Disulfide Oil Catalyst Activation Process
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The disposal and utilization of disulfide oil, a byproduct from the MEROX process used in hydrocarbon processing, is problematic due to its environmental unsuitability and the need for hydrogen in further processing, which increases costs.
Innovation Solution
The integration of a process where disulfide oil is purified and used directly to activate hydroprocessing catalysts, converting sulfur compounds from caustic solutions into mercaptans or disulfides for catalyst activation, thereby utilizing the waste product effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If disulfide oil is further processed via hydrotreating or hydrocracking, then it can be converted to useful products, but hydrogen consumption increases operational costs
Solution Approach 1:
The patent converts the harmful waste product (disulfide oil) directly into a beneficial activating agent for hydroprocessing catalysts. Instead of treating disulfide oil as waste requiring expensive hydrogen-intensive processing, the invention utilizes its sulfur content to sulfide catalyst metals, transforming a disposal problem into a value-adding process that eliminates hydrogen consumption for this specific purpose.
Solution Approach 2:
The invention changes the functional parameter of disulfide oil from waste material to catalyst activating agent. By controlling the contact between disulfide oil and catalyst under specific conditions (temperature, pressure, residence time), the sulfur compounds are transferred to the catalyst surface, converting the catalyst from oxidized to sulfided state without requiring additional hydrogen.
2Object-affected harmful factors
If disulfide oil is disposed of by burning, then environmental problems are avoided, but this is far from desirable due to resource waste
Solution Approach 1:
The invention transforms the environmentally problematic disulfide oil into a useful chemical reagent for catalyst activation. The sulfur compounds that would otherwise require expensive treatment or disposal are instead utilized to sulfide catalyst metals, eliminating both environmental concerns and resource waste simultaneously.
Solution Approach 2:
Instead of discarding disulfide oil as waste, the invention recovers and utilizes its sulfur content for catalyst activation. The process extracts value from the waste stream by using disulfide oil as a sulfur source, thereby preventing both environmental pollution and material loss.
3Reliability
If commercially available disulfides are used for catalyst activation, then catalyst performance is optimized, but operational costs increase
Solution Approach 1:
The invention replaces expensive commercially available disulfides with a cheaper alternative (disulfide oil derived from waste streams). Although disulfide oil requires purification, the overall cost is reduced because it originates from waste material rather than requiring synthesis or purchase of commercial chemicals.
Solution Approach 2:
The invention enables the refinery to produce its own catalyst activating agent from internal waste streams (disulfide oil from MEROX process or caustic extraction). This self-sufficiency eliminates the need to purchase external disulfide products, reducing operational costs while maintaining catalyst activation functionality.
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 allows for the effective activation of hydroprocessing catalysts using disulfide oil, demonstrating similar performance to commercially available disulfides, thus addressing the disposal and cost issues associated with disulfide oil while optimizing catalyst conversion.
Implementation Method 1
sulfur containing compounds are removed from the feedstock by contact with a caustic (i.e., alkaline) solution, into which the sulfur containing compounds (e.g., thiosulfates) dissolve
Implementation Method 2
The process requires an organometallic catalyst and an alkaline solution in order to accelerate oxidation
Implementation Method 3
oxidation of mercaptans in hydrocarbon mixtures, via the basic reaction: RSH+1⁄4O2→1⁄2RSSR+1⁄2H2O
Implementation Method 4
converting sulfur compounds from caustic solutions into mercaptans or disulfides for catalyst activation, thereby utilizing the waste product effectively
Data Source
AI summary
The invention involves an integrated process in which a hydrocarbon feedstock is treated with a caustic (alkaline) extraction to remove sulfides, disulfides, and mercaptans. These extracted materials are further treated, and are then used to activate hydrotreating catalysts.