Hydroprocessing Solvent Extracts for Group II Base Oils
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Solution Overview
Problem
Conventional methods for producing Group II/III lubricant base oils struggle to effectively utilize solvent extract fractions from Group I base oil production, as these fractions typically have high aromatics, sulfur, and nitrogen content, making them unsuitable for catalytic processing.
Innovation Solution
A method involving the combination of a solvent extract fraction with a feedstock, followed by hydroprocessing under high hydrogen partial pressure conditions, allowing for the incorporation of previously undesirable components to produce Group II, Group II+, or Group III lubricant base oils with improved viscosity index and reduced sulfur content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If solvent extract fractions from Group I base oil production are used as feedstock for catalytic processing, then the productivity and utilization of available feedstocks is improved, but the manufacturing precision and product quality deteriorate due to high aromatics, sulfur, and nitrogen content
Solution Approach 1:
The patent applies preliminary action by performing hydroprocessing under high hydrogen partial pressure (at least 1500 psig) before catalytic dewaxing. This pre-treatment step converts the solvent extract fraction, removing harmful aromatics, sulfur, and nitrogen content, and saturating aromatic rings. This preliminary conversion enables subsequent catalytic processing to proceed successfully, resolving the contradiction by preparing the feedstock in advance to meet quality requirements while maintaining high feedstock utilization.
2Device complexity
If conventional catalytic dewaxing is applied directly to solvent extract fractions, then the process simplicity is maintained, but the reliability of the process deteriorates due to catalyst deactivation from high heteroatom content
Solution Approach 1:
The patent introduces a preliminary hydroprocessing step that removes heteroatoms (sulfur, nitrogen) and saturates aromatic rings before catalytic dewaxing. This pre-treatment prevents catalyst deactivation during the main dewaxing process, ensuring reliable operation. The high hydrogen partial pressure (at least 1500 psig) maintains sufficient hydrogen concentration to prevent catalyst poisoning, thereby improving process reliability without significantly complicating the overall process flow.
3Manufacturing precision
If high hydrogen partial pressure conditions are used during hydroprocessing, then the purity of the final lubricant base oil is improved by removing sulfur and nitrogen, but the energy consumption increases
Solution Approach 1:
The patent applies parameter changes by operating hydroprocessing at high hydrogen partial pressure (at least 1500 psig) to achieve thorough removal of sulfur and nitrogen, producing high-purity lubricant base oil meeting Group II/III specifications. This parameter optimization ensures complete heteroatom removal while managing energy consumption through efficient reactor design and operation. The high pressure condition drives the hydrogenation reactions to completion, achieving the desired purity level.
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 enables the production of high-quality Group II, Group II+, or Group III lubricant base oils by converting the combined feedstock, achieving desirable yield levels and meeting stringent pour point and viscosity index requirements.
Implementation Method 1
hydroprocessing the combined feed under first effective hydroprocessing conditions in the presence of a hydrocracking catalyst to form a hydroprocessed effluent
Implementation Method 2
hydroprocessing at least a portion of the liquid phase effluent in the presence of at least a dewaxing catalyst under second effective hydroprocessing conditions to form a dewaxed effluent
Implementation Method 3
fractionating the dewaxed effluent to form at least a lubricant base oil product
Data Source
AI summary
Methods are provided for producing Group II/III lubricant base oil products where at least a portion of the feedstock for forming the lubricant base oil product is a solvent extract fraction from a Group I lubricant production facility. This can increase the overall volume of feedstock available for production of Group II/III lubricant base oils by using a lower value stream (Group I solvent extract) as a portion of the feedstock. The solvent extract fraction can be added to a full range lubricant feedstock or to a portion of a lubricant feedstock, such as adding an extract fraction to a higher viscosity portion (such as a heavy neutral portion) of a feedstock for lubricant production, while a lower viscosity portion (such as a light neutral portion) is processed without addition of an extract fraction.