Heavy Oil Conversion via Hydrotreating and Fractionation
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Solution Overview
Problem
The petrochemical industry faces challenges in efficiently producing intermediate compounds like ethylene, propylene, and aromatic hydrocarbons due to the limitations and high costs associated with traditional thermal cracking processes using petroleum gases and distillates as feedstocks, necessitating alternative and cost-effective methods for producing these compounds.
Innovation Solution
The proposed solution involves a multi-step process that includes hydrotreating heavy oil feedstocks to remove impurities, separating them into fractions, and then subjecting these fractions to hydrocracking and steam cracking to produce petrochemical products such as BTX and light olefins, optimizing product selectivity and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional thermal cracking processes use petroleum gases and distillates as feedstocks, then petrochemical products can be produced, but the feedstock costs are high and availability is limited
Solution Approach 1:
The patent changes the feedstock parameter from light petroleum fractions (gases, naphtha, kerosene) to heavy petroleum fractions (residues, vacuum gas oils). This parameter change allows utilization of abundant, low-cost heavy oil feedstocks that were previously unsuitable for steam cracking, thereby improving both feedstock availability and reducing costs while maintaining petrochemical product production
Solution Approach 2:
The patent applies preliminary hydrotreatment and fractionation actions to heavy oil feedstocks before steam cracking. The heavy oil undergoes hydrotreatment to remove impurities, then fractionation to separate into appropriate ranges, preparing it for successful steam cracking. This preliminary processing enables the use of heavy oils as feedstocks, resolving the contradiction between feedstock availability and suitability
2Quantity of substance
If heavy oil feedstocks are directly used in steam cracking, then feedstock cost and availability improve, but product selectivity and efficiency deteriorate due to impurities and inappropriate molecular weight distribution
Solution Approach 1:
The patent segments the heavy oil feedstock into different boiling point fractions through fractionation. By dividing the heavy oil into appropriate molecular weight ranges, each fraction can be optimally processed in the steam cracker to produce desired petrochemical products with high selectivity, while the feedstock itself remains abundant and low-cost
Solution Approach 2:
The patent applies preliminary hydrotreatment to remove sulfur, nitrogen, and metal impurities from heavy oil before cracking. This preliminary purification action ensures that when the processed heavy oil fractions undergo steam cracking, they produce high-selectivity petrochemical products without the harmful effects of impurities, thus resolving the contradiction between feedstock availability and product selectivity
3Adaptability or versatility
If conventional hydrotreatment and hydrocracking processes are applied to heavy oils, then feedstock processing capability improves, but process complexity and energy consumption increase
Solution Approach 1:
The patent applies partial hydrocracking rather than complete conversion. By selectively hydrocracking only the heavy fractions that need molecular weight reduction while leaving lighter fractions intact for direct steam cracking, the process achieves necessary feedstock adaptability while minimizing energy consumption compared to full hydrocracking of the entire heavy oil feedstock
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 allows for the direct conversion of heavy oils into valuable petrochemical products, offering a more cost-effective and efficient method compared to traditional processes by leveraging hydrotreatment and hydrocracking followed by steam cracking, thereby addressing the limitations of existing methods.
Implementation Method 1
hydrotreating the feedstock oil to reduce or remove one or more of sulfur content, metals content, nitrogen content, or aromatics content
Implementation Method 2
hydrocracking the greater boiling point oil fraction stream
Implementation Method 3
steam cracking the lesser boiling point oil fraction stream
Implementation Method 4
separating the hydrotreated oil stream into a lesser boiling point oil fraction stream and a greater boiling point oil fraction stream
Data Source
AI summary
According to one or more embodiments presently described, a feedstock oil may be processed by a method which may include hydrotreating the feedstock oil to reduce or remove one or more of sulfur content, metals content, nitrogen content, or aromatics content to produce a hydrotreated oil stream; separating at least a portion of the hydrotreated oil stream into a at least a lesser boiling point oil fraction stream and a greater boiling point oil fraction stream in a first separator; hydrocracking the greater boiling point oil fraction stream; and steam cracking the lesser boiling point oil fraction stream.