Hydroprocessed Tar Product via Utility Fluid Mediator
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Solution Overview
Problem
Conventional catalytic hydroprocessing of steam-cracker tar (SCT) suffers from significant catalyst deactivation due to catalyst coking, which is exacerbated by high hydrogen partial pressures and reduced temperatures, leading to undesirable hydrogenation reactions and increased costs.
Innovation Solution
Hydroprocessing SCT in the presence of a utility fluid comprising aromatics, allowing operation at favorable temperatures and pressures that promote hydrocracking over aromatics hydrogenation, resulting in a hydroprocessed product with specific molecular class compositions and reduced viscosity and sulfur content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If conventional catalytic hydroprocessing is operated at elevated hydrogen partial pressure, diminished space velocity, and reduced temperature to lessen catalyst coking, then catalyst life is improved, but hydrogenation reactions become undesirable and process economics worsen
Solution Approach 1:
The patent changes the operational parameters by introducing a utility fluid that modifies the reaction environment. This allows the process to operate at higher temperatures and lower hydrogen partial pressures while preventing catalyst coking, thereby avoiding undesired hydrogenation reactions and improving process economics
Solution Approach 2:
The utility fluid acts as an intermediary substance that facilitates the hydroprocessing reaction. It enables the catalyst to function effectively at conditions that would otherwise cause coking and unwanted hydrogenation, thus protecting the catalyst and controlling the reaction pathway
2Reliability
If conventional catalytic hydroprocessing operates at high hydrogen partial pressure to reduce catalyst coking, then catalyst deactivation is reduced, but hydrogen consumption and equipment costs increase
Solution Approach 1:
The utility fluid serves as a mediator that enables the hydroprocessing to proceed with lower hydrogen partial pressure. It protects the catalyst from coking without requiring high hydrogen pressures, thereby reducing hydrogen consumption and equipment costs while maintaining catalyst reliability
Solution Approach 2:
The introduction of the utility fluid changes the operational parameters, allowing the process to achieve catalyst protection from coking at lower hydrogen partial pressures. This parameter change reduces the energy input required for hydrogen consumption and lowers equipment operating costs
3Stability of the object's composition
If conventional catalytic hydroprocessing operates at reduced temperature to lessen catalyst coking, then catalyst stability is improved, but hydrocracking efficiency decreases
Solution Approach 1:
The utility fluid acts as an intermediary that enables the catalyst to maintain stability at higher temperatures. It prevents coking and allows the process to operate at temperatures that favor hydrocracking efficiency, thus resolving the contradiction between catalyst stability and productivity
Solution Approach 2:
The utility fluid changes the thermal and chemical environment of the reaction, allowing the catalyst to remain stable at higher temperatures. This parameter change enables the process to achieve both catalyst stability and high hydrocracking efficiency simultaneously
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 extends catalyst life, reduces hydrogen consumption, and produces a hydroprocessed product suitable for use as a fuel oil blending component with improved properties, such as increased aromatic content and reduced viscosity, while minimizing coke formation.
Implementation Method 1
contacting the feed mixture with at least one hydroprocessing catalyst under catalytic hydroprocessing conditions in the presence of molecular hydrogen to convert at least a portion of the feed mixture to a conversion product
Implementation Method 2
contacting the feed mixture with at least one hydroprocessing catalyst under catalytic hydroprocessing conditions in the presence of molecular hydrogen
Data Source
AI summary
The invention relates to a hydroprocessed product that can be produced by hydroprocessing tar, such as a tar obtained from hydrocarbon pyrolysis. The invention also relates to methods for producing such a hydroprocessed product, and the use of such a product, e.g., as a fuel oil blending component.