Flexible Hydroprocessing of Slurry Effluent Fractions

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Solution Overview

Problem

The high capital investment in hydroprocessing units for slurry hydrocracking (SHC) products is due to the need for separate hydroprocessing conditions for fractions with varying properties, leading to increased costs and complexity.

Innovation Solution

A process involving the separation of SHC effluent into multiple streams, followed by fractionation and hydrotreating with specific catalysts and conditions tailored to each fraction, allowing for integrated hydroprocessing of different boiling point fractions in shared equipment, optimizing conditions for each stream to achieve comparable product properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If separate hydroprocessing conditions are used for each fraction with varying properties, then product quality is improved, but capital investment and equipment costs increase

Engineering Contradiction:

Improveproduct qualityVSAvoidequipment costs

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The effluent from slurry hydrocracking is separated into multiple streams based on boiling point ranges using distillation columns. Each stream (light ends, naphtha, diesel, gas oil) is then routed to appropriate hydroprocessing units with conditions optimized for that specific fraction's properties, achieving high product quality while avoiding the need for a single complex unit to handle all fractions

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The hydroprocessing conditions (temperature, pressure, catalyst type) are dynamically adjusted according to the specific fraction being processed. Lighter fractions receive milder conditions while heavier fractions receive more severe conditions, allowing each stream to be optimized without requiring separate fixed infrastructure for every possible condition

Inventive Principle:

Principle #15Dynamics

2Productivity

If separate hydroprocessing units are used for each fraction, then processing efficiency is improved, but capital investment increases

Engineering Contradiction:

Improveprocessing efficiencyVSAvoidcapital investment

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The hydroprocessing system is designed with multiple units that can handle different fractions, but the system operates most efficiently when fed specific boiling point ranges. The distillation separation upstream creates a universal platform where multiple fractions are processed through appropriately matched hydroprocessing units, achieving high productivity without requiring every possible fraction to be processed simultaneously through every unit

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Manufacturing precision

If fractions are processed separately with optimized conditions, then product properties are improved, but equipment and hydrogen compression costs increase

Engineering Contradiction:

Improveproduct propertiesVSAvoidequipment and hydrogen costs

Core Design Contradiction:

Manufacturing precisionVSQuantity of substance

Solution Approach 1:

Each hydroprocessing unit is configured with specific catalysts, temperatures, and pressures matched to the local requirements of each fraction. Light ends use different conditions than diesel or gas oil streams, allowing each local processing zone to be optimized for its specific feedstock properties, achieving superior product properties without uniformly expensive equipment throughout the entire system

Inventive Principle:

Principle #3Local quality

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 the capital investment in hydroprocessing units by integrating the processing of fractions with varying properties, achieving comparable or improved product properties while minimizing equipment and hydrogen compression costs.

Implementation Method 1

hydrotreating the second fraction in the presence of hydrogen and a hydrotreating catalyst in a first hydrotreating reactor to form a first hydrotreated effluent

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 2

hydrotreating the first hydrotreated effluent and the first fraction in the presence of hydrogen and a hydrotreating catalyst in a second hydrotreating reactor

Methodology Applied

Scientific EffectHydrogenation: Hydrogenation

Implementation Method 3

the at least two fractions comprise at least a first fraction and a second fraction, the second fraction having a T5 boiling point above the T5 boiling point of the first fraction

Methodology Applied

Scientific EffectDistillation: Distillation

Data Source

PatentUS10563139B2Flexible hydroprocessing of slurry hydrocracking products

Publication Date: 2020.02.18 UOP LLC

AI summary

Processes for hydrotreating an effluent from a slurry hydrocracking process are described. Different streams are formed from the SHC effluent, and different hydroprocessing conditions are applied to the streams, e.g., more severe conditions are applied to streams which need additional hydroprocessing, while less severe conditions are applied to streams which do not need as much hydroprocessing. Common equipment is shared between different hydroprocessing steps.