Integrated Hydrocracking Process for Heavy Hydrocarbon Upgrading
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Solution Overview
Problem
Conventional petroleum refinery processes for upgrading heavy hydrocarbons are complex and energy-intensive, leading to suboptimal yields of valuable distillates and increased environmental impact due to separate processing of crude oil fractions.
Innovation Solution
A process involving hydrocracking heavy hydrocarbons in a first and second hydrocracker at specific temperature and pressure ranges in the presence of a catalyst and hydrogen, followed by fractionation and further processing to obtain light distillates, middle distillates, and atmospheric bottoms, with recycling of streams to enhance yield and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If crude oil is separated into various fractions and processed individually in separate hydro-processing units, then each fraction can be treated to meet product quality, but the complexity of the entire process increases and energy consumption increases
Solution Approach 1:
The patent combines multiple hydro-processing operations into a single integrated hydrocracking process. Instead of separating crude oil into fractions and processing them individually in separate units, the invention processes the entire crude oil feedstock through one hydrocracker unit, merging multiple functions (hydrocracking, hydrodesulfurization, hydrodenitrogenation) into a single integrated system that produces multiple valuable products simultaneously
Solution Approach 2:
The hydrocracker unit is designed to perform multiple functions simultaneously - it cracks heavy hydrocarbons, removes sulfur, removes nitrogen, and produces a range of products including light distillates, middle distillates, and refined fractions. This multi-functional approach eliminates the need for multiple separate processing units while maintaining product quality
2Reliability
If crude oil is separated into various fractions and processed individually in separate hydro-processing units, then each fraction can be treated to meet product quality, but the energy consumption increases
Solution Approach 1:
By merging multiple hydro-processing operations into a single hydrocracking unit, the patent eliminates redundant heating, cooling, and pumping operations that would occur in separate units. The integrated system processes all fractions simultaneously in one reactor, reducing overall energy consumption while maintaining product quality specifications
3Productivity
If the number of distillation columns is increased to increase crude oil conversion, then the conversion of crude oil can be increased, but the complexity of the entire process increases
Solution Approach 1:
The patent segments the crude oil feedstock processing into distinct product streams (light distillates, middle distillates, atmospheric bottoms, vacuum gas oil, vacuum residue) within a single integrated hydrocracking system. This allows high conversion of crude oil into multiple valuable fractions without requiring multiple separate distillation columns, as the hydrocracker itself produces the separated fractions through controlled cracking reactions
Solution Approach 2:
The invention uses parameter changes in the hydrocracking process (temperature, pressure, catalyst type, residence time) to control the distribution of products across different boiling ranges. By adjusting these parameters, the system achieves high crude oil conversion and produces the desired mix of light and middle distillates without requiring additional complex separation infrastructure
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
The process significantly increases the yield of light distillates while reducing the yield of heavier fractions, making the process more economical and environmentally friendly by optimizing energy consumption and product distribution.
Implementation Method 1
hydrocracking a heavy hydrocarbon feed in a first hydrocracker in the presence of a catalyst and hydrogen gas
Implementation Method 2
hydrocracking a heavy hydrocarbon feed in a first hydrocracker in the presence of a catalyst and hydrogen gas
Implementation Method 3
The first effluent is then fractionated to obtain light distillates comprising hydrocarbons with boiling points below 180° C., middle distillates comprising hydrocarbons with boiling points in the range of 180° C. to 370° C.
Data Source
AI summary
The present invention discloses a process by which the heavy hydrocarbons are subjected to hydroprocessing for producing distillates which can be further treated or converted downstream, to fuels and chemicals.