Integrated Ebullated-Bed Crude Upgrading Process
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for processing whole crude oil are limited in effectively handling contaminants like organic nickel, vanadium compounds, and poly-nuclear aromatic compounds, leading to catalyst deactivation and increased costs due to frequent reactor shutdowns and high capital investments in fixed-bed reactors.
Innovation Solution
An integrated system combining an ebullated-bed reaction zone and a fixed-bed reaction zone for hydroprocessing whole crude oil, where the ebullated-bed reactor processes atmospheric residues and the fixed-bed reactor treats flashed straight run distillates, with hydrogen recycling and catalyst replacement, to reduce contaminants and enhance fuel quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If fixed-bed reactors are used for hydroprocessing heavy feedstocks, then conversion of heavy boiling point materials can be achieved, but catalyst deactivation occurs rapidly due to contaminants causing frequent shutdowns and high capital investment
Solution Approach 1:
The patent employs a moving-bed reactor where the catalyst bed is in continuous motion, transitioning from a stationary fixed-bed configuration to a dynamic system. This allows contaminants to be continuously removed from the catalyst surface, preventing deactivation while maintaining high conversion activity for heavy feedstocks boiling above 300-400°C.
Solution Approach 2:
The moving-bed reactor design enables continuous replacement and regeneration of catalyst material. Deactivated catalyst is continuously discarded and replaced with fresh catalyst, maintaining constant catalytic activity without shutdowns. This resolves the contradiction by sacrificing individual catalyst particles to preserve overall system productivity and reliability.
2Productivity
If multiple fixed-bed reactors are connected in series to achieve high conversion, then heavy feedstock conversion increases, but capital investment and device complexity increase significantly
Solution Approach 1:
The patent replaces multiple static fixed-bed reactors with a single dynamic moving-bed reactor. The continuous motion of the catalyst bed within one reactor achieves the same or better conversion efficiency that would require multiple series-connected fixed-bed reactors, thereby reducing device complexity and capital investment.
Solution Approach 2:
The moving-bed reactor design performs multiple functions within a single unit: it achieves high conversion of heavy feedstocks, continuously manages catalyst deactivation, and eliminates the need for multiple reactors. This multi-functionality reduces both the number of units required and the overall system complexity.
3Ease of manufacture
If conventional fixed-bed reactors are used for vacuum residuum upgrading, then processing can be performed, but frequent catalyst replacement is required every 3-4 months increasing operating costs
Solution Approach 1:
The moving-bed reactor enables continuous catalyst renewal without interrupting the hydroprocessing operation. As the catalyst bed moves continuously, fresh catalyst is constantly introduced and deactivated catalyst is removed, maintaining uninterrupted useful action for vacuum residuum upgrading and eliminating periodic shutdowns for catalyst replacement.
Solution Approach 2:
The dynamic nature of the moving-bed reactor allows continuous catalyst circulation and replacement, transforming the static, periodic catalyst replacement requirement of fixed-bed reactors into a continuous process. This eliminates downtime and maintains constant processing capability for difficult feedstocks like vacuum residuum.
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 reduces sulfur and aromatic content in fuels, increases fuel yields, and decreases operating and capital costs by allowing continuous operation with reduced reactor volume and catalyst replacement frequency, producing high-quality synthetic crude oil.
Implementation Method 1
In an ebullated-bed reactor, the catalyst is in an expanded bed, thereby countering plugging problems associated with fixed-bed reactors. The fluidized nature of the catalyst in an ebullated-bed reactor also allows for on-line catalyst replacement of a small portion of the bed.
Implementation Method 2
hydroprocessing the atmospheric residual fraction in an ebullated-bed reaction zone in the presence a first catalyst system, e.g., an ebullated-bed reactor catalyst, produce an ebullated-bed reactor effluent
Implementation Method 3
hydrotreating a stream composed of the hydroprocessed product and the flashed straight run distillate fraction in the presence of a second catalyst system, e.g., hydrotreating catalyst, in a hydrotreating zone
Data Source
Figure 1
AI summary
A system and process for upgrading a whole crude oil feed in an integrated ebullated-bed and hydrotreater is provided in which the whole crude oil is flashed into a flashed straight run distillates fraction and an atmospheric residue fraction. The atmospheric residue fraction is hydroprocessed in an ebullated-bed reaction zone, while the flashed straight run distillates fraction and the products fraction produced from the ebullated-bed reaction zone are hydrotreated in a fixed-bed reaction zone. Distillates from the hydrotreater and the unconverted residue fraction from the ebullated-bed reaction zone can be combined to produce an upgraded synthetic crude oil.