Integrated Hydroprocessing With Green Hydrogen and CO2 Hydrogenation
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Solution Overview
Problem
Existing hydrocarbon processing methods contribute significantly to carbon emissions and lack efficient utilization of renewable energy sources for producing clean fuels and chemicals.
Innovation Solution
A hydrocarbon hydroprocessing system that utilizes green hydrogen generated from renewable energy sources, such as solar and wind, to convert hydrocarbon feedstocks into saturated hydrocarbons while capturing and converting carbon dioxide into useful products, thereby reducing the carbon footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If conventional hydrocarbon processing methods are used, then hydrocarbon feedstocks can be processed into fuels and chemicals, but carbon emissions are significantly high
Solution Approach 1:
The patent captures carbon dioxide emitted during hydrocarbon processing and converts it into useful chemicals such as methanol, formic acid, and dimethyl ether through hydrogenation reactions. This transforms the harmful carbon emissions into valuable products, simultaneously reducing environmental impact and creating additional revenue streams.
Solution Approach 2:
The patent implements carbon capture and recovery systems that intercept carbon dioxide at the source during hydrocarbon processing, separate it from the process stream, and redirect it to chemical synthesis units. This prevents carbon emissions from being released while recovering the carbon for productive use in synthesizing oxygenated chemicals.
2Object-generated harmful factors
If renewable energy sources are utilized to produce green hydrogen, then carbon footprint is reduced, but energy conversion efficiency and cost-effectiveness face challenges
Solution Approach 1:
The patent integrates renewable energy systems (wind turbines, solar panels) directly with the hydrocarbon processing plant to generate green hydrogen on-site through water electrolysis. This combined system allows immediate utilization of the green hydrogen in hydroprocessing units, minimizing energy loss and creating a cohesive low-carbon processing ecosystem.
Solution Approach 2:
The hydrocarbon processing plant generates its own green hydrogen through on-site electrolysis units powered by renewable energy, reducing dependence on external hydrogen supplies. The system serves itself by producing the reducing agent needed for hydroprocessing directly within the facility boundaries.
3Object-generated harmful factors
If carbon dioxide is captured and converted into useful products, then carbon emissions are reduced, but process complexity increases
Solution Approach 1:
The carbon capture and conversion system serves multiple functions: it reduces carbon emissions, produces valuable chemicals (methanol, formic acid, dimethyl ether), and generates additional revenue streams. This multi-functional approach justifies the added complexity by delivering multiple benefits from a single integrated system.
Solution Approach 2:
The patent introduces carbon dioxide capture units and hydrogenation catalysts as intermediary components between the hydrocarbon processing units and the environment. These intermediaries transform carbon dioxide from a waste product into a reactant for chemical synthesis, managing the complexity through specialized intermediate processing stages.
4Object-generated harmful factors
If green hydrogen is used in hydroprocessing, then clean fuels are produced, but hydrogen production cost increases
Solution Approach 1:
The patent implements continuous electrolysis systems that operate alongside hydrocarbon processing, maintaining a steady supply of green hydrogen. The continuous operation optimizes energy utilization and reduces startup/shutdown losses, improving the overall cost-effectiveness of green hydrogen production compared to intermittent operation.
Solution Approach 2:
The patent combines green hydrogen production through electrolysis with the hydrocarbon processing operations in an integrated system. The spatial and operational merging allows shared infrastructure, optimized energy use, and synergistic heat and mass transfer, reducing the total cost of green hydrogen production compared to separate facilities.
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 system effectively converts refinery and consumer waste into valuable chemicals and fuels, utilizing renewable energy to produce green hydrogen, which reduces carbon emissions and promotes a sustainable energy transition.
Implementation Method 1
An electrolysis unit receives electrical power derived from a renewable energy source. The electrolysis unit splits water into oxygen and hydrogen using the received electrical power
Implementation Method 2
The hydroprocessing unit combusts a fuel using at least a portion of the oxygen stream produced by the electrolysis unit to produce heat and a flue gas including carbon dioxide
Implementation Method 3
The hydroprocessing unit reacts the feed stream with the first portion of the hydrogen stream using the produced heat to remove non-carbon impurities from the feed stream and break a carbon-carbon bond of the hydrocarbon oil
Implementation Method 4
At least a portion of the carbon dioxide of the flue gas is hydrogenated using a second portion of the hydrogen stream produced by the electrolysis unit to produce a product stream including a hydrocarbon, an oxygenate, or both
Data Source
AI summary
Electrical power derived from a renewable energy source is used to perform water electrolysis to produce oxygen and hydrogen. A flue gas and heat are produced from combustion of a fuel using at least a portion of the oxygen generated by electrolysis. A feed stream including hydrocarbon oil is hydroprocessed using the generated heat and at least a portion of the hydrogen generated by electrolysis to produce a product including a saturated hydrocarbon. At least a portion of the flue gas is hydrogenated using at least a portion of the hydrogen generated by electrolysis to produce a second product stream including a hydrocarbon, an oxygenate, or both.