Hydroprocessing System for Alternating Distillate and Lube Production
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Solution Overview
Problem
Current refining systems require separate processes and apparatus to produce distillate fuels and lube base stocks from heavy hydrocarbons, necessitating different operating conditions and catalyst compositions, which is inefficient and costly.
Innovation Solution
A refining system with a dewaxing zone using a hydroisomerization catalyst and a hydrofinishing zone with a noble metal catalyst on an acidic support, capable of alternately producing middle distillate fuels and lube base stocks by adjusting operating conditions between fuel and lube modes, allowing for the same system to produce both products with minimal adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate process apparatus are used to produce distillate fuels and lube basestocks, then product quality can be optimized for each product, but device complexity and operational costs increase
Solution Approach 1:
The patent applies universality by designing a single hydroprocessing system that can alternatively produce both distillate fuels and lube basestocks. The same reactor, catalyst, and process conditions are used for both products, eliminating the need for separate dedicated apparatus while maintaining optimization capability for each product through adjustable operating parameters.
2Manufacturing precision
If separate process apparatus are used for different products, then each process can be optimized independently, but operational complexity and costs increase
Solution Approach 1:
The system enables independent process optimization for each product by using a single versatile unit with adjustable parameters. When producing distillate fuels, the system operates under fuel-optimized conditions; when producing lube basestocks, it switches to lube-optimized conditions. This maintains the benefit of product-specific optimization while eliminating the operational complexity of managing multiple separate apparatus.
3Manufacturing precision
If different catalyst compositions are used for different products, then catalytic performance can be maximized for each product, but device complexity and maintenance requirements increase
Solution Approach 1:
The patent employs a single catalyst composition that effectively catalyzes both distillate fuel production and lube basestock production reactions. This universal catalyst eliminates the need for catalyst changes or multiple catalyst inventories, reducing device complexity and maintenance requirements while maintaining high catalytic performance for both products through its ability to facilitate the necessary hydroprocessing reactions under different operating conditions.
4Device complexity
If a single refining system is used for both products, then device complexity is reduced, but the ability to optimize each product independently may be compromised
Solution Approach 1:
The system applies dynamics by making the operating conditions adjustable and flexible. The same physical system can dynamically switch between fuel-mode operations and lube-mode operations by changing parameters such as temperature, pressure, and residence time. This dynamic adaptability allows the single system to maintain optimization capability for each product while benefiting from reduced device complexity.
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
Enables the efficient production of high-quality distillate fuels and lube base stocks from heavy hydrocarbons using the same refining system, reducing operational complexity and costs by minimizing the need for separate equipment and processes.
Implementation Method 1
a dewaxing zone (14) comprising a hydroisomerization catalyst
Implementation Method 2
a hydrofinishing zone (16) comprising a noble metal catalyst on an acidic support
Data Source
AI summary
Methods and apparatus are provided for converting heavy hydrocarbons to middle distillate fuels and, alternately, to Group II and III lube oils, in the presence of suitable metal catalysts using the same refining system with minor adjustments required to change between operating in fuel mode and operating in lube mode.