Liquid-Phase Hydroprocessing of Non-Petroleum Feeds for Hydrogen Production
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Solution Overview
Problem
Conventional hydroprocessing systems face challenges in controlling temperature and pressure, managing catalyst coking, and handling high-contaminant and high-olefinic feedstocks, which can lead to runaway reactions and catalyst deactivation due to excessive heat and harmful byproducts.
Innovation Solution
The process involves using multiple small reactors or reaction zones, a liquid phase reaction system with a diluent to maintain hydrogen solubility, and heat exchangers or flash vessels to manage heat and byproducts, ensuring controlled temperature and catalyst activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional hydroprocessing systems use large volumes of hydrogen gas and operate at high pressure to transfer hydrogen into liquid phase for reaction, then hydrogen availability for reaction is improved, but reactor size and system complexity increase significantly
Solution Approach 1:
The patent changes the physical state parameter of hydrogen from gas phase to liquid phase by increasing pressure and temperature conditions. This parameter change allows hydrogen to be stored and transported in a compact liquid form, dramatically reducing the volume required while maintaining high hydrogen availability for reactions with petroleum feedstocks.
2Temperature
If conventional systems inject cold hydrogen gas into the reaction zone to control temperature, then temperature control is achieved, but safety risks and operational complexity increase
Solution Approach 1:
The patent converts the exothermic heat of reaction, which is normally a harmful factor causing runaway reactions, into a beneficial feature by using it to maintain the hydrogen in liquid phase. The reaction heat itself serves as the heating source, eliminating the need for external cold hydrogen injection for cooling and converting a safety risk into a process advantage.
3Productivity
If high-contaminant and high-olefinic feedstocks are processed using conventional methods, then product yield is achieved, but catalyst deactivation due to coking increases
Solution Approach 1:
The patent changes the reaction medium parameter from gas-liquid two-phase to single liquid phase by dissolving hydrogen in the petroleum feedstock. This creates a homogeneous liquid reaction environment that improves mass transfer and reduces localized hot spots, thereby minimizing catalyst coking and deactivation while maintaining high product yield from challenging feedstocks.
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 approach effectively stabilizes reaction zone temperatures, reduces catalyst deactivation, and minimizes the formation of harmful byproducts, enhancing the safety and efficiency of hydroprocessing high-contaminant and high-olefinic feedstocks.
Implementation Method 1
a liquid phase reaction system with a diluent to maintain hydrogen solubility
Implementation Method 2
heat exchangers or flash vessels to manage heat and byproducts
Implementation Method 3
They generate a great deal of heat, significantly more than what is found in a typical hydroprocessing process of petroleum products
Data Source
AI summary
A method of hydroprocessing is performed wherein non-petroleum feedstocks are treated in a first reaction zone to provide reaction products. The process involves introducing the feedstock along with diluents or a recycle and hydrogen in a first reaction zone and allowing the feed and hydrogen to react in a liquid phase within the first reaction zone to produce reaction products, at least some of the reaction products being in a liquid phase. Gases are separated from the liquid phase reaction products. At least a portion of the gases comprising at least one of C1 or greater hydrocarbons are reformed to form hydrogen gas, which may be used as hydrogen gas for the hydroprocessing process or elsewhere.