Heavy Oil Hydrocracking with Colloidal Catalyst for Coke Reduction
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Solution Overview
Problem
Conventional hydroprocessing methods are inefficient in upgrading heavy oil feedstocks with high boiling points and high concentrations of asphaltenes, sulfur, nitrogen, and metals, leading to low conversion rates, equipment fouling, and excessive coke formation.
Innovation Solution
A hydroprocessing method that combines a colloidal or molecular catalyst with a coking process, where the catalyst is dispersed in the heavy oil feedstock and used in a pre-coking hydrocracking reactor to reduce asphaltenes and coke precursors, followed by thermal cracking in a coking reactor to produce upgraded hydrocarbons and reduce coke formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional hydroprocessing methods are used to upgrade heavy oil feedstocks, then the process can be implemented with existing equipment, but the conversion rate is low and equipment fouling occurs
Solution Approach 1:
The process is divided into two distinct stages: a hydrocracking stage that converts high boiling hydrocarbons to lower boiling fractions, and a coking stage that converts remaining heavy fractions to liquid products and coke. This segmentation allows each stage to be optimized independently, with the hydrocracking stage reducing fouling precursors before the coking stage processes the remaining material.
Solution Approach 2:
The hydrocracking stage performs preliminary conversion of asphaltenes and high boiling hydrocarbons to lighter fractions before the material enters the coking stage. This preliminary action reduces the concentration of fouling precursors and coke-forming compounds that would otherwise accumulate in conventional single-stage coking processes.
2Productivity
If conventional hydroprocessing methods are used, then existing equipment can be utilized, but coke formation is excessive
Solution Approach 1:
By separating the upgrading process into hydrocracking and coking stages, the system achieves more complete conversion of heavy fractions to liquid products. The hydrocracking stage converts asphaltenes and high boiling hydrocarbons to lighter fractions, reducing the feedstock to the coking stage and thereby reducing excessive coke formation.
Solution Approach 2:
The process changes the physical and chemical parameters of the feedstock through controlled hydrocracking conditions (temperature, pressure, hydrogen partial pressure) before coking. This parameter modification optimizes the balance between conversion and coke formation by preparing the feedstock in a more favorable state for the coking stage.
3Device complexity
If conventional hydroprocessing methods are used, then the process is simple, but energy and water consumption are excessive
Solution Approach 1:
The two-stage process allows for more efficient heat integration and energy recovery. The exothermic coking stage can utilize heat from the endothermic hydrocracking stage, and water used in decoking can be reused or treated more efficiently. This segmentation enables better energy management despite increased process complexity.
Solution Approach 2:
The sequential operation of hydrocracking followed by coking ensures continuous conversion of heavy feedstock to valuable liquid products. This continuous action eliminates idle time and maximizes productive operation, reducing energy and water consumption per unit of product despite the additional process step.
4Duration of action of stationary object
If conventional hydroprocessing methods are used, then equipment life is short, but operational costs are high
Solution Approach 1:
The hydrocracking stage performs preliminary removal of asphaltenes and coke-forming compounds before the material enters coking equipment. This preliminary action significantly reduces the rate of fouling and equipment degradation during the coking stage, thereby extending equipment life and reducing maintenance costs.
Solution Approach 2:
The process converts the potentially harmful asphaltenes and high boiling hydrocarbons into useful liquid hydrocarbon products through controlled hydrocracking. This transformation turns what would be fouling agents into valuable products, reducing equipment fouling and extending operational life while generating revenue.
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 method increases the conversion rate and quality of liquid hydrocarbon products, reduces coke formation, and decreases energy and water consumption, while extending equipment life and reducing operational costs.
Implementation Method 1
the colloidal or molecular catalyst catalyzing upgrading reactions between hydrogen and the hydrocarbon free radicals to yield an upgraded material
Implementation Method 2
causing thermal-cracking of the liquid hydrocarbon fraction to form coke and upgraded hydrocarbon products
Data Source
AI summary
Methods and systems for hydroprocessing heavy oil feedstocks to form an upgraded material involve the use of a colloidal or molecular catalyst dispersed within a heavy oil feedstock, a pre-coking hydrocracking reactor, a separator, and a coking reactor. The colloidal or molecular catalyst promotes upgrading reactions that reduce the quantity of asphaltenes or other coke forming precursors in the feedstock, increase hydrogen to carbon ratio in the upgraded material, and decrease boiling points of hydrocarbons in the upgraded material. The methods and systems can be used to upgrade vacuum tower bottoms and other low grade heavy oil feedstocks. The result is one or more of increased conversion level and yield, improved quality of upgraded hydrocarbons, reduced coke formation, reduced equipment fouling, processing of a wider range of lower quality feedstocks, and more efficient use of supported catalyst if used in combination with the colloidal or molecular catalyst, as compared to a conventional hydrocracking process or a conventional thermal coking process.