Hydrocracker Resid Upgrading via Filtration, Aromatics, and Hydrotreating
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Solution Overview
Problem
The challenge lies in effectively processing unconverted heavy oil (UCO residuum) from hydrocracking processes due to its high viscosity, propensity to flocculate, and foul process equipment, along with high sulfur content, making it difficult to meet stringent fuel oil specifications such as low sulfur and sediment content requirements, particularly for IMO 2020 regulations.
Innovation Solution
A process involving filtration to remove insolubles, blending with aromatics feeds, and hydrotreatment to stabilize and upgrade UCO residuum, allowing it to meet low sulfur fuel oil specifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If unconverted heavy oil is processed directly without pretreatment, then the processing simplicity is maintained, but the equipment fouling and operational stability deteriorate due to high viscosity and flocculation propensity
Solution Approach 1:
The patent applies preliminary action by performing filtration and blending operations before the main hydrotreatment process. The unconverted heavy oil is first filtered to remove insolubles and then blended with aromatics to reduce viscosity and prevent flocculation, thereby preparing the feedstock in advance to avoid equipment fouling during processing
Solution Approach 2:
The patent uses an intermediary substance (aromatics feed) to mediate between the unconverted heavy oil and the processing equipment. The aromatic blend component acts as a mediator that reduces the harmful effects of high viscosity and flocculation propensity, enabling smooth flow through the hydrotreatment system without direct contact between the problematic heavy oil and equipment surfaces
2Device complexity
If unconverted heavy oil is sent to coker or blended into bunker fuel oil without further processing, then the processing complexity is minimized, but the product quality and sulfur content specifications deteriorate
Solution Approach 1:
The patent applies parameter changes by modifying the chemical composition parameters of the unconverted heavy oil through hydrotreatment. The process changes the sulfur content, viscosity, and compositional distribution by subjecting the oil to hydroprocessing conditions with catalysts, thereby transforming the product properties to meet low sulfur fuel oil specifications
Solution Approach 2:
The patent replaces the mechanical separation approach (coking) with a chemical treatment approach (hydrotreatment). Instead of using mechanical/thermal decomposition in a coker, the process uses chemical reactions with hydrogen in the presence of catalysts to remove sulfur and upgrade the product quality, achieving better environmental compliance
3Reliability
If filtration and blending processes are applied to unconverted heavy oil, then the operational stability and equipment reliability improve, but the device complexity and processing steps increase
Solution Approach 1:
The patent merges multiple functions into an integrated processing train. The filtration unit, blending unit, and hydrotreatment unit are combined into a cohesive system where the output of one unit directly feeds the next, creating a streamlined process that achieves operational stability without excessive complexity through functional integration
4Manufacturing precision
If hydrotreatment is applied to reduce sulfur content, then the product quality and environmental compliance improve, but the energy consumption and processing cost increase
Solution Approach 1:
The patent applies local quality by targeting specific sulfur removal in the hydrotreatment process. The catalysts and processing conditions are optimized to selectively remove sulfur compounds from the unconverted heavy oil while minimizing unnecessary energy consumption on other aspects of the oil composition, thereby achieving efficient sulfur reduction
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 process stabilizes UCO residuum, reducing sediment and sulfur content, enabling its use in low sulfur fuel oil, meeting IMO 2020 regulations and improving operational stability by preventing equipment fouling.
Implementation Method 1
passing the unconverted heavy oil feed or mixture directly to a separation process, or more particularly a filtration process, to remove insolubles
Implementation Method 2
passing the unconverted heavy oil feed or mixture to a heavy oil hydrotreating process, thereby forming a hydrotreated heavy oil stream
Data Source
AI summary
Processes and systems for upgrading hydrocracker unconverted heavy oil are provided. The invention is useful in upgrading unconverted heavy oil such as resid derived from hydrocracking processes and may be used to upgrade such resids to form fuel oils such as low sulfur fuel oil for marine use. A combination of solutions is applied in the invention including applying a separation process for unconverted heavy oil comprising hydrocracker resid, combining an aromatic feed with the unconverted heavy oil, followed by subjecting the unconverted heavy oil to a hydrotreating process.