Hydroprocessing Oxidized Disulfide Oils to Alkanes

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Solution Overview

Problem

There is a long-standing need for an efficient and economical process to treat large volumes of disulfide oil (DSO) by-products and their derivatives to facilitate environmentally acceptable disposal or utilization within refineries, enhancing their value.

Innovation Solution

The process involves using oxidized disulfide oils (ODSO) or a blend of ODSO and DSO as reactants in a hydroprocessing zone in the presence of hydrogen, converting them into hydrogen sulfide, water, and alkanes, thereby improving refinery dynamics and efficiencies.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If DSO by-products are produced through the MEROX process to remove mercaptans, then the foul smell is eliminated, but large volumes of sulfur-containing by-products require problematical disposal

Engineering Contradiction:

Improvefoul smellVSAvoiddisposal of sulfur-containing by-products

Core Design Contradiction:

Object-affected harmful factorsVSLoss of substance

Solution Approach 1:

The patent converts the harmful sulfur-containing DSO by-products into beneficial hydrogen sulfide that can be processed through existing hydroprocessing units. The DSO is fed to hydroprocessing where it reacts with hydrogen to produce H2S and hydrocarbons, transforming a disposal problem into a value-added process that generates usable products and reduces environmental impact.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Ease of operation

If DSO compounds are produced as by-products of mercaptan oxidation, then mercaptans are removed from petroleum streams, but the DSO compounds require post treatment to remove undesirable by-products

Engineering Contradiction:

Improvemercaptan removalVSAvoidpost treatment requirements

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent merges the DSO treatment process with existing hydroprocessing operations. Instead of requiring separate post-treatment units, the DSO is integrated into the hydroprocessing feed stream, utilizing the same catalysts, reactors, and separation systems already present in the refinery to convert DSO into desirable products.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If large volumes of DSO by-products are generated for environmentally acceptable disposal, then regulatory requirements are met, but refinery efficiency is reduced due to disposal problems

Engineering Contradiction:

Improveenvironmental complianceVSAvoidrefinery efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent transforms the environmental compliance burden into a productivity enhancement opportunity. By converting DSO disposal from a waste removal operation into a chemical conversion process that produces hydrogen sulfide and hydrocarbons, the system simultaneously meets environmental requirements and generates valuable products that can be sold or used within the refinery.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

4Loss of substance

If DSO compounds are disposed of traditionally, then sulfur content is reduced from the main product, but the disposal process is problematical and economically inefficient

Engineering Contradiction:

Improvesulfur content reductionVSAvoiddisposal process

Core Design Contradiction:

Loss of substanceVSEase of manufacture

Solution Approach 1:

The patent converts the problematical disposal process into a beneficial chemical transformation. Instead of simply removing sulfur from the main product stream, the DSO is systematically converted into hydrogen sulfide and hydrocarbons through hydroprocessing, creating a structured, economically viable process that handles sulfur removal while generating sellable products.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 effectively converts ODSO or ODSO/DSO into hydrogen sulfide and alkanes, simplifying the disposal of DSO by-products and enhancing their value within the refinery by integrating them into hydroprocessing operations.

Implementation Method 1

The hydroprocessing zone reacts a hydroprocessing feed in the presence of hydrogen and an ODSO stream and converts the oxidized disulfide oils or a blend of oxidized disulfide oils and disulfide oils into hydrogen sulfide, water and alkanes

Methodology Applied

Scientific EffectChemical reaction: Chemical Bonding

Data Source

PatentUS11603499B2Hydroprocess integrating oxidized disulfide oil compounds

Publication Date: 2023.03.14 SAUDI ARABIAN OIL CO

AI summary

Oxidized disulfide oil (ODSO) compounds or ODSO compounds and disulfide oil (DSO) compounds are reacted with a hydrogen addition feed in a hydroprocessing complex. The hydrogen addition process can include naphtha hydrotreatment, middle distillate hydrotreatment, vacuum gas oil hydrocracking, and vacuum gas oil hydrotreatment. The ODSO or ODSO and DSO components are converted to hydrogen sulfide, water and alkanes.