Flexible Heat Integration Layout for Hydroprocessing Sulfidation Control

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing hydroprocessing processes face challenges in efficiently controlling catalyst activation temperatures during in-situ sulfidation, particularly in processes with short catalyst cycles, as they require independent thermal control to compensate for non-correlated deactivation rates, which is costly and inefficient.

Innovation Solution

A process layout is designed with heat exchange and flow control mechanisms to minimize excess heating, allowing for flexible thermal management by distributing heat from a charge heater to multiple reactors, enabling in-situ sulfidation without additional charge heaters, and optimizing temperature control across reactors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If in-situ sulfidation is used to avoid extra costs, then capital and operational expenses are reduced, but temperature control becomes more complex and costly due to non-correlated deactivation rates

Engineering Contradiction:

Improvecatalyst activation efficiencyVSAvoidthermal control system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The thermal control system is segmented into multiple independent heating zones, with separate charge heaters for different reactor groups. This allows independent temperature control for each reactor, compensating for non-correlated deactivation rates without requiring a completely complex integrated system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The charge heaters are designed to serve multiple functions: they provide heating during normal operation and also enable in-situ sulfidation by controlling temperature profiles during catalyst activation. This multi-functionality reduces the need for separate specialized equipment.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Duration of action of stationary object

If independent thermal control is implemented to compensate for non-correlated deactivation rates, then catalyst lifetime is optimized, but capital and operational expenses increase

Engineering Contradiction:

Improvecatalyst lifetimeVSAvoidnumber of charge heaters

Core Design Contradiction:

Duration of action of stationary objectVSDevice complexity

Solution Approach 1:

Instead of providing independent charge heaters to every reactor, the system is segmented into groups that share common heating infrastructure. Reactors within the same group have correlated deactivation patterns and can be controlled by shared charge heaters, reducing the total number of heaters while still addressing non-correlated deactivation between groups.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple reactors are combined into thermal control groups where a single charge heater serves multiple reactors. The effluent from upstream reactors is used to preheat feedstock for downstream reactors in the same group, creating a merged thermal control system that reduces equipment count while maintaining effective temperature control.

Inventive Principle:

Principle #5Merging (Combining)

3Manufacturing precision

If excess heat is transferred to process streams by heat exchange, then temperature control precision is improved, but energy loss increases

Engineering Contradiction:

Improvetemperature control precisionVSAvoidexcess heat loss

Core Design Contradiction:

Manufacturing precisionVSLoss of energy

Solution Approach 1:

The excess heat that would otherwise be wasted is converted into a useful resource by using it to preheat feedstock streams through heat exchange with effluent. This transforms energy loss into beneficial preheating, improving temperature control precision while reducing overall energy consumption.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

Heat that would be discarded in the effluent stream is recovered through heat exchange with incoming feedstock. This recovery process improves temperature control precision for the reactors while minimizing energy loss, as the effluent heat is reused rather than wasted.

Inventive Principle:

Principle #34Discarding and recovering

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 enables cost-effective and flexible thermal control during catalyst activation and operation, reducing capital and operational expenses while maintaining catalyst efficiency and extending catalyst life.

Implementation Method 1

the charge heater may heat a stream above the required temperature

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

transferring this excess heat to another process stream by heat exchange

Methodology Applied

Scientific EffectHeat exchange: Heat Exchanger

Implementation Method 3

recuperating the heat by heat exchange with an upstream flow

Methodology Applied

Scientific EffectHeat recuperation: Heat Exchanger

Data Source

PatentUS20260042965A1Process plant with flexible heat integration scheme

Publication Date: 2026.02.12 HALDOR TOPSOE AS

AI summary

A thermal configuration for use during sulfidation and operation is disclosed which may involve multiple of the following heating steps, (a) heating a process feed by a charge heater, heating (b) a process feed stream or a recycle oil stream by heat exchange with a process effluent, heating (c) a process feed stream or a recycle oil stream by heat exchange with a said process feed after having been heated in the charge heater. Furthermore, the steps may be made independent by controlling the ratio of the streams directed to (b) or (c), controlling an amount of feed stream or recycle oil stream by-passed around the heating of (b) or (c) and controlling the temperature of step (a).