Hydrocarbon Desulfurization via Oxidation and Caustic Reaction
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Solution Overview
Problem
Current methods for reducing heteroatom content, particularly sulfur, in hydrocarbon streams are costly and inefficient, especially for heavy crude oils, due to high energy input and waste disposal issues, and fail to effectively remove sterically hindered sulfur compounds and other impurities like nitrogen and vanadium.
Innovation Solution
A reaction system utilizing a caustic compound, such as sodium hydroxide or potassium hydroxide, in combination with a selectivity promoter, to oxidize and remove heteroatoms from hydrocarbon streams, producing non-ionic hydrocarbon products with reduced heteroatom content, lower total acid number, and increased API gravity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If hydrodesulfurization (HDS) is used to remove sulfur from hydrocarbon streams, then sulfur content is reduced, but energy input and hydrogen consumption increase substantially
Solution Approach 1:
The patent changes the chemical parameters of the reaction system by using oxidation conditions instead of hydrodesulfurization conditions. The oxidized heteroatom compounds are then reacted with caustic under different chemical conditions to produce sulfur-free products, thereby reducing energy input while achieving the same sulfur removal goal
Solution Approach 2:
The patent replaces the mechanical/chemical process of hydrodesulfurization with an oxidation-based chemical process followed by caustic reaction. This substitution eliminates the need for high-pressure hydrogen and high-energy HDS conditions while achieving equivalent sulfur removal
2Quantity of substance
If hydrodesulfurization (HDS) is used to remove sulfur from heavy and sour streams, then sulfur content is reduced, but CO2 emissions increase substantially
Solution Approach 1:
The patent converts the harmful oxidation process that traditionally produces CO2 emissions into a beneficial process by using controlled oxidation to create oxidized heteroatom compounds that can be selectively removed with caustic. The oxidation is used to create removable compounds rather than to combust hydrocarbons, thereby converting a harmful process into a useful one
3Quantity of substance
If conventional methods are used to remove heteroatoms, then sulfur content is reduced, but sterically hindered sulfur compounds and other impurities remain
Solution Approach 1:
The patent changes the chemical state of sulfur compounds by oxidizing them to different oxidation states. This transformation makes even sterically hindered sulfur compounds reactive toward caustic, enabling complete removal of all sulfur forms including those that conventional methods cannot remove
Solution Approach 2:
The patent performs preliminary oxidation of heteroatom compounds before the main removal step. This preliminary action transforms refractory sulfur compounds into more reactive oxidized forms that can be completely removed by subsequent caustic reaction, ensuring no sulfur remains in the final product
4Quantity of substance
If current methods are used to reduce heteroatom content, then some sulfur is removed, but operational costs remain high
Solution Approach 1:
The patent uses caustic as a disposable reagent that reacts with oxidized heteroatom compounds to form water-soluble salts. The caustic can be easily separated from the hydrocarbon phase and the process requires no expensive catalysts or complex equipment, significantly reducing operational costs
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 effectively reduces heteroatom content, including sulfur, nitrogen, and metals, while minimizing waste generation and operational costs, achieving high conversion rates and selectivity towards sulfur-free products, suitable for various hydrocarbon streams.
Implementation Method 1
After subjecting a liquid hydrocarbon stream to oxidation conditions, thereby oxidizing at least a portion of the heteroatom compounds (e.g., oxidizing dibenzothiophenes to sulfones)
Data Source
AI summary
A reaction system and method for removing heteroatoms from oxidized-heteroatom-containing hydrocarbon streams and products derived therefrom are disclosed. An oxidized-heteroatom-containing hydrocarbon feed is reacted in a reaction system thereby forming non-ionic hydrocarbon products. The products derived therefrom are useful as transportation fuels, lubricants, refinery intermediates, or refinery feeds.