Hydrocracking Fischer-Tropsch and Petroleum Blends for Fuel Properties
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Solution Overview
Problem
Fischer-Tropsch distillate fuels exhibit poor seal swell properties, low densities, and thermal instability, which limit their use in engines and result in decreased performance and customer dissatisfaction, while also requiring costly hydrogen for hydroprocessing.
Innovation Solution
A process involving blending a Fischer-Tropsch derived product with a petroleum derived product, followed by hydrocracking under specific conditions to produce a distillate fuel with increased aromatics, oxygenates, and reduced sulfur and nitrogen content, enhancing seal swell, density, and thermal stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If Fischer-Tropsch distillate fuels are produced by hydroprocessing to achieve low sulfur and aromatic content, then environmental compliance is improved, but seal swell properties deteriorate
Solution Approach 1:
The patent changes the chemical composition parameters of the distillate fuel by controlling the hydroprocessing conditions and blending ratios to achieve an optimal balance between sulfur content and aromatic content, thereby improving seal swell properties while maintaining low sulfur compliance
Solution Approach 2:
The patent creates a composite distillate fuel product by blending Fischer-Tropsch derived wax with petroleum derived vacuum gas oil in specific ratios, combining the low sulfur advantages of FT products with the better seal swell properties of petroleum products
2Object-affected harmful factors
If Fischer-Tropsch distillate fuels are produced with high paraffin content to achieve low aromatic content, then sulfur content is reduced, but density deteriorates
Solution Approach 1:
The patent blends Fischer-Tropsch derived wax (high paraffin content) with petroleum derived vacuum gas oil (higher density) in optimized ratios to produce a composite fuel that maintains low aromatic content while achieving acceptable density specifications
Solution Approach 2:
The patent adjusts the blending ratio and hydroprocessing parameters to control the final paraffin-to-aromatics ratio, optimizing both the low aromatic content requirement and the density specification simultaneously
3Object-affected harmful factors
If hydroprocessing is applied to Fischer-Tropsch products to reduce sulfur, then sulfur content is improved, but hydrogen consumption increases
Solution Approach 1:
The patent applies partial hydroprocessing rather than complete hydroprocessing, removing sulfur to the extent necessary for compliance while avoiding excessive hydrogen consumption by stopping the process at the optimal point
Solution Approach 2:
The patent optimizes the hydroprocessing parameters including temperature, pressure, catalyst type, and contact time to achieve maximum sulfur removal with minimum hydrogen consumption, finding the optimal operating window for the process
4Object-affected harmful factors
If Fischer-Tropsch distillate fuels are produced with low aromatic content to meet environmental specifications, then sulfur content is reduced, but thermal stability deteriorates
Solution Approach 1:
The patent creates a composite fuel system where the petroleum derived vacuum gas oil component provides thermal stability that compensates for the low aromatic content of the Fischer-Tropsch derived wax, achieving both environmental compliance and operational stability
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 resulting distillate fuel demonstrates improved seal swell, density, and thermal stability, reducing fuel leaks and performance issues, and minimizing hydrogen consumption during processing.
Implementation Method 1
hydrocracking the blend; and recovering a distillate fuel
Data Source
AI summary
The present invention relates to distillate fuels or distillate fuel blend stocks comprising a blend of a Fischer-Tropsch derived product and a petroleum derived product that is hydrocracked under conditions to preserve aromatics. The resulting distillate fuel product is a low sulfur, moderately aromatic distillate fuel. The resulting distillate fuel or distillate fuel blend stock exhibits excellent properties, including good seal swell, density, and thermal stability. The present invention also relates to processes for making these distillate fuels or distillate fuel blend stocks.