Heavy Fuel Production via Hydrotreatment and Hybrid Hydrocracking
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Solution Overview
Problem
Current processes for producing fuel oils and fuel-oil bases, such as bunker oils, fail to meet the low sulphur and sediment content requirements set by the MARPOL convention and ISO 8217 standard, particularly in maritime fuels, as they do not effectively incorporate a prior hydrotreatment stage and sediment reduction treatments.
Innovation Solution
A process involving a fixed-bed hydrotreatment stage followed by a hybrid-bed hydrocracking stage, including a separation of effluents to reduce sulphur content and a sediment treatment stage to minimize sediment content, utilizing a combination of supported and dispersed catalysts in ebullating and hybrid reactors to achieve the desired fuel oil quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional hydrocracking processes are used without prior hydrotreatment, then the process is simpler and faster, but the sulphur content in the fuel oil exceeds the MARPOL convention limits
Solution Approach 1:
The patent applies preliminary action by implementing a hydrotreatment stage before the hydrocracking stage. This preliminary hydrotreatment step removes sulphur and other impurities from the heavy hydrocarbon feedstock before it enters the hydrocracking reactor, ensuring that the subsequent hydrocracking process produces fuel oil with sulphur content below MARPOL convention limits while maintaining process efficiency
2Manufacturing precision
If no sediment treatment stage is included, then the process is simpler, but the sediment content in the fuel oil exceeds ISO 8217 standard limits
Solution Approach 1:
The patent implements a sediment treatment stage as a preliminary step before the final separation and fuel oil production. This stage removes sediments and catalyst residues from the hydrocracking effluent through filtration and centrifugation, ensuring that the final fuel oil meets ISO 8217 standard limits for sediment content after ageing
3Productivity
If hybrid-bed reactors with dispersed catalyst are used, then conversion and hydrodesulphurization performances are improved, but catalyst consumption increases
Solution Approach 1:
The patent applies the discarding and recovering principle by implementing a sediment treatment stage that recovers and removes catalyst residues and sediments from the hydrocracking effluent. This recovery process captures dispersed catalyst particles and sediments that would otherwise be lost, reducing catalyst consumption while maintaining the high conversion and hydrodesulphurization performances of the hybrid-bed reactor
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 process effectively reduces sulphur content to less than 0.5% and sediment content to less than 0.1% by weight, meeting the stringent quality standards for bunker oils and marine fuels, while optimizing catalyst consumption and product yield.
Implementation Method 1
a fixed-bed hydrotreatment stage, in which the hydrocarbon-containing feedstock and hydrogen are brought into contact on a hydrotreatment catalyst
Implementation Method 2
on a hydrotreatment catalyst
Implementation Method 3
a stage of hydrocracking of at least a part of the heavy fraction... in at least one reactor operating in hybrid mode
Implementation Method 4
operating in an ebullating bed with a supported catalyst combined with a dispersed catalyst
Implementation Method 5
a stage of separation of the effluent from the hydrotreatment stage making it possible to release a heavy cut
Data Source
AI summary
The present invention describes a process for the production of fuel of the heavy fuel oil type, this fuel optionally being able to become a marine fuel, from a heavy hydrocarbon-containing feedstock having a sulphur content of at least 0.5% by weight, an initial boiling temperature of at least 350° C. and a final boiling temperature of at least 450° C., a process using a fixed-bed hydrotreatment stage, an intermediate separation and a hydrocracking stage comprising at least one reactor of the hybrid type.