Integrated Hydroprocessing Reactor for Residuum Conversion
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Solution Overview
Problem
Refineries face limitations in processing heavy crudes due to constraints in existing crude distillation columns, which hinder the efficient conversion of carbon-rich hydrocarbons to carbon-poor hydrocarbons, particularly in producing high-quality white oil products and ultra-low-sulfur diesel.
Innovation Solution
The implementation of an integrated hydroprocessing system that includes an ebullated bed hydroconversion reactor, followed by a hydrofinishing reactor with staged separation and hydrogen quenching, and a polishing hydrotreating reactor, optimized to maximize distillate selectivity and control sulfur levels, while minimizing hydrogen solution loss and capital costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing crude distillation columns are used to process heavy crudes, then the current processing capability is maintained, but the conversion efficiency of carbon-rich hydrocarbons to carbon-poor hydrocarbons is limited
Solution Approach 1:
The integrated hydroprocessing reactor divides the processing function into distinct zones: a hydrocracking zone for breaking down carbon-rich hydrocarbons and a hydrofinishing zone for sulfur removal and product polishing. This segmentation allows each zone to specialize in specific conversion tasks, thereby improving overall conversion efficiency without requiring multiple separate units
Solution Approach 2:
The patent combines hydrocracking and hydrofinishing operations into a single integrated reactor unit with multiple catalyst beds. This merging of functions reduces the number of separate processing units needed, maintaining device simplicity while enhancing conversion capability through the synergistic interaction of different catalytic zones
2Manufacturing precision
If heavy crudes are processed in existing distillation columns, then the current operational limits are maintained, but the production of high-quality white oil products and ultra-low-sulfur diesel is hindered
Solution Approach 1:
Different zones within the integrated reactor are equipped with catalysts having specific properties tailored to local requirements: the hydrocracking zone uses catalysts optimized for breaking heavy hydrocarbon molecules, while the hydrofinishing zone employs catalysts specialized for sulfur removal. This local optimization of catalyst properties enables production of high-quality white oil and ultra-low-sulfur diesel with precise control over product specifications
Solution Approach 2:
The integrated reactor is designed to handle multiple feedstock types and produce various high-quality hydrocarbon products simultaneously. The multi-functional catalyst system can process different heavy crude compositions and adjust product distribution to meet diverse quality requirements, thereby enhancing both manufacturing precision and processing versatility
3Manufacturing precision
If conventional hydroprocessing systems are used, then the current equipment configuration is maintained, but distillate selectivity and sulfur level control are suboptimal
Solution Approach 1:
The integrated reactor employs a dynamic multi-bed catalyst system where each catalyst bed can operate independently at optimized conditions. The reactor design allows for flexible adjustment of temperature, pressure, and flow distribution across different zones, enabling precise control of distillate selectivity and sulfur removal efficiency without requiring complex external equipment modifications
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 system enhances the conversion of residuum hydrocarbons, achieving 2-4% increase in distillate selectivity, meets ultra-low-sulfur diesel requirements, and reduces capital and operating costs by optimizing equipment count and operating conditions.
Implementation Method 1
contacting the residuum hydrocarbon fraction with hydrogen and a hydroconversion catalyst in the ebullated bed hydroconversion reactor to produce a partially converted reactor effluent product
Implementation Method 2
contacting the heavy gas oil stream with hydrogen and hydroconversion catalyst in the hydrofinishing reactor
Implementation Method 3
separating, in a first separation zone, the partially converted reactor effluent product into a distillate stream and a heavy hydrocarbon stream
Data Source
AI summary
Techniques for processing residuum include receiving a feed stream that includes a residuum hydrocarbon fraction at an ebullated bed hydroconversion reactor; contacting the residuum hydrocarbon fraction with hydrogen and a hydroconversion catalyst in the ebullated bed hydroconversion reactor to produce a partially converted reactor effluent product; separating, in a first separation zone, the partially converted reactor effluent product into a distillate stream and a heavy hydrocarbon stream; feeding the distillate stream to a bottom portion of an integrated hydrocracking/hydrofinishing reactor; and feeding the heavy hydrocarbon stream to a top portion of the hydrofinishing reactor.