Hydroprocessing Disadvantaged Feeds for Lubricant Base Stocks
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Solution Overview
Problem
Traditional methods for producing lubricant base stocks from disadvantaged feeds are inefficient, as they often require additional processing steps and do not fully utilize the potential of hydroprocessed bottoms fractions, which can be rich in aromatics and sulfur, limiting their suitability for high-quality lubricant production.
Innovation Solution
Hydroprocessing disadvantaged feeds to reduce aromatics and sulfur content, followed by blending with conventional feeds to form Group I and Group II lubricant base stocks, utilizing the hydroprocessed bottoms fractions to enhance the quality and value of the resulting lubricant products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If hydroprocessed bottoms fractions rich in aromatics and sulfur are used directly for lubricant production, then the yield of lubricant base stock is increased, but the quality of the lubricant deteriorates due to high impurity content
Solution Approach 1:
The patent divides the hydroprocessed bottoms fraction into different boiling range segments through vacuum distillation, separating the lubricant base stock (LBS) fraction from other fractions. This segmentation allows selective processing of the LBS fraction while maintaining high yield, resolving the contradiction between maximizing yield and ensuring quality by treating different segments differently.
Solution Approach 2:
The patent performs preliminary hydroprocessing to reduce sulfur and aromatics content in the feedstock before distillation and LBS production. This preliminary treatment reduces impurity content in the resulting LBS fraction, allowing higher yield from the hydroprocessed bottoms while maintaining quality standards.
2Manufacturing precision
If additional processing steps are added to reduce impurities in hydroprocessed bottoms, then the quality of lubricant base stock is improved, but the process complexity increases
Solution Approach 1:
The patent combines multiple functions into the vacuum distillation process, which simultaneously achieves separation of the LBS fraction, concentration of impurities in the residue, and production of a ready-to-use LBS stream. This merging reduces the number of separate processing steps needed while maintaining quality improvements.
Solution Approach 2:
The patent utilizes parameter changes in the vacuum distillation process, specifically controlling temperature and pressure conditions, to selectively vaporize and condense the LBS fraction while leaving impurities behind. By adjusting these parameters, the process achieves quality improvement through a single integrated operation rather than multiple sequential steps.
3Loss of substance
If hydroprocessed bottoms fractions are fully utilized for lubricant production, then the loss of substance is reduced, but the harmful factors in the product increase due to aromatics and sulfur content
Solution Approach 1:
The patent extracts the LBS fraction from the hydroprocessed bottoms through vacuum distillation, separating it from the impurity-rich residue. This extraction allows full utilization of the feedstock by directing the LBS fraction to lubricant production while the remaining fraction can be used for other purposes, minimizing loss of substance while removing harmful components.
Solution Approach 2:
The patent converts the high-aromatics, high-sulfur hydroprocessed bottoms fraction into a beneficial product by using vacuum distillation to concentrate impurities in a small residue fraction while producing a high-quality LBS fraction. The harmful components are effectively concentrated into a minor stream that can be handled separately, while the majority of the feedstock is converted into useful lubricant base stock.
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 significantly improves the quality and yield of lubricant base stocks by effectively reducing impurities and enhancing the viscosity index, allowing for the production of high-quality lubricants with improved properties.
Implementation Method 1
hydroprocessing the feed to form a hydroprocessed bottoms fraction
Data Source
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AI summary
Methods are provided for upgrading disadvantaged feeds for use in lubricant base stock production. A disadvantaged feed can be upgraded by hydroprocessing the feed to form a hydroprocessed bottoms fraction. The hvdroprocessed bottoms fraction can then be used as a feed for forming Group I and/or Group II lubricant base stocks, optionally in combination with a conventional feed for lubricant production. The remaining portions of the hydroprocessing effluent can optionally be used for FCC processing and/or for other conventional applications of naphtha and distillate fractions.