Hydrocracking Process Control via Near-Infrared Spectroscopy

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Solution Overview

Problem

The existing hydrocracking process for wax fractions from Fischer-Tropsch synthesis struggles to determine the degree of hydrocracking progression in real-time, making it difficult to control the process effectively and achieve a high yield of middle distillate, as conventional analysis methods are time-consuming and limit rapid adjustments.

Innovation Solution

A multi-stage gas-liquid separation process is employed to separate hydrocracked products into heavy and light oil components, allowing for the determination of their flow rate ratio, which correlates with the content of specific hydrocarbon components, enabling rapid estimation and control of hydrocracking conditions to maintain optimal product yields.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If distillation gas chromatography is used to analyze hydrocracked product, then measurement precision of specific hydrocarbon component content is improved, but loss of time increases due to time-consuming analysis

Engineering Contradiction:

Improvecontent determination accuracyVSAvoidanalysis time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent replaces the mechanical/chemical analysis system (distillation gas chromatography) with an optical detection system (near-infrared spectroscopy). This substitution enables rapid determination of specific hydrocarbon component content without the time-consuming separation and detection processes of chromatography, while maintaining sufficient measurement precision for process control purposes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent creates a spectral copy or fingerprint of the hydrocracked product using near-infrared spectroscopy. Instead of physically separating and analyzing components through distillation and chromatography, the method uses spectral characteristics to rapidly determine component content, providing a time-efficient alternative that maintains adequate precision for hydrocracking process control.

Inventive Principle:

Principle #26Copying

2Productivity

If hydrocracking proceeds excessively, then molecular weight reduction is improved, but yield of middle distillate deteriorates due to further lightening

Engineering Contradiction:

Improvemolecular weight reduction efficiencyVSAvoidmiddle distillate yield

Core Design Contradiction:

ProductivityVSQuantity of substance

Solution Approach 1:

The patent implements a feedback control system where near-infrared spectroscopy continuously monitors the content of specific hydrocarbon components (C5-C20) in the hydrocracked product. This real-time information feeds back to the hydrocracking process control, allowing adjustment of operating conditions to maintain optimal conversion levels that maximize middle distillate yield while achieving sufficient molecular weight reduction.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent enables dynamic control of the hydrocracking process by using rapid spectroscopic analysis to monitor product composition changes in real-time. This allows the process conditions (temperature, pressure, catalyst activity, residence time) to be dynamically adjusted to optimize the balance between molecular weight reduction and middle distillate yield, preventing both insufficient cracking and excessive lightening.

Inventive Principle:

Principle #15Dynamics

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 enables rapid determination and control of hydrocracking progression, stabilizing and increasing the yield of middle distillate from Fischer-Tropsch synthesis reactions.

Implementation Method 1

a gas-liquid separation step of separating the hydrocracked product into a gas component, a heavy oil component and a light oil component using a multi-stage gas-liquid separator

Methodology Applied

Scientific EffectGas-liquid separation: Density Gradient

Implementation Method 2

a wax fraction hydrocracking step of hydrocracking the wax fraction contained within a liquid hydrocarbon produced by a FT synthesis reaction, thereby obtaining a hydrocracked product

Methodology Applied

Scientific EffectHydrocracking: Chemical Bonding

Data Source

PatentUS8702969B2Hydrocracking process and process for producing hydrocarbon oil

Publication Date: 2014.04.22 INPEX CORP

AI summary

A hydrocracking process that includes a wax fraction hydrocracking step of hydrocracking the wax fraction contained within a Fischer-Tropsch synthetic oil to obtain a hydrocracked product, a gas-liquid separation step of using a multi-stage gas-liquid separator to separate the hydrocracked product into a gas component, a heavy oil component and a light oil component, a specific component content estimation step of determining the flow rate ratio between the heavy oil component and the light oil component, and using this flow rate ratio to determine an estimated value for the content of a specific hydrocarbon component contained within the hydrocracked product, and a control step of controlling the operation of the wax fraction hydrocracking step on the basis of this estimated value, so that the content of the specific hydrocarbon component falls within a predetermined range.