Integrated Staging Vessel for Deep Desulfurization
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Solution Overview
Problem
Conventional caustic-based mercaptans removal technologies require a greater number of reaction stages to achieve deep desulfurization of mercaptans below 10 ppmw, which is limited by space constraints and operational costs, necessitating a cost-effective and caustic-free solution for hydro-processing of low boiling hydrocarbon streams.
Innovation Solution
An integrated staging hydro-processing process in a single reaction vessel that combines a reactor, separator, and stabilization sections, utilizing a shift reaction between mercaptans/H2S in a low boiling hydrocarbon stream and olefins in a heavy boiling hydrocarbon stream to convert sulfur compounds into high boiling sulphur compounds, which are then removed with multiple mass transfer stages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional caustic-based treatment methods are used for mercaptan removal, then deep desulfurization can be achieved, but the number of reaction stages increases and space requirements expand
Solution Approach 1:
The patent combines multiple reaction stages into a single integrated reaction vessel, merging the reactor, separator, and stabilization sections into one unit. This consolidation achieves deep desulfurization below 10 ppmw while reducing the number of separate reaction stages and associated equipment, directly resolving the contradiction between desulfurization depth and device complexity
Solution Approach 2:
The integrated reaction vessel performs multiple functions simultaneously: it acts as a reactor for hydroprocessing, a separator for phase separation, and a stabilization unit for product finishing. This multi-functionality allows the system to achieve deep desulfurization while minimizing the number of separate reaction stages and equipment units required
2Manufacturing precision
If conventional caustic-based treatment methods are used for mercaptan removal, then deep desulfurization can be achieved, but operational costs and space constraints increase
Solution Approach 1:
By integrating the reactor, separator, and stabilization sections into a single vessel, the patent reduces equipment footprint and capital costs while maintaining deep desulfurization performance below 10 ppmw, directly addressing the contradiction between desulfurization depth and ease of manufacture
Solution Approach 2:
The patent replaces expensive caustic-based treatment chemicals with a catalytic hydroprocessing system that uses hydrogen and a catalyst. This substitution eliminates the need for costly caustic chemicals and associated waste treatment, reducing operational costs while achieving the same desulfurization depth
3Manufacturing precision
If conventional caustic-based treatment methods are used for mercaptan removal, then deep desulfurization can be achieved, but the process requires more reaction stages
Solution Approach 1:
The patent merges multiple reaction stages into a single integrated vessel with internal staging, allowing simultaneous multi-stage hydroprocessing reactions to occur within one unit. This achieves deep desulfurization below 10 ppmw while maintaining high reaction stage efficiency and productivity within a compact footprint
Solution Approach 2:
The integrated reaction vessel incorporates internal staging with multiple catalyst beds arranged in sequence, creating distinct reaction zones within a single vessel. This segmentation allows multiple reaction stages to occur simultaneously in different zones, achieving deep desulfurization while maintaining high productivity within a compact unit
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 process effectively reduces mercaptans and H2S levels in low boiling hydrocarbon streams to below 10 ppmw with fewer reaction stages, minimizing space and operational costs while avoiding the use of caustic chemicals, thus providing a cost-effective and eco-friendly treatment solution.
Implementation Method 1
utilizing a shift reaction between mercaptans/H2S in a low boiling hydrocarbon stream and olefins in a heavy boiling hydrocarbon stream to convert sulfur compounds into high boiling sulphur compounds
Implementation Method 2
moving upwards across catalytic reactor section of hydroprocessing reaction vessel
Implementation Method 3
separator section... continuously removing the converted high boiling sulphur compounds with multiple mass transfer stages
Data Source
AI summary
The present invention relates to selective removal of mercaptans and H2S from low boiling hydrocarbon streams (primary stream) by reacting with olefins present in heavy/high boiling hydrocarbon stream (secondary stream) and get converted into high boiling sulphur compounds ending up into the secondary stream in an integrated staging reactor, which comprises of reactor, separator and stabilization sections in a single vessel. The separation of primary and secondary streams is integrated in the same reaction vessel with a self-regulating liquid seal mechanism at bottom and a vapour enriching mechanism at the top by utilization of change in phases of streams.