Integrated Solvent Deasphalting and Resin Hydroprocessing
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Solution Overview
Problem
The existing solvent deasphalting process has limitations in maximizing the yield of deasphalted oil (DAO) and is costly due to the need for separate hydroprocessing of the resin fraction, which affects the profitability of refining heavy oils and the production of valuable transportation fuels.
Innovation Solution
A process integrating solvent deasphalting with dedicated resin hydroprocessing and delayed coking, where the resin fraction is separated and hydroprocessed, then processed in a delayed coker, optimizing DAO yield and reducing coke production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the resin fraction is separated and hydroprocessed separately, then the quality of deasphalted oil is improved, but the processing cost increases and productivity decreases
Solution Approach 1:
The patent combines the resin hydroprocessing function with the main deasphalting process by integrating a hydroprocessing reactor directly into the solvent deasphalting unit. The resin fraction is hydroprocessed in-situ within the same vessel where solvent extraction occurs, eliminating the need for separate hydroprocessing equipment and operations. This merging of functions maintains product quality while improving productivity and reducing capital costs.
Solution Approach 2:
The deasphalting reactor is designed to perform multiple functions simultaneously: solvent extraction of asphaltenes, separation of resin fraction, and hydroprocessing of the resin. This multi-functional approach allows a single piece of equipment to accomplish what traditionally required multiple separate units, thereby increasing processing throughput without compromising the quality of the deasphalted oil product.
2Reliability
If separate hydroprocessing of resin fraction is implemented, then contaminant removal is improved, but capital investment and operating costs increase
Solution Approach 1:
The patent integrates the hydroprocessing reactor into the solvent deasphalting unit, combining contaminant removal operations with the main extraction process. The reactor is positioned to receive the resin fraction directly from the separation section and process it in-situ, eliminating the need for separate hydroprocessing trains and reducing both capital investment and operational complexity while maintaining effective contaminant removal.
Solution Approach 2:
The patent extracts the resin fraction from the main deasphalting stream and directs it specifically to the integrated hydroprocessing reactor for targeted contaminant removal. This selective extraction and processing approach ensures that only the resin portion requiring hydroprocessing receives treatment, optimizing contaminant removal efficiency while minimizing the scale and cost of hydroprocessing equipment needed.
3Quantity of substance
If maximum DAO yield is pursued, then production volume increases, but coke production increases and product value decreases
Solution Approach 1:
The patent applies preliminary hydroprocessing action to the resin fraction before it would otherwise be processed in the delayed coker. By hydroprocessing the resin in advance within the integrated reactor, the resin is cleaned and stabilized prior to any thermal cracking operations, significantly reducing coke formation in downstream units while preserving maximum DAO yield from the deasphalting process.
Solution Approach 2:
The patent converts the potentially harmful effect of resin contamination (which causes coke formation) into a benefit by using the resin fraction as feedstock for the integrated hydroprocessing reactor. The hydroprocessing transforms the problematic resin into a cleaner product that can be handled more favorably downstream, turning what would be a source of coke and value loss into an opportunity to protect DAO yield while minimizing harmful byproducts.
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 integration increases DAO yield, reduces hydroprocessing costs, and enhances the production of valuable transportation fuels by minimizing coke production, thereby improving the overall profitability of the refining process.
Implementation Method 1
heating the solvent solution so as to precipitate the resin
Implementation Method 2
applying heat to the mixture so as to vaporize a fraction of the solvent
Implementation Method 3
adding a solvent to a heavy hydrocarbon stream comprising asphaltenes, resin, and oil
Data Source
AI summary
The invention is directed to a process that combines the solvent deasphalting with resin hydrotreatment and coupled with delayed coking so as to reduce the costs associated with performing each of the steps separately. The integrated process of the invention permits higher product yields coupled with lower energy and transportation costs.