Integrated Refinery Unit for Heavy Base Oil Production
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
There is a need for improved processes and refinery units to effectively produce heavy API Group II base oil from feeds comprising aromatic extracts, as existing methods are inefficient in achieving the desired quality and yield.
Innovation Solution
A process involving aromatic extraction followed by mixing with a second hydrocarbon feed to create a mixed feed with high sulfur content, which is then hydroprocessed to produce heavy API Group II base oil with a kinematic viscosity of 22.6 to 100 mm^2/s, while also producing heavy API Group I base oil through solvent dewaxing and hydrofinishing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If aromatic extraction is performed to produce heavy API Group II base oil, then the quality and viscosity of the base oil are improved, but the process complexity and production efficiency deteriorate due to multiple processing stages
Solution Approach 1:
The patent combines aromatic extraction and solvent dewaxing operations into an integrated process unit. The aromatic extract from the extraction unit is directly mixed with fresh feed and recycled raffinate, then sent to the solvent dewaxing unit. This merging eliminates separate processing lines and optimizes the overall flow, reducing process complexity while maintaining base oil quality specifications.
Solution Approach 2:
The solvent dewaxing unit serves multiple functions: it processes the aromatic extract from the extraction unit, handles fresh hydrocarbon feed, and processes recycled raffinate. This multi-functionality allows a single unit to perform dewaxing operations on multiple feed streams, simplifying the overall process configuration and reducing the number of dedicated units needed.
2Manufacturing precision
If aromatic extraction is performed to produce heavy API Group II base oil, then the viscosity and quality of the base oil are improved, but the production time and operational complexity increase
Solution Approach 1:
The patent implements continuous operation of the aromatic extraction unit and solvent dewaxing unit. The aromatic extract is continuously produced and immediately mixed with fresh feed and recycled raffinate. The solvent dewaxing unit continuously processes this mixed feed, maintaining steady-state operation. This continuity eliminates batch processing interruptions and optimizes production throughput, reducing overall production time while maintaining quality.
Solution Approach 2:
The aromatic extraction unit performs preliminary separation of aromatics from the hydrocarbon feed before the solvent dewaxing step. By pre-processing the feed to remove aromatic components, the subsequent dewaxing operation becomes more efficient and requires less time to achieve the desired base oil quality specifications.
3Productivity
If aromatic extract is mixed with second hydrocarbon feed to create high sulfur mixed feed, then the yield of heavy API Group II base oil is improved, but the difficulty of hydroprocessing increases
Solution Approach 1:
The patent adjusts hydroprocessing parameters including temperature, pressure, and catalyst composition to effectively process the high sulfur mixed feed. By optimizing these parameters, the hydroprocessing unit can handle the increased sulfur content while maintaining production efficiency and product quality, turning a challenging feedstock into a viable source of heavy API Group II base oil.
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 integrated refinery process unit efficiently produces high-quality heavy API Group II base oil with improved viscosity and yield, while also producing heavy API Group I base oil, addressing the inefficiencies of existing methods.
Implementation Method 1
performing an aromatic extraction of a first hydrocarbon feed to produce an aromatic extract, and a waxy raffinate
Implementation Method 2
feeding the mixed feed to a hydroprocessing unit configured to produce a heavy API Group II base oil
Implementation Method 3
hydroprocessing unit configured to produce
Implementation Method 4
a solvent dewaxing unit configured to produce a heavy API Group I base oil
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A process for heavy base oil production, comprising: a. performing an aromatic extraction of a first hydrocarbon feed to produce an aromatic extract, and a waxy raffinate; b. mixing the aromatic extract with a second hydrocarbon feed to make a mixed feed having greater than 2,000 wt ppm sulfur; c. feeding the mixed feed to a hydroprocessing unit to produce a heavy API Group II base oil having a kinematic viscosity at 70 C from 22.6 to 100 mm2/s. An integrated refinery process unit for making heavy base oils, comprising: a. an aromatic extraction unit fluidly connected to a solvent dewaxing unit and a hydroprocessing unit; b. a first line from the aromatic extraction unit, that feeds an aromatic extract to a second hydrocarbon feed to make a mixed feed having greater than 2,000 wt ppm sulfur; and c. a connection that feeds the mixed feed to the hydroprocessing unit.