Hydrogen Compression Split for Multi-Pressure Hydroprocessing
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Solution Overview
Problem
Current hydroprocessing methods face challenges in producing sufficient diesel that meets stringent sulfur and nitrogen content regulations, particularly when hydrocracking units operate at different pressures, requiring improved methods for hydrogen supply and integration between hydrocracking and hydrotreating units.
Innovation Solution
The proposed solution involves a system with make-up hydrogen lines, compressors, and split streams to efficiently compress and distribute hydrogen between hydrocracking and hydrotreating reactors, allowing for effective hydroprocessing of hydrocarbon streams at different pressures, integrating the units to enhance diesel production quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If hydrocracking unit operates at higher pressure than hydrotreating unit, then hydrocracking efficiency is improved, but hydrogen supply complexity increases
Solution Approach 1:
The hydrogen supply system is segmented into multiple compression stages. A first compressor compresses make-up hydrogen to an intermediate pressure, and a second compressor further compresses a portion of this hydrogen to the higher pressure required by the hydrocracking unit. This segmentation allows each compressor to operate within optimal pressure ranges, improving overall system efficiency while meeting different pressure requirements.
Solution Approach 2:
The first compressed make-up hydrogen stream serves multiple functions: it provides hydrogen for the hydrotreating unit directly, and after further compression by the second compressor, provides hydrogen for the hydrocracking unit. This multi-functionality reduces the need for separate hydrogen supply systems for each unit, simplifying the overall configuration.
2Reliability
If separate hydrogen supply systems are used for hydrocracking and hydrotreating units, then each unit's hydrogen requirements are met, but capital costs increase
Solution Approach 1:
The patent merges the hydrogen supply systems of the hydrocracking and hydrotreating units into an integrated configuration. The first compressor serves both units by providing compressed hydrogen to the hydrotreating unit, and a portion is further compressed by the second compressor for the hydrocracking unit. This combined system reduces capital costs by eliminating redundant equipment while maintaining reliable hydrogen supply to both units.
3Productivity
If mild hydrocracking is used to improve unconverted oil quality, then diesel yield is improved, but sulfur and nitrogen removal efficiency decreases
Solution Approach 1:
The hydroprocessing is segmented into two distinct stages: mild hydrocracking followed by hydrotreating. The mild hydrocracking stage focuses on converting heavy hydrocarbons to diesel-range molecules while preserving unconverted oil quality. The subsequent hydrotreating stage specifically targets sulfur and nitrogen removal. This segmentation allows each stage to optimize for its specific function, achieving both high diesel yield and effective contaminant removal.
Solution Approach 2:
The process maintains continuous useful action by seamlessly connecting the mild hydrocracking unit with the hydrotreating unit. The effluent from the hydrocracking unit flows continuously to the hydrotreating unit, where sulfur and nitrogen removal occurs. This continuous operation ensures that diesel production and contaminant removal occur in an integrated manner, meeting both yield and purity requirements.
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 the production of diesel that meets stringent sulfur and nitrogen standards by optimizing hydrogen supply and processing conditions across units, improving diesel yield and quality while reducing capital and operating costs.
Implementation Method 1
A first compressor in communication with the make-up hydrogen line is for compressing the make-up hydrogen stream to provide a first compressed make-up hydrogen stream
Implementation Method 2
A second compressor is in communication with the first split line for compressing the first portion of the first compressed make-up hydrogen stream to provide a second compressed make-up hydrogen stream
Implementation Method 3
A hydrocracking reactor is in communication with the first split line for hydrocracking a hydrocarbon stream to produce a diesel stream
Implementation Method 4
a hydrotreating reactor is in communication with the second split line and the hydrocracking reactor for hydrotreating the diesel stream
Data Source
AI summary
An apparatus is disclosed for hydroprocessing two hydrocarbon streams at two different pressures. A hydrogen stream is compressed and split. A first split compressed stream is further compressed to feed a first hydroprocessing unit that requires higher pressure for operation. A second split compressed stream is fed to a second hydroprocessing unit that requires lower pressure. Recycle hydrogen from the second hydroprocessing unit is recycled back to the compression section.