Hydroconversion Unit for Crude Oil Refining

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Solution Overview

Problem

Current refining processes face inefficiencies and environmental challenges due to the production of coke and fuel oil by-products, requiring a more flexible and environmentally friendly approach to convert crude oil into distillates, especially with changing demand and quality of crude oils.

Innovation Solution

Substituting the coking unit with a hydroconversion unit using Eni Slurry Technology (EST), which includes a hydroconversion reactor in slurry phase with a dispersed hydrogenation catalyst, allowing for the conversion of heavy fractions into distillates without producing coke and optimizing the production of medium distillates.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a coking unit is used to process vacuum residue, then heavy fractions are converted into distillates, but coke is produced as a harmful by-product requiring additional handling and storage facilities

Engineering Contradiction:

Improveconversion of heavy fractions to distillatesVSAvoidcoke production

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The harmful coke by-product is extracted and removed from the process by replacing the coking unit with a hydroconversion unit that converts vacuum residue into distillates without producing coke, thereby eliminating the need for coke handling and storage facilities

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The chemical parameters of the conversion process are changed by using hydroconversion instead of coking, altering the reaction conditions and catalyst system to produce distillates without coke formation, thus changing the product distribution from harmful to beneficial

Inventive Principle:

Principle #35Parameter changes

2Productivity

If multiple conversion units (coking, visbreaking, cracking) are installed to maximize distillate production, then refining capacity increases, but device complexity and operational difficulty increase

Engineering Contradiction:

Improvedistillate production capacityVSAvoidrefinery configuration

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

Multiple conversion functions are merged into a single hydroconversion unit that can process vacuum residue and produce distillates without requiring separate coking, visbreaking, or cracking units, thereby simplifying the overall refinery configuration

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The hydroconversion unit performs multiple functions simultaneously - it converts heavy fractions, produces distillates, and eliminates coke formation - making it a universal replacement for several specialized units and reducing operational complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

If conventional coking processes are used, then heavy residue is converted to distillates, but energy consumption increases due to multiple processing steps

Engineering Contradiction:

Improvevacuum residue conversionVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The energy-intensive coking step is extracted and removed from the process sequence, replacing it with a hydroconversion process that achieves the same conversion goal with lower energy consumption by eliminating intermediate processing steps

Inventive Principle:

Principle #2Taking out (Extraction)

4Adaptability or versatility

If coking units are operated to meet current demand, then production flexibility is maintained, but adaptability to changing market demands (reduced gasoline, increased diesel) is limited

Engineering Contradiction:

Improveproduct mix flexibilityVSAvoiddistillate yield

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The product distribution parameters are changed by using hydroconversion instead of coking, which produces a different yield pattern favoring diesel and gas oil over gasoline, thereby adapting the refinery output to current market demands

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 approach simplifies refinery operations, reduces energy consumption, and increases refining margins by eliminating coke production, enhancing operational and environmental efficiency while maintaining flexibility in processing various crude oil qualities.

Implementation Method 1

a hydroconversion reactor in slurry phase with a dispersed hydrogenation catalyst, allowing for the conversion of heavy fractions into distillates

Methodology Applied

Scientific EffectHydrogenation: Hydrogenation

Implementation Method 2

a hydroconversion reactor in slurry phase with a dispersed hydrogenation catalyst

Methodology Applied

Scientific EffectCatalysis: Catalysis

Data Source

PatentUS10407628B2Process for the refining of crude oil

Publication Date: 2019.09.10 ENI SPA

AI summary

A process for the refining of crude oil with at least one atmospheric distillation unit for separating the various fractions, a sub-atmospheric distillation unit, a conversion unit of the heavy fractions obtained, a unit for enhancing the quality of some of the fractions obtained by actions on the chemical composition of their constituents and a unit for the removal of undesired components, where the sub-atmospheric distillation residue is sent to one of the conversion units, the conversion unit includes at least one hydroconversion reactor in slurry phase, into which hydrogen or a mixture of hydrogen and H2S, is fed, in the presence of a suitable dispersed hydrogenation catalyst with dimensions ranging from 1 nanometer to 30 microns.