Hydroprocessing Feed Exchanger Temperature Control for Diesel Cold Flow
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Solution Overview
Problem
Current hydroprocessing and hydroisomerization methods face challenges in efficiently managing cold flow properties of diesel fuel across varying climate conditions, particularly in maintaining optimal cold flow specifications during temperature fluctuations, which affects diesel yield and product quality.
Innovation Solution
Incorporating a heater and hydroprocessing feed exchanger between the hydroprocessing and hydroisomerization reactors to control the temperature of the hydroprocessed effluent, allowing for flexible heating or cooling to optimize the hydroisomerization process, thereby reducing the need for multiple fired heaters and minimizing unnecessary hydroisomerization during warmer months.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a heater is used to heat hydroprocessed effluent to improve cold flow properties, then cold flow properties are improved, but energy consumption increases
Solution Approach 1:
The patent combines the heating function with the existing hydroprocessing feed exchanger, merging two functions (heating and heat exchange) into a single piece of equipment. This eliminates the need for a separate fired heater, reducing energy consumption while maintaining the ability to heat hydroprocessed effluent to improve cold flow properties.
Solution Approach 2:
The hydroprocessing feed exchanger is designed to serve multiple functions: it acts as both a heat exchange device for cooling hydrocarbon feed and as a heating device for hydroprocessed effluent. This multi-functionality reduces the number of separate equipment pieces needed and optimizes energy utilization.
2Temperature
If two fired heaters are used to heat feed to each reactor, then temperature control is achieved, but device complexity increases
Solution Approach 1:
The patent merges the heating function for both reactors into a single hydroprocessing feed exchanger system. Instead of using two separate fired heaters, the process uses one exchanger to heat the feed and another to manage the hydroprocessed effluent, reducing equipment complexity while maintaining temperature control.
Solution Approach 2:
The system uses the heat from the hydroprocessed effluent itself to preheat the hydrocarbon feed, creating a self-service heating arrangement. This reduces reliance on external fired heaters and simplifies the overall heating system.
3Productivity
If hydroprocessed effluent is fed at high temperature to hydroisomerization reactor, then reaction rate increases, but unnecessary hydroisomerization occurs during warmer months
Solution Approach 1:
The patent implements a dynamic temperature control system that can adjust the temperature of hydroprocessed effluent fed to the hydroisomerization reactor based on seasonal conditions. During warmer months, the system can reduce or eliminate heating, allowing the process to adapt to varying ambient temperatures and prevent unnecessary hydroisomerization.
Solution Approach 2:
The system changes the operating temperature parameter of the hydroprocessed effluent based on seasonal requirements. By controlling the temperature dynamically rather than maintaining a constant high temperature, the process can optimize reaction rate when needed while avoiding unnecessary reactions during warmer periods.
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 enhances the flexibility of the hydroprocessing and hydroisomerization process, improving cold flow properties in colder climates while maintaining diesel yield and reducing energy consumption by eliminating the need for two fired heaters, thus optimizing the hydrocarbon feed stream's temperature management across different seasonal conditions.
Implementation Method 1
cooling the heated hydroprocessed effluent stream by heat exchange with the hydrocarbon feed stream
Implementation Method 2
heating the hydroprocessed effluent stream to a desired temperature to improve cold flow properties
Data Source
AI summary
The process and apparatus of the disclosure utilize a heater between a hydroprocessing reactor and a hydroisomerization reactor. A hydroprocessing feed exchanger cools hydroprocessed effluent to effect turndown of heated hydroprocessed effluent so as to not feed the hydroprocessed effluent to the hydroisomerization reactor at a higher temperature than necessary.