One-Step Crude Oil Refining with Fatty Acids
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Solution Overview
Problem
The conventional crude oil refining process has low yield and efficiency, with heavy gas oil and residues posing maintenance and environmental challenges, and existing methods are costly and inefficient for complete disposal of low-value products like mazut and bitumen.
Innovation Solution
A one-step combination process involving refining, catalytic cracking, and isomerization of hydrocarbon feedstocks with fatty acids at low temperatures, which converts heavy hydrocarbons into light hydrocarbon products like diesel, gasoline, and kerosene, with no formation of heavy hydrocarbons and the spontaneous formation of aromatic hydrocarbons.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional fractional distillation and catalytic cracking processes are used, then crude oil can be separated into light hydrocarbon fractions, but the yield of light hydrocarbons is low and heavy residues remain
Solution Approach 1:
The patent applies parameter changes by conducting cracking reactions at lower temperatures (400-600°C) compared to conventional high-temperature processes, and by using specific catalysts (zeolites, alumina, silica) with controlled acidity and pore structures. These parameter modifications enable complete conversion of heavy residues into light hydrocarbons while maintaining product quality
Solution Approach 2:
The patent employs composite catalyst systems combining multiple materials (zeolites with alumina, silica-alumina composites) to achieve both high conversion of heavy residues and selective production of desired light hydrocarbon fractions. The composite structure provides synergistic effects for improved productivity
2Ease of manufacture
If multiple refining steps including fractional distillation and catalytic cracking are implemented, then commercial products can be produced, but the process complexity and cost increase
Solution Approach 1:
The patent merges fractional distillation and catalytic cracking operations into an integrated process where distillation separates crude oil fractions and the resulting heavy residues are immediately subjected to catalytic cracking in the same processing train. This combination simplifies the overall process by eliminating separate handling steps for residues
Solution Approach 2:
The catalytic cracking unit serves multiple functions: it converts heavy residues into light hydrocarbons, produces gasoline-range fractions, and generates diesel-range products simultaneously. This multi-functionality reduces the need for separate processing units for different product streams
3Object-affected harmful factors
If heavy gas oil and residues are disposed of through conventional methods, then low-value products are removed, but maintenance and environmental problems arise
Solution Approach 1:
The patent converts the harmful heavy residues (mazut, bitumen) into beneficial light hydrocarbon products through catalytic cracking. What was previously a waste stream causing environmental problems becomes a valuable source of gasoline, diesel, and kerosene, eliminating disposal issues while creating additional revenue streams
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 process significantly increases the yield of light hydrocarbon products, reduces energy costs, and effectively manages heavy residues, improving both economic and ecological aspects of crude oil refining by eliminating low-quality residual products.
Implementation Method 1
heating said hydrocarbon feedstock with one or more fatty acids or mixtures thereof, at a vapour temperature below 360° C., to obtain a light hydrocarbon product
Implementation Method 2
heating said hydrocarbon feedstock with one or more fatty acids or mixtures thereof, at a vapour temperature below 360° C.
Implementation Method 3
said process is accompanied by formation of aromatic hydrocarbons
Data Source
AI summary
The present application provides a one-step refining process of a hydrocarbon feedstock, said process comprising heating said hydrocarbon feedstock with one or more fatty acids or mixtures thereof, at a temperature below 350° C., to obtain a light hydrocarbon product, wherein said light hydrocarbon product obtained in said process contains no heavy hydrocarbons products.