution Overview

Problem

Current solvent de-asphalting processes face limitations in upgrading heavy hydrocarbons to high-value lighter hydrocarbons due to restricted cracker operation at low temperature and low severity, which compromises the yield of desirable products like kerosene and diesel oils.

Innovation Solution

A process involving selective separation of hydrocarbons using mixers and separators to achieve supercritical conditions, allowing for the separation of light and heavy deasphalted oils, followed by fluidized catalytic cracking of the heavy deasphalted oil to produce lighter hydrocarbon products, enabling operation at higher temperatures and severities.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the cracker operates at low temperature and low severity to preserve light hydrocarbons, then the integrity of light hydrocarbons is maintained, but the conversion of heavy hydrocarbons to high-value lighter products is limited

Engineering Contradiction:

Improveintegrity of light hydrocarbonsVSAvoidconversion of heavy hydrocarbons

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The deasphalted oil is divided into two separate streams: a light DAO stream containing valuable light hydrocarbons that bypasses the cracker, and a heavy DAO stream containing primarily heavy hydrocarbons that is fed to the cracker. This segmentation allows the cracker to operate at high temperature and severity to maximize heavy hydrocarbon conversion while the light hydrocarbons remain intact in the uncracked light DAO stream.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The light hydrocarbon fraction is extracted from the total deasphalted oil stream before cracking by using a solvent extraction unit operated at specific temperature and solvent-to-feed ratios to selectively produce a light DAO stream rich in light hydrocarbons. This extracted light hydrocarbon stream is then bypassed from the cracker, allowing the remaining heavy DAO to be cracked at high severity.

Inventive Principle:

Principle #2Taking out (Extraction)

2Productivity

If the cracker operates at high temperature and high severity to increase heavy hydrocarbon conversion, then the yield of high-value lighter hydrocarbons increases, but the light hydrocarbons present in the DAO are destroyed

Engineering Contradiction:

Improveyield of high-value lighter hydrocarbonsVSAvoidintegrity of light hydrocarbons

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The deasphalted oil is divided into two separate streams: a light DAO stream containing valuable light hydrocarbons that bypasses the cracker, and a heavy DAO stream containing primarily heavy hydrocarbons that is fed to the cracker. This segmentation allows the cracker to operate at high temperature and severity to maximize heavy hydrocarbon conversion while the light hydrocarbons remain intact in the uncracked light DAO stream.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The light hydrocarbon fraction is extracted from the total deasphalted oil stream before cracking by using a solvent extraction unit operated at specific temperature and solvent-to-feed ratios to selectively produce a light DAO stream rich in light hydrocarbons. This extracted light hydrocarbon stream is then bypassed from the cracker, allowing the remaining heavy DAO to be cracked at high severity.

Inventive Principle:

Principle #2Taking out (Extraction)

3Manufacturing precision

If the solvent-to-feed ratio is increased to improve separation efficiency, then the separation of light and heavy deasphalted oils is enhanced, but the energy consumption and operational complexity increase

Engineering Contradiction:

Improveseparation efficiencyVSAvoidoperational complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The solvent extraction unit is operated at an elevated temperature of about 70°C to 120°C, which changes the solubility parameters and allows for effective separation at moderate solvent-to-feed ratios. This temperature parameter change enhances separation efficiency without requiring excessive solvent quantities or complex multi-stage extraction systems.

Inventive Principle:

Principle #35Parameter changes

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 enhances the conversion of heavy hydrocarbons to high-value lighter products, increasing the yield of valuable hydrocarbons like kerosene and diesel oils while maintaining the integrity of light hydrocarbons, thus improving the overall efficiency of the hydrocarbon upgrading process.

Implementation Method 1

achieve supercritical conditions, allowing for the separation of light and heavy deasphalted oils

Methodology Applied

Scientific EffectSupercritical conditions: Supercritical Fluid

Implementation Method 2

fluidized catalytic cracking of the heavy deasphalted oil to produce lighter hydrocarbon products

Methodology Applied

Scientific EffectFluidized catalytic cracking: Catalysis

Data Source

PatentUS8277637B2System for upgrading of heavy hydrocarbons

Publication Date: 2012.10.02 KELLOGG BROWN & ROOT INC

AI summary

Systems and methods for processing one or more hydrocarbons are provided. One or more hydrocarbons can be selectively separated to provide one or more heavy deasphalted oils. At least a portion of the heavy deasphalted oil can be cracked using a fluidized catalytic cracker to provide one or more lighter hydrocarbon products.