Hydroprocessing and Hydrotreating Effluent Mixing for Ultra-Low Sulfur Diesel
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Solution Overview
Problem
Current hydroprocessing methods face challenges in producing motor fuels that meet stringent sulfur and nitrogen removal standards, particularly in achieving ultra-low sulfur diesel requirements, while coordinating processes at different pressures is inefficient.
Innovation Solution
A hydroprocessing and hydrotreating process that involves hydroprocessing a first hydrocarbon stream and hydrotreating a second stream, with the effluents being mixed and fractionated to produce low sulfur diesel, utilizing an interstage compression arrangement to provide hydrogen streams at different pressures, and recycling hydrogen to optimize the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If hydroprocessing and hydrotreating are performed at different pressures to meet product specifications, then sulfur and nitrogen removal efficiency is improved, but process coordination complexity increases
Solution Approach 1:
The process is divided into two distinct units: a high-pressure hydroprocessing unit for sulfur and nitrogen removal, and a low-pressure hydrotreating unit for additional treatment and saturation. Each unit operates at optimized pressure levels for its specific function, allowing independent optimization of sulfur and nitrogen removal while maintaining overall process coordination through shared hydrogen recycle systems.
2Productivity
If hydrogen is recycled between process units to optimize reactions, then hydrogen utilization efficiency is improved, but compression energy consumption increases
Solution Approach 1:
The high-pressure hydroprocessing unit and low-pressure hydrotreating unit are connected through a shared hydrogen recycle system. Hydrogen from the high-pressure unit is compressed and recycled to the low-pressure unit, merging the hydrogen utilization functions of both units into a coordinated system that maximizes hydrogen efficiency while managing compression energy through strategic recycling points.
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 process effectively converts hydrocarbons to meet ultra-low sulfur diesel standards by efficiently removing sulfur and nitrogen, optimizing hydrogen use, and coordinating high and low-pressure process units, thereby enhancing fuel product quality and operational efficiency.
Implementation Method 1
Hydrocracking is a hydroprocessing process in which hydrocarbons crack in the presence of hydrogen and hydrocracking catalyst to lower molecular weight hydrocarbons
Implementation Method 2
Hydrotreating is a hydroprocessing process used to remove heteroatoms such as sulfur and nitrogen from hydrocarbon streams to meet fuel specifications and to saturate olefinic compounds
Implementation Method 3
Hydroprocessing can include processes which convert hydrocarbons in the presence of hydroprocessing catalyst and hydrogen to more valuable products
Implementation Method 4
At least a portion of said mixture is fractionated
Data Source
AI summary
An apparatus and process is disclosed for hydroprocessing hydrocarbon feed in a hydroprocessing unit and hydrotreating a second hydrocarbon. The hydrotreating effluent is mixed with hydroprocessing effluent and together fractionated.