Hydrotreating Unit Integrated Oxidative Desulfurization
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Solution Overview
Problem
Existing hydrotreating units struggle to achieve ultra-low sulfur levels in hydrocarbon fuels due to the difficulty in removing refractory sulfur compounds, requiring significant capital investments for new equipment or substantial retrofitting, especially when existing facilities were designed for milder conditions.
Innovation Solution
Integrating an oxidative desulfurization step within the hydrotreating unit by mixing an aqueous oxidant and oxidative catalyst with the hydrotreated hydrocarbon effluent in a low-pressure separation zone, allowing for the oxidation of remaining sulfur compounds into sulfoxides and sulfones, which are then separated, thereby reducing the sulfur content without the need for new reaction vessels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional hydrotreating technology is used to remove sulfur compounds, then sulfur content is reduced, but refractory sulfur compounds remain and require substantially higher temperature and pressure conditions to achieve ultra-low sulfur levels
Solution Approach 1:
The patent combines conventional hydrotreating with oxidative desulfurization in a single reactor system. The oxidative desulfurization section uses oxygen to convert refractory sulfur compounds into removable forms, complementing the conventional hydrodesulfurization process and enabling ultra-low sulfur levels without requiring substantially higher temperatures and pressures
Solution Approach 2:
The patent introduces oxygen as a new chemical parameter to the hydrotreating process. By adding oxidative desulfurization capabilities, the system changes the chemical environment from purely hydrogen-based to a combined hydrogen-oxygen system, enabling removal of refractory sulfur compounds under milder conditions
2Manufacturing precision
If conventional hydrotreating technology is used to remove sulfur compounds, then sulfur content is reduced, but achieving ultra-low sulfur levels requires substantial capital investment for new equipment or retrofitting
Solution Approach 1:
The patent integrates oxidative desulfurization within the existing hydrotreating reactor, combining two desulfurization mechanisms in one unit. This integration eliminates the need for separate oxidative desulfurization equipment and reduces capital investment compared to conventional approaches that would require new reactors or extensive retrofitting
Solution Approach 2:
The reactor is designed to perform multiple functions: conventional hydrodesulfurization, oxidative desulfurization, and separation of reaction products. This multi-functionality allows a single piece of equipment to achieve ultra-low sulfur levels, reducing the need for additional specialized equipment
3Ease of operation
If existing hydrotreating facilities operating at milder conditions are used, then operational flexibility is maintained, but they cannot achieve ultra-low sulfur levels required by stringent environmental standards
Solution Approach 1:
The patent introduces oxygen as a new chemical parameter that enables ultra-low sulfur removal under milder temperature and pressure conditions. This parameter change allows existing facilities to maintain operational flexibility while achieving the stringent sulfur specifications required by environmental standards
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 efficient desulfurization of hydrocarbon streams to ultra-low sulfur levels using existing infrastructure, minimizing capital investments and effectively addressing the challenge of refractory sulfur compounds, while producing fuels that meet stringent environmental standards.
Implementation Method 1
mixing an aqueous oxidant and oxidative catalyst with the hydrotreated hydrocarbon effluent in a low-pressure separation zone, allowing for the oxidation of remaining sulfur compounds into sulfoxides and sulfones
Implementation Method 2
mixing an aqueous oxidant and oxidative catalyst with the hydrotreated hydrocarbon effluent in a low-pressure separation zone, allowing for the oxidation of remaining sulfur compounds
Implementation Method 3
which are then separated, thereby reducing the sulfur content
Data Source
AI summary
A system and process for desulfurizing a hydrocarbon feed stream containing organosulfur compounds is provided. In general, the system includes a conventional hydrotreating unit through the high pressure cold or hot separator. Aqueous oxidant and an oxidative catalyst are mixed with the hydrotreated hydrocarbon effluent from the high pressure cold or hot separator, and oxidative desulfurization reactions occur in the low pressure separation zone, thereby minimizing or eliminating the requirement of additional oxidative desulfurization reactors.