Contaminated Hydrocarbon Re-refining via Flash Separator and Evaporator

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Solution Overview

Problem

Current methods for reprocessing contaminated hydrocarbons are inefficient in producing higher-valued products, leading to significant waste and environmental concerns due to the high content of non-distillable components that foul equipment and deactivate catalysts.

Innovation Solution

A process involving a re-refining zone with a series of units including flash feed separators, hydroprocessing reactors, and film generating evaporators, where contaminated hydrocarbons are treated with hydrogen to vaporize and separate distillable components, minimize coke formation, and remove impurities, ultimately producing higher-value lubricating oil products.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional reprocessing methods are used to treat contaminated hydrocarbons, then the process is simpler and less costly, but the production of higher-valued products is inefficient and significant waste occurs due to non-distillable components

Engineering Contradiction:

Improveproduction efficiency of higher-valued productsVSAvoidwaste of contaminated hydrocarbons

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The reprocessing process is divided into multiple distinct zones: a flash feed separator zone for initial separation, a hydroprocessing zone for chemical treatment, and a film generating evaporator zone for final purification. This segmentation allows each zone to perform its specific function optimally, enabling efficient production of higher-valued products while minimizing waste of contaminated hydrocarbons

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The flash feed separator performs preliminary separation of distillable and non-distillable components before the main hydroprocessing step. By removing a portion of non-distillable components early in the process, the subsequent hydroprocessing operates more efficiently, improving overall productivity and reducing waste

Inventive Principle:

Principle #10Preliminary action

2Ease of manufacture

If contaminated hydrocarbons are processed without removing non-distillable components, then the process is simpler, but equipment becomes fouled and catalysts are deactivated

Engineering Contradiction:

Improveprocess simplicityVSAvoidequipment and catalyst performance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The flash feed separator performs preliminary removal of non-distillable components before the hydroprocessing step. This preliminary action prevents fouling of equipment and deactivation of catalysts in subsequent processing stages, maintaining reliability without significantly complicating the overall process

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The flash feed separator acts as an intermediary unit between the feedstock input and the hydroprocessing reactors. It prepares the contaminated hydrocarbons by removing problematic non-distillable components, protecting the catalysts and equipment in the hydroprocessing zone while maintaining process simplicity

Inventive Principle:

Principle #24Intermediary (Mediator)

3Manufacturing precision

If thermal processing is used to vaporize and separate components, then separation is achieved, but thermal degradation and coke formation increase

Engineering Contradiction:

Improveseparation precision of distillable componentsVSAvoidcoke formation and thermal degradation

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

Hydrogen serves as an intermediary substance in the hydroprocessing zone, facilitating the vaporization and separation of distillable components from non-distillable components without requiring extreme thermal conditions. This prevents thermal degradation and minimizes coke formation while achieving precise separation

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The process changes the chemical environment by introducing hydrogen in the hydroprocessing zone, allowing separation to occur under milder thermal conditions. This parameter change from pure thermal processing to hydrothermal processing reduces thermal degradation and coke formation while maintaining separation precision

Inventive Principle:

Principle #35Parameter changes

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 effectively upgrades contaminated hydrocarbons by reducing non-distillable components, minimizing thermal degradation, and producing higher-value lubricating oil products while reducing environmental impact by utilizing hydrogen to prevent coke formation and remove impurities.

Implementation Method 1

contaminated hydrocarbons are treated with hydrogen to vaporize and separate distillable components, minimize coke formation, and remove impurities

Methodology Applied

Scientific EffectHydroprocessing: Hydrogenation

Implementation Method 2

contaminated hydrocarbons are treated with hydrogen to vaporize and separate distillable components

Methodology Applied

Scientific EffectVaporization: Evaporation

Data Source

PatentEP2809746B1Process for contacting one or more contaminated hydrocarbons

Publication Date: 2020.04.29 UOP LLC

Figure 1

AI summary

One exemplary embodiment can be a process. The process can include contacting one or more contaminated hydrocarbons with a hydrogen gas stream in a flash feed separator to generate a first liquid stream, stripping the first liquid stream to generate a residue stream, and separating the residue stream in a film generating evaporator to obtain a recovered distillate.