Hydrocracking Process Maximizing Light Distillate Yield
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Solution Overview
Problem
Conventional petroleum refining processes are complex, energy-intensive, and inefficient in producing high yields of light distillates, with asphaltenes in heavy crude oil posing a threat to downstream processing units and reducing their efficiency.
Innovation Solution
An integrated hydrocracking process involving two catalysts at specific temperature and pressure ranges, with hydrogen, to convert hydrocarbons into light distillates, reducing asphaltene content and recycling fractions to enhance yield and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the number of process units such as distillation columns is increased to increase conversion of crude oil, then the yield of light distillates is improved, but the complexity of the entire process increases
Solution Approach 1:
The patent combines hydrocracking and fractionation processes into an integrated system where the hydrocracker directly feeds into fractionation columns, eliminating the need for separate conventional distillation units. This merging of processes achieves high yield of light distillates while reducing overall process complexity through functional integration.
Solution Approach 2:
The patent segments the hydrocracked stream into different boiling point fractions (light distillates, middle fraction, bottom fraction) through fractionation, allowing selective recovery of valuable light distillates while managing the complexity of processing heavy residues through controlled fractional separation.
2Reliability
If hydro-processing is carried out to remove sulfur and nitrogen content, then the product quality is improved, but the consumption of energy increases
Solution Approach 1:
The patent optimizes hydrocracking parameters including temperature (300-500°C), pressure (2-80 bar), and hydrogen-to-oil ratio to achieve effective removal of sulfur and nitrogen while minimizing energy consumption. By carefully controlling these parameters, the process achieves product quality improvement without excessive energy input.
Solution Approach 2:
The patent implements continuous hydrocracking operation where hydrogen is continuously supplied and recycled through the system. This continuous action maintains optimal conditions for sulfur and nitrogen removal while improving energy efficiency through sustained operation rather than batch processing.
3Productivity
If asphaltenes are present in heavy oil to increase conversion, then the yield of distillates is improved, but the formation of sediments and coke precursors increases
Solution Approach 1:
The patent extracts and removes asphaltenes from the hydrocracked stream through fractionation processes. By separating asphaltenes into the bottom fraction and managing them separately, the process maintains the beneficial conversion of heavy oil to distillates while eliminating the harmful effects of asphaltene-induced sediment and coke formation in downstream equipment.
4Quantity of substance
If steam cracking is used to produce olefins for petrochemical plant, then the olefins production is improved, but the plant complexity and capital cost increase
Solution Approach 1:
The patent enables the hydrocracking process to self-produce olefins as a byproduct of the hydrocracking reaction itself, rather than requiring separate steam cracking units. This self-service approach generates the necessary olefins for petrochemical operations while avoiding the added complexity and capital cost of dedicated steam cracking infrastructure.
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 achieves a significant increase in light distillate yield, reduces asphaltene content by 60-98%, and simplifies the refining process, making it more economical and efficient.
Implementation Method 1
hydrocracking the hydrocarbons, in the presence of hydrogen and a first catalyst, at a temperature in the range of 300° C. to 500° C., preferably in the range of 320 to 480° C. and at a pressure in the range of 2 to 80 bar, preferably in the range of 15 bar to 50 bar
Implementation Method 2
hydrocracking the hydrocarbons, in the presence of hydrogen and a first catalyst
Implementation Method 3
The first hydrocracked stream is fractionated to obtain a first top product stream having boiling point less than or equal to 180° C., a middle fraction having boiling point above 180° C. and below or equal to 370° C. and a bottom fraction having boiling point above 370° C.
Data Source
AI summary
The present disclosure relates to a process for hydro-processing of hydrocarbons to maximize the yield of light distillates. The process comprises hydrocracking hydrocarbons and separating to respective products based on the boiling points. The heavier vacuum residue is further hydrocracked to light distillates.