Modular Ultralight Crude Oil Refining System
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Solution Overview
Problem
Conventional refineries are inefficient in processing ultralight fluids, such as tight oil and condensates, due to their distinct properties, leading to limited production capacity and increased costs, especially when trying to produce high-quality transportation fuels like ultra-low sulfur diesel and low sulfur marine fuel oil.
Innovation Solution
A modular, simplified refining system that utilizes a condensate splitter to separate ultralight fluids into light naphtha, heavy naphtha, diesel, and low sulfur fuel oil, with additional equipment upgrading these streams into high-quality transportation fuels, minimizing equipment and footprint, and optimizing processing conditions to reduce sulfur content and enhance octane levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional refineries process ultralight fluids, then production capacity is maintained, but processing efficiency deteriorates and costs increase
Solution Approach 1:
The patent applies segmentation by dividing the refining process into modular units: a distillation unit that separates ultralight fluids into light naphtha, heavy naphtha, diesel, and fuel oil fractions, followed by specialized treatment units for each fraction. This modular approach allows efficient processing of ultralight fluids without requiring a complete conventional refinery infrastructure.
Solution Approach 2:
The patent utilizes parameter changes by adjusting distillation conditions and treatment parameters to optimize the separation and upgrading of ultralight fluid fractions. The process modifies temperature, pressure, and composition parameters to transform ultralight fluids into high-quality transportation fuels with specific gravity and sulfur content specifications.
2Productivity
If conventional refineries process ultralight fluids, then production capacity is maintained, but operational costs increase
Solution Approach 1:
The patent extracts only the necessary processing steps for ultralight fluids from a conventional refinery configuration. By taking out and implementing only the distillation unit and essential treatment units needed for ultralight fluid processing, the system maintains production capacity while eliminating unnecessary equipment and reducing operational costs associated with full-scale conventional refining.
3Adaptability or versatility
If a full-scale conventional refinery is built, then processing capability is sufficient, but footprint and equipment requirements increase
Solution Approach 1:
The patent implements segmentation by creating a decentralized, modular refining system where distillation and treatment units are distributed rather than centralized in a large conventional refinery. This allows the system to maintain adequate processing capability for ultralight fluids while occupying significantly less land area and requiring fewer ancillary equipment facilities.
4Ease of operation
If refineries are located away from production sites, then logistics are simplified, but transportation costs increase
Solution Approach 1:
The patent applies dimensionality change by transitioning from a centralized refinery model to a distributed, modular system that can be located near production sites. This spatial reconfiguration allows the refining capacity to move closer to ultralight fluid sources, reducing transportation costs while maintaining operational simplicity through standardized modular units.
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 system achieves efficient production of ultra-low sulfur diesel, low sulfur marine fuel oil, and regular gasoline with reduced equipment needs, lower operational costs, and a smaller footprint, allowing for placement near production sites, thereby reducing transportation costs and logistics.
Implementation Method 1
distilling said ultralight fluid in a distillation unit to produce a light naphtha fraction, a heavy naphtha fraction, a diesel fraction, and a fuel oil fraction
Implementation Method 2
hydrotreating said light naphtha fraction and said heavy naphtha fraction in a hydrotreating unit to produce a sulfur-free light naphtha product, a sulfur-free heavy naphtha product, and ultra-low sulfur diesel
Data Source
AI summary
A method comprising the steps of feeding condensate to a splitter unit; directing the resulting naphtha product to a naphtha hydrotreater and the resulting diesel product to a diesel hydrotreater; directing ULSD product from the diesel hydrotreater to ULSD storage and naphtha product from the diesel hydrotreater to the naphtha hydrotreater; directing treated naphtha product from the naphtha hydrotreater to a naphtha splitter; isomerizing the light naphtha product and reforming the heavy naphtha product; sending the isomerate and the reformate to a gasoline separator; directing the products to storage.