Hydroprocessing Reactor for Aromatics from Wide-Boiling Feedstocks
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Solution Overview
Problem
The production of aromatic chemicals like benzene, toluene, and xylenes from wide-boiling temperature range hydrocarbon feedstocks is hindered by contamination from sulfurous and nitrogenous compounds, as well as metals, which requires inefficient separation and treatment processes, and results in less reactive and valuable BTEX chemicals that are costly to handle and transport.
Innovation Solution
A method involving the introduction of wide-boiling range condensates and hydrogen into a hydroprocessing reactor, followed by processing in an aromatization reactor system, which reduces contaminants and converts the feedstock into aromatic hydrocarbons, including benzene, toluene, and xylenes, with a hydrogen-to-condensate volume ratio of 0.01 to 10, and subsequent hydrogen extraction and recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If wide-boiling temperature range hydrocarbon feedstocks are processed using conventional fractionation and distillation processes, then the hydrocarbon fractions can be separated into light petroleum liquids, but the process requires multiple separation steps and results in contamination from sulfurous and nitrogenous compounds as well as metals
Solution Approach 1:
The patent combines multiple processing functions into a single hydroprocessing reactor that simultaneously performs hydrocracking, hydrodesulfurization, hydrodenitrogenation, and metal removal. This integration eliminates the need for separate fractionation, distillation, and treatment units, reducing device complexity while achieving high purity aromatic products from wide-boiling feedstocks
Solution Approach 2:
The process utilizes specific parameter ranges including hydrogen-to-oil volume ratios of 0.01 to 10, operating temperatures and pressures optimized for hydroprocessing, and controlled residence times to achieve simultaneous cracking and contaminant removal. These parameter optimizations enable the reactor to produce naphtha-range liquids with minimal contaminants in a single pass
2Productivity
If steam-cracking reformation or pyrolysis furnace based processes are used to crack heavy hydrocarbon material into light olefins, then light olefins can be produced, but the process is energy intensive and the resulting olefins are highly reactive and expensive to handle and transport
Solution Approach 1:
The hydroprocessing reactor operates under controlled parameters including moderate temperatures and pressures with hydrogen presence, enabling cracking to naphtha-range hydrocarbons without the extreme conditions of steam cracking. This produces less reactive saturated hydrocarbons that are cheaper and safer to handle while maintaining good productivity
Solution Approach 2:
The process converts the wide-boiling feedstock that would require energy-intensive cracking into a beneficial naphtha-range liquid product with useful boiling points (30°C to 240°C). The hydrogen present in the feedstock and added hydrogen are utilized to saturate cracked products, reducing reactivity and handling costs while maintaining energy efficiency
3Ease of manufacture
If wide-boiling temperature range hydrocarbon fractions are processed with minimal treatment, then processing costs are reduced, but contaminants such as sulfur, nitrogen, and metals remain in the product
Solution Approach 1:
The hydroprocessing reactor integrates contaminant removal functions (hydrodesulfurization, hydrodenitrogenation, metal hydrotreating) with the cracking reaction in a single unit. This combination achieves effective contaminant removal without requiring separate treatment steps, maintaining ease of manufacture while producing high-purity aromatic products
Solution Approach 2:
Hydrogen acts as an intermediary that facilitates both the cracking reaction and contaminant removal. It participates in hydrocracking to form saturated hydrocarbons and in hydrotreating reactions to convert sulfur, nitrogen, and metal compounds into removable forms, achieving purification without complex additional treatment
4Productivity
If fractional separation is performed prior to processing and refining, then feedstock can be prepared for conversion, but the process complexity and energy consumption increase
Solution Approach 1:
The hydroprocessing reactor performs preliminary cracking and contaminant removal directly on the wide-boiling feedstock before aromatization. This pre-treatment within the reactor eliminates the need for upstream fractionation and separation steps, reducing energy consumption while preparing the feedstock for efficient aromatic conversion in subsequent steps
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 method effectively reduces contaminants and increases the yield of aromatic hydrocarbons, enhancing the efficiency and cost-effectiveness of producing BTEX chemicals by minimizing the need for fractional separation and reducing energy consumption, while producing high-purity hydrogen for recycling.
Implementation Method 1
introducing the wide boiling range condensate and hydrogen into a hydroprocessing reactor where a volume ratio of the hydrogen to the wide boiling range condensate introduced is in a range of from about 0.01 to about 10
Implementation Method 2
passing the naphtha boiling temperature range liquid product to an aromatization reactor system and operating the aromatization reactor system under conditions appropriate for forming one or more hydrocarbon products
Implementation Method 3
passing the hydrogen to the hydrogen extraction unit and producing hydrogen and a mixed hydrogen-poor gas in the hydrogen extraction unit
Data Source
AI summary
The present invention relates to methods and systems useful for producing aromatics-rich products from liquid hydrocarbon condensates. The production system includes a hydroprocessing reactor, an aromatization reactor system and a hydrogen extraction unit. The methods for producing the aromatics-rich products include introducing a wide boiling range condensate into the hydroprocessing reactor and operating the aromatics production system such that the hydroprocessing reactor forms a naphtha boiling temperature range liquid product. The liquid hydrocarbons produced in accordance with the present invention may optionally be further processed using a hydrogen extraction unit to produce a high-purity hydrogen fraction.