Hydroprocessing and HS-FCC Integration for Heavy Oil Conversion

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Solution Overview

Problem

Current high-severity fluidized catalytic cracking (HS-FCC) processes face limitations due to the need for costly and energy-intensive refining steps to obtain suitable feedstocks, and crude oil's high metal, nitrogen, and sulfur content leads to catalyst deactivation, making it difficult to efficiently crack feedstocks with wide boiling point ranges without intermediate separations.

Innovation Solution

A system and method involving a hydroprocessing unit that uses HDM, HDS, and HDA catalysts to process heavy oils, followed by HS-FCC, directly converting heavy oils into valuable olefins without intermediate separations, reducing catalyst deactivation and eliminating the need for energy-intensive steam cracking.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If crude oil is used as feedstock for HS-FCC, then the process can handle a wide boiling point range, but catalyst deactivation occurs due to high metal, nitrogen, and sulfur content

Engineering Contradiction:

Improvefeedstock flexibilityVSAvoidcatalyst activity

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The hydroprocessing unit segments the crude oil feedstock processing into distinct catalytic reactions (hydrodemetalization, hydrodesulfurization, hydrodearomatization) that occur simultaneously, separating the harmful components removal from the main cracking process and protecting the FCC catalyst

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The hydroprocessing catalysts act as intermediaries between the crude oil feedstock and the FCC catalyst, removing harmful components (metals, sulfur, nitrogen, aromatics) before the feed reaches the FCC unit, thereby protecting the FCC catalyst from deactivation

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If intermediate separations are implemented before HS-FCC, then catalyst deactivation is reduced, but the process becomes more complex and energy-intensive

Engineering Contradiction:

Improvecatalyst activityVSAvoidprocess complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges multiple functions (hydrodemetalization, hydrodesulfurization, hydrodearomatization) into a single hydroprocessing unit operating under high-severity conditions, eliminating the need for separate intermediate separation units and simplifying the overall process flow

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The hydroprocessing unit performs multiple protective functions simultaneously (removing metals, sulfur, nitrogen, and aromatics) in one integrated process, making it a universal pretreatment solution that protects the FCC catalyst without requiring multiple separate units

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If conventional fractionation is used before cracking, then feedstock is prepared for HS-FCC, but energy-intensive steam cracking is required with little control over product distribution

Engineering Contradiction:

Improvefeedstock preparationVSAvoidenergy consumption

Core Design Contradiction:

Ease of manufactureVSUse of energy by moving object

Solution Approach 1:

The patent changes the operating parameters (high temperature, high pressure, specific catalyst composition) of the hydroprocessing unit to enable direct conversion of crude oil to desired products without conventional fractionation and steam cracking, achieving both energy savings and product control

Inventive Principle:

Principle #35Parameter changes

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 increases the efficiency of the HS-FCC process by reducing catalyst deactivation and eliminating the need for costly intermediate separations, enabling direct conversion of crude oil to light olefins with improved control over product ratios.

Implementation Method 1

contacting the heavy oil feed with a hydrodemetalization (HDM) catalyst

Methodology Applied

Scientific EffectHydrodemetalization: Hydrogenation

Implementation Method 2

contacting the heavy oil feed with a hydrodesulfurization (HDS) catalyst

Methodology Applied

Scientific EffectHydrodesulfurization: Hydrogenation

Implementation Method 3

contacting the heavy oil feed with a hydrodearomatization (HDA) catalyst

Methodology Applied

Scientific EffectHydrodearomatization: Hydrogenation

Implementation Method 4

the hydroprocessed effluent is contacted with an FCC catalyst under high-severity conditions to crack at least a portion of the hydroprocessed effluent

Methodology Applied

Scientific EffectFluidized catalytic cracking: Catalysis

Data Source

PatentUS11485917B2Systems and methods including hydroprocessing and high-severity fluidized catalytic cracking for processing petroleum-based materials

Publication Date: 2022.11.01 SAUDI ARABIAN OIL CO

AI summary

According to at least one aspect of the present disclosure, a method for processing a heavy oil includes introducing the heavy oil to a hydroprocessing unit, the hydroprocessing unit being operable to hydroprocess the heavy oil to form a hydroprocessed effluent by contacting the heavy oil feed with an HDM catalyst, an HDS catalyst, and an HDA catalyst. The hydroprocessed effluent is passed directly to a HS-FCC unit, the HS-FCC unit being operable to crack the hydroprocessed effluent to form a cracked effluent comprising at least one product. The cracked effluent is passed out of the HS-FCC unit. The heavy oil has an API gravity of from 25 degrees to 50 degrees and at least 20 wt. % of the hydroprocessed effluent passed to the HS-FCC unit has a boiling point less than 225 degrees ° C.