Desulfurization System Using Oxidation and Liquid-Liquid Extraction
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Solution Overview
Problem
Existing desulfurization technologies are not economically viable for processing high-sulfur fuels in regions without the necessary infrastructure, leading to equipment damage and inefficiencies in meeting ultra-low sulfur fuel standards.
Innovation Solution
A desulfurization system comprising an oxidation process unit, a liquid-liquid extraction unit, and a solvent separation process unit, which works in a closed-loop arrangement to efficiently remove sulfur from fuels, allowing for on-site processing of high-sulfur fuels and producing ultra-low sulfur fuels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional desulfurization technologies are used, then sulfur removal capability is limited, but processing cost and infrastructure requirements become prohibitively high
Solution Approach 1:
The desulfurization process is divided into three distinct functional units: oxidation process unit (converts sulfur compounds to sulfones), liquid-liquid extraction unit (separates sulfones from fuel using extraction fluid), and solvent separation process unit (recovers and recycles extraction fluid). This segmentation allows each unit to be optimized independently and enables modular deployment without requiring extensive integrated infrastructure.
Solution Approach 2:
An extraction fluid acts as an intermediary substance that temporarily binds to sulfones during separation, enabling efficient sulfur removal. The extraction fluid is then regenerated in the solvent separation unit and recycled, serving as a reusable mediator that facilitates the desulfurization process without becoming a waste product.
2Ease of manufacture
If high-sulfur fuels are processed without proper desulfurization, then processing simplicity is maintained, but equipment damage and corrosion occur
Solution Approach 1:
The oxidation process unit performs preliminary conversion of sulfur compounds to sulfones before the extraction process. This preliminary chemical transformation makes the sulfur compounds more amenable to separation and ensures thorough desulfurization, protecting downstream equipment from corrosion while maintaining process simplicity.
3Manufacturing precision
If multi-stage liquid-liquid extraction is implemented, then sulfur removal efficiency increases, but system complexity and operational steps increase
Solution Approach 1:
The system operates in continuous mode with the oxidation unit continuously converting sulfur compounds, the extraction unit continuously separating sulfones, and the solvent separation unit continuously regenerating extraction fluid. This continuous operation maintains high sulfur removal efficiency while avoiding the start-stop complexity of batch processes.
Solution Approach 2:
The solvent separation process unit provides feedback by recycling the regenerated extraction fluid back to the liquid-liquid extraction unit. This closed-loop feedback ensures consistent separation performance and maintains system efficiency without requiring external intervention or complex control mechanisms.
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 system achieves deep desulfurization, reducing sulfur levels to below 15 ppm, while maintaining other fuel properties within specifications, and is economically scalable for use in various locations without the need for extensive infrastructure.
Implementation Method 1
an oxidation process unit that outputs a fuel, the fuel comprising an oxidized fuel having sulfur therein
Implementation Method 2
a liquid-liquid extraction unit coupled to the oxidation process unit. The liquid-liquid extraction unit comprises at least one liquid-liquid extraction stage, where each liquid-liquid extraction stage has a mixer and a separation vessel coupled to the mixer
Data Source
AI summary
A desulfurization system has an oxidation process unit, and a multi-stage, liquid-liquid extraction unit in series with the oxidation process unit. The multi-stage, liquid-liquid extraction unit spits a fuel input from the oxidation process unit into a desulfurized fuel that is output for use, and a by-product. A solvent/sulfur/hydrocarbon separation process unit receives the by-product from the multi-stage, liquid-liquid extraction unit.