High-Rate Hydrothermal Reactor for Low-Fouling Feedstock Upgrading
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Solution Overview
Problem
Conventional petroleum refining processes face challenges in efficiently upgrading waxy crude oils and other heavy organic feedstocks due to poor heat transfer, batch operation, coke formation, reactor plugging, and high viscosity, which are not effectively addressed by existing hydrothermal processes.
Innovation Solution
A continuous-flow, high-rate hydrothermal reactor system utilizing high fluid velocity, turbulent flow, and short residence times to convert organic feedstocks into higher-value hydrocarbon products, with features like rapid heating, water management, and rapid quenching to inhibit secondary reactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional hydrothermal processes are used to upgrade heavy organic feedstocks, then the feedstock can be converted into hydrocarbon products, but the process suffers from poor heat transfer, batch operation, coke formation, reactor plugging, and high viscosity
Solution Approach 1:
The patent applies parameter changes by operating at extremely high temperatures (above 700°C, preferably 750-900°C) and high pressures (30-300 atm) to achieve supercritical conditions. This fundamental parameter change transforms the reaction environment, enabling continuous operation, improving heat transfer, reducing viscosity, and minimizing coke formation compared to conventional hydrothermal processes
Solution Approach 2:
The patent implements preliminary action through a quench zone that rapidly cools the reaction mixture immediately after the reaction zone. This preliminary cooling action prevents secondary reactions, inhibits coke formation, and maintains reactor operation stability by controlling the reaction products before they can cause fouling
2Productivity
If high temperature and pressure are applied to convert organic feedstocks, then conversion rate increases, but secondary reactions and coke formation increase
Solution Approach 1:
The patent applies the skipping principle by rapidly transitioning the reaction mixture through the high-temperature reaction zone and immediately into the quench zone. This rapid passage through the reaction conditions minimizes the residence time at temperatures that promote coke formation, allowing high conversion rates while reducing harmful secondary reactions
Solution Approach 2:
The quench zone performs preliminary action by immediately cooling the reaction products before they can undergo secondary reactions. This preliminary cooling prevents the accumulation of coke and other harmful byproducts that would otherwise form at high temperatures
3Ease of operation
If batch operation is used for hydrothermal processing, then process control is simplified, but productivity is reduced and heat transfer is poor
Solution Approach 1:
The patent implements continuity of useful action by designing a continuous-flow reactor system where the organic feedstock and water are continuously pumped through the reaction zone at supercritical conditions. This continuous operation maintains constant high temperature and pressure, ensuring sustained high conversion rates and improved heat transfer compared to batch processes
Solution Approach 2:
The transition from batch to continuous operation is enabled by parameter changes including maintaining supercritical conditions (T>700°C, P>30 atm) throughout the continuous flow, which keeps the reaction mixture in a state that prevents plugging and maintains high productivity
4Productivity
If conventional catalysts are used for upgrading heavy oils, then conversion can occur, but expensive catalysts are required and periodic regeneration is needed
Solution Approach 1:
The patent applies the taking out principle by eliminating the catalyst from the system entirely. The supercritical water oxidation process achieves the desired conversion of heavy organic feedstocks through thermal and oxidative mechanisms without requiring any catalyst, thereby removing the complexity of catalyst selection, installation, and periodic regeneration
Solution Approach 2:
The patent substitutes the chemical catalysis mechanism with a thermal-oxidative mechanism operating at supercritical conditions. Instead of using catalysts to lower activation energy, the process uses high temperature and pressure to directly drive the conversion reactions, replacing the need for catalyst management with simplified thermal processing
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 system achieves efficient conversion of organic feedstocks into high-octane naphtha, kerosene, and diesel fuels with reduced viscosity and sulfur content, while minimizing coke formation and reactor fouling, thereby improving the quality and yield of distillate fuels.
Implementation Method 1
The high-rate reactor of the invention utilizes both high fluid velocity and turbulent flow to achieve very short residence times
Implementation Method 2
The system employs high fluid velocity, high heat transfer rates, and turbulent flow
Implementation Method 3
The mixture is subjected to heat and pressure, maintaining the heat and pressure applied to the mixture for a residence time of less than three minutes
Implementation Method 4
cooling the hydrocarbon products at a rate sufficient to inhibit additional reaction and to enable recovering of process heat
Implementation Method 5
The system employs high fluid velocity, high heat transfer rates, and turbulent flow
Data Source
AI summary
A process and system for upgrading an organic feedstock including providing an organic feedstock and water mixture, feeding the mixture into a high-rate, hydrothermal reactor, wherein the mixture is rapidly heated, subjected to heat, pressure, and turbulent flow, maintaining the heat and pressure of the mixture for a residence time of less than three minutes to cause the organic components of the mixture to undergo conversion reactions resulting in increased yields of distillate fuels, higher-quality kerosene and diesel fuels, and the formation of high octane naphtha compounds. Hydrocarbon products are cooled at a rate sufficient to inhibit additional reaction and recover of process heat, and depressurizing the hydrocarbon products, and separating the hydrocarbon products for further processing. The process and system can include devices to convert olefinic hydrocarbons into paraffinic hydrocarbons and convert olefinic byproduct gas to additional high-octane naphtha and/or heavier hydrocarbons by one of hydrogenation, alkylation, or oligomerization.