HRU Regeneration Loop Absorbent Separation for Mercaptan Control

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Solution Overview

Problem

Existing hydrocarbon recovery units (HRUs) face challenges in effectively removing contaminants like mercaptans and heavy hydrocarbons during the regeneration process, leading to their reintroduction into the feed gas, which increases contaminant concentration in the adsorbent beds.

Innovation Solution

A regeneration loop process that introduces an absorbent, such as C7+ hydrocarbons or polyethylene glycol, into the regeneration gas stream to adsorb and separate C5+ hydrocarbons or organic sulfur species, followed by cooling and three-phase separation to remove these contaminants before reintroducing the gas into the feed stream.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the regeneration loop uses heating followed by cooling with treated gas stream, then the adsorbent bed is regenerated, but contaminants like mercaptans and heavy hydrocarbons are reintroduced into the feed gas, increasing contaminant concentration in the adsorbent beds

Engineering Contradiction:

Improveregeneration effectivenessVSAvoidcontaminant concentration

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces an absorbent as an intermediary substance that selectively absorbs contaminants (C5+ hydrocarbons and organic sulfur species like mercaptans) from the regeneration gas stream. This absorbent acts as a mediator between the regeneration process and the feed gas, removing harmful contaminants before the gas is recycled, thus resolving the contradiction between effective regeneration and contaminant removal

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent changes the temperature parameter by cooling the regeneration gas stream to less than 50° C. after introducing the absorbent. This temperature change enhances the absorption efficiency of the absorbent for contaminants and facilitates the separation process, thereby improving contaminant removal while maintaining regeneration effectiveness

Inventive Principle:

Principle #35Parameter changes

2Device complexity

If contaminants are not adequately removed by the condenser during cooling, then the separation process is simple, but excess contaminants are reintroduced into the feed gas, resulting in higher contaminant concentration at the feed side

Engineering Contradiction:

Improveseparation process complexityVSAvoidcontaminant concentration

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The absorbent serves as a chemical intermediary that selectively binds to contaminants through absorption, providing an additional separation mechanism beyond physical condensation. This intermediary substance enables effective removal of light contaminants like mercaptans that would otherwise pass through the condenser, improving purification without significantly complicating the overall process

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent applies local quality by introducing the absorbent specifically into the regeneration gas stream where contaminants are present, rather than treating the entire system uniformly. The absorbent locally addresses the contaminant removal need in the regeneration loop, allowing different parts of the system to have different functions: condensation for heavy hydrocarbons and absorption for light contaminants

Inventive Principle:

Principle #3Local quality

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

Effectively reduces the buildup of mercaptans and heavy hydrocarbons in the adsorbent beds, maintaining lower contaminant concentrations and enhancing the efficiency of the hydrocarbon recovery process.

Implementation Method 1

introducing an absorbent into the regeneration gas stream to remove a portion of the C5+ hydrocarbons or organic sulfur species

Methodology Applied

Scientific EffectAdsorption: Adsorption

Implementation Method 2

cooling the regeneration gas stream to less than 50° C. after introducing the absorbent

Methodology Applied

Scientific EffectCooling: Cooling

Implementation Method 3

subsequently removing the portion of the C5+ hydrocarbons or organic sulfur species from the regeneration gas stream

Methodology Applied

Scientific EffectPhase separation: Phase Change

Data Source

PatentUS20260055036A1Hydrocarbon recovery unit with recycle loop for adsorbent bed regeneration

Publication Date: 2026.02.26 BASF CORPORATON

AI summary

Disclosed in certain embodiments are processes for heavy hydrocarbon removal that implement a regeneration loop that introduces an absorbent into a regeneration gas stream, and systems for implementing the same.