Heavy Oil Hydroconversion with Slurry Catalyst and Deasphalting
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Solution Overview
Problem
Current processes for converting heavy crude oils, bitumen from 'oil sands,' and distillation residues face challenges such as high coke formation and catalyst deactivation in thermal processes, and economic and environmental issues with catalyst recycling in hydrogenation processes, particularly with fixed and ebullated bed technologies.
Innovation Solution
A process utilizing deasphalting, hydroconversion with catalysts in the slurry phase, and distillation or flash units, where the heavy charge is processed in multiple stages with separate hydroprocessing sections and distillation, allowing for efficient conversion and upgrading with reduced coke production and catalyst recycling needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If thermal conversion process is used, then conversion of heavy charges is achieved, but high coke formation and low product quality occur
Solution Approach 1:
The invention changes the chemical environment parameters by introducing hydrogen atmosphere and modifying temperature/pressure conditions to transform the thermal conversion process into a hydroconversion process, thereby reducing coke formation while maintaining conversion efficiency
Solution Approach 2:
The invention uses hydrogen as a reactive gas phase component that chemically interacts with the heavy charge, accelerating the conversion process and preventing coke formation through hydrogenation reactions
2Productivity
If fixed bed hydrogenation technology is used, then hydrogenation treatment is achieved, but catalyst deactivation occurs quickly due to contaminants
Solution Approach 1:
The invention segments the heavy charge into lighter fractions through deasphalting before hydroconversion, preventing contaminants from directly contacting and deactivating the catalyst in the fixed bed reactor
Solution Approach 2:
The invention performs preliminary deasphalting and contaminant removal operations before the hydroconversion stage, preparing the charge in advance to protect the catalyst from deactivation
3Reliability
If ebullated bed technology is used, then processing of heavy charges with high contaminants is improved, but device complexity and cost increase
Solution Approach 1:
The invention divides the conversion process into separate stages (deasphalting, hydroconversion, distillation) with distinct functions, allowing each unit to be optimized independently rather than requiring a complex integrated ebullated bed system
Solution Approach 2:
The invention introduces deasphalting as an intermediary process that prepares the charge before hydroconversion, simplifying the requirements for the hydroconversion reactor itself
4Object-generated harmful factors
If catalyst is used at low concentration, then environmental impact is reduced, but product upgrading is insufficient
Solution Approach 1:
The invention segments the catalyst system into multiple stages with different concentration requirements, allowing low catalyst concentration in the main hydroconversion stage while achieving high upgrading through the combined effect of multiple processing steps
Solution Approach 2:
The invention implements continuous recycling of the catalyst from distillation residue back to the hydroconversion reactor, maintaining continuous catalytic action that achieves high upgrading efficiency at low steady-state catalyst concentrations
5Productivity
If catalyst recycling is implemented, then catalyst utilization is improved, but process complexity and cost increase
Solution Approach 1:
The invention merges the catalyst separation function with the existing distillation operation, where the distillation column simultaneously performs product separation and catalyst concentration, eliminating the need for separate catalyst recovery equipment
Solution Approach 2:
The distillation column performs multiple functions: separating distillate products, concentrating the catalyst in the bottom residue, and facilitating catalyst recycling, thereby simplifying the overall process architecture
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 process achieves high conversion and upgrading efficiency with minimal coke production, flexibility in handling different hydrocarbon charges, and the possibility of complete catalyst recycling without regeneration, improving product quality and reducing environmental impact.
Implementation Method 1
hydroconversion of the charge using a catalyst in the dispersed phase
Implementation Method 2
distillation or flash units
Implementation Method 3
deasphalting
Data Source
AI summary
Heavy hydrocarbon charges are converted in a deasphalting section in the presence of solvents and obtaining two streams, one consisting of deasphalted oil and the other one containing asphaltenes, mixing the deasphalted oil stream with a hydrogenation catalyst and passing the thus obtained mixture to a hydroprocessing section containing hydrogen or hydrogen/H2S, mixing the stream consisting of asphaltenes discharged from the deasphalting section with an appropriate hydrogenation catalyst and passing the obtained mixture to a second hydroprocessing section where it is reacted with hydrogen or a mixture of hydrogen and H2S, passing both the stream containing the reaction product with dispersed catalyst from the hydroprocessing section and the stream containing the reaction product with dispersed catalyst from the second hydroprocessing section, to one or more distillation or flash stages, whereby the more volatile fractions are separated from the distillation residue (tar) or from the liquid discharged from the flash unit, sending the distillation residue (tar) or the liquid discharged from the flash unit, containing the catalyst in the dispersed phase, with a high content of metal sulphides, produced by demetallization of the charge, to a second deasphalting section thereby obtaining deasphalted oil and asphaltenes.