Integrated Hydrodesulfurization and Hydrocracking Process
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Solution Overview
Problem
Current hydroprocessing methods for producing low sulfur diesel from residual and heavy distillate hydrocarbon feedstocks are costly and inefficient, as they require separate processing units and do not effectively reduce sulfur concentrations in diesel boiling range hydrocarbons.
Innovation Solution
An integrated process that combines hydrodesulfurization and hydrocracking using a single hydrogen gas circuit, where residual hydrocarbon feedstocks are desulfurized and then mixed with hydrogen-rich vapors to produce ultra-low sulfur diesel through a hydrocracking reaction, minimizing equipment needs and operating costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate processing units are used for hydrodesulfurization and hydrocracking, then processing capability is maintained, but investment and operating costs increase
Solution Approach 1:
The patent combines hydrodesulfurization and hydrocracking operations into a single integrated processing unit. The reactor contains both hydrotreating catalyst (for desulfurization) and hydrocracking catalyst (for molecular weight reduction) in separate zones, allowing simultaneous execution of both functions in one vessel. This merging eliminates the need for separate processing units, thereby reducing capital investment and operating costs while maintaining both desulfurization and hydrocracking capabilities.
2Manufacturing precision
If conventional hydroprocessing is used, then processing simplicity is maintained, but sulfur concentration in diesel remains high
Solution Approach 1:
The patent implements preliminary hydrodesulfurization before hydrocracking by positioning the hydrotreating catalyst zone upstream in the reactor. This preliminary desulfurization removes sulfur from the feedstock before it enters the hydrocracking zone, ensuring that the diesel boiling range hydrocarbons produced have low sulfur content. This sequential arrangement within a single reactor achieves ultra-low sulfur diesel production without requiring complex post-processing units.
3Ease of operation
If separate hydrogen circuits are used for each process, then process independence is maintained, but compression equipment requirements and operating costs increase
Solution Approach 1:
The patent implements a single shared hydrogen circuit that serves both the hydrodesulfurization and hydrocracking reactions. The hydrogen feed system, compression equipment, and circulation loops are common to both catalytic functions within the integrated reactor. This multi-functional hydrogen circuit eliminates duplicate compression equipment and reduces operating costs while providing sufficient hydrogen for both desulfurization and hydrocracking processes simultaneously.
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 integrated process reduces sulfur concentrations in diesel boiling range hydrocarbons, producing ultra-low sulfur diesel while minimizing investment and operating costs by utilizing a single hydrogen gas circuit and optimizing catalysts and operating conditions.
Implementation Method 1
The residual hydrocarbon feedstock is reacted with a hydrogen-rich gaseous stream in a hydrodesulfurization reaction zone to produce diesel boiling range hydrocarbons and a residual product stream having a reduced concentration of sulfur
Implementation Method 2
The vaporous stream containing diesel boiling range hydrocarbons and hydrogen is introduced along with a heavy distillate hydrocarbon stream into a hydrocracking reaction zone
Implementation Method 3
The effluent from the hydrodesulfurization reaction zone is separated in a hot, high pressure vapor liquid separator to produce a vaporous hydrocarbonaceous stream containing hydrogen and diesel boiling range hydrocarbons
Data Source
AI summary
A process for the production of low sulfur diesel and a residual hydrocarbon stream containing a reduced concentration of sulfur. A residual hydrocarbon feedstock and a heavy distillate hydrocarbon feedstock are used in the process.