Hydroprocessing Hydrogen Compression Integration
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Solution Overview
Problem
Current hydroprocessing methods face challenges in producing sufficient high-quality diesel that meets stringent sulfur and nitrogen standards, particularly when integrating hydrocracking and hydrotreating units operating at different pressures, and require efficient hydrogen supply management across these units.
Innovation Solution
A process involving the compression of a make-up hydrogen stream, with a portion being further compressed and used in hydroprocessing units, allowing for the integration of hydrocracking and hydrotreating operations by recycling vaporous effluents to optimize hydrogen distribution and reduce the need for separate recycle gas compressors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate recycle gas compressors are used for each hydroprocessing unit operating at different pressures, then each unit can maintain its required pressure independently, but capital costs and operating costs increase due to redundant compression equipment
Solution Approach 1:
The patent combines the functions of multiple recycle gas compressors into a single compressor unit. The first hydroprocessing unit's recycle gas is compressed, and a portion is diverted to the second hydroprocessing unit after pressure reduction. This merging eliminates redundant compression equipment while maintaining independent pressure control for each unit through strategic branching and pressure reduction.
Solution Approach 2:
The first recycle gas compressor serves dual purposes: it compresses recycle gas for the first hydroprocessing unit and simultaneously provides compressed hydrogen for the second hydroprocessing unit. This multi-functional approach allows one piece of equipment to fulfill the roles previously requiring separate compressors, reducing overall system complexity.
2Reliability
If hydrogen is supplied at different pressures to hydrocracking and hydrotreating units, then each unit receives appropriate pressure for its process requirements, but the system requires multiple compressors increasing capital investment
Solution Approach 1:
The patent segments the hydrogen supply system into two pressure levels using a single compressor. The first recycle gas compressor generates high-pressure hydrogen, which is then divided into two streams: one maintained at high pressure for the hydrocracking unit and another reduced to lower pressure for the hydrotreating unit. This segmentation allows different pressure requirements to be met without requiring separate compressors for each pressure level.
Solution Approach 2:
The patent introduces a pressure reduction mechanism as an intermediary between the first recycle gas compressor and the second hydroprocessing unit. This intermediary component enables the system to deliver hydrogen at the appropriate lower pressure to the second unit while utilizing the same compression source, thereby avoiding the need for a second compressor and reducing capital investment.
3Device complexity
If a single compressor supplies hydrogen to both hydroprocessing units, then capital costs are reduced, but the ability to independently control pressure for each unit is compromised
Solution Approach 1:
The patent implements a dynamic hydrogen distribution system where the first recycle gas compressor can flexibly adjust its output to meet the varying pressure and flow requirements of both hydroprocessing units. By using a single dynamic compression source with branching pathways and pressure reduction capabilities, the system maintains reliable pressure control for each unit while adapting to changing process conditions without requiring multiple fixed compressors.
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 diesel production quality, meets stringent fuel specifications, and reduces capital and operating costs by integrating hydroprocessing units and optimizing hydrogen use across different pressure operations.
Implementation Method 1
compressing a make-up hydrogen stream in a first compressor to provide a first compressed make-up hydrogen stream
Implementation Method 2
A first portion of the first compressed make-up hydrogen stream is compressed in a second compressor to provide a second compressed make-up hydrogen stream
Implementation Method 3
hydrocracking refers to a process in which hydrocarbons crack in the presence of hydrogen and catalyst to lower molecular weight hydrocarbons
Implementation Method 4
hydrotreating must meet lower and lower limits on contaminates, such as sulfur and nitrogen
Implementation Method 5
The second hydroprocessing effluent stream is separated to provide a vaporous second hydroprocessing effluent stream
Implementation Method 6
the vaporous second hydroprocessing effluent stream is added to the make-up hydrogen stream upstream of the second compressor
Data Source
AI summary
A process is disclosed for hydroprocessing two hydrocarbon streams at two different pressures. A hydrogen stream is compressed and split. A first split compressed stream is further compressed to feed a first hydroprocessing unit that requires higher pressure for operation. A second split compressed stream is fed to a second hydroprocessing unit that requires lower pressure. Recycle hydrogen from the second hydroprocessing unit is recycled back to the compression section.