Naphthenic Brightstock Hydroprocessing for Broader DAO Feedstock Range
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Solution Overview
Problem
Existing methods limit the range of naphthenic DAO feedstocks that can be used to produce naphthenic brightstocks with reduced viscosity and increased viscosity index, necessitating careful selection and costly processing steps.
Innovation Solution
A method involving low pressure catalytic hydroprocessing, high pressure catalytic hydroprocessing, catalytic dewaxing, and optionally catalytic hydrofinishing, divided into three distinct steps, allows for a broader range of naphthenic DAO feedstocks to be processed, resulting in a naphthenic brightstock with kinematic viscosity of about 30 mm2/s and viscosity index of 90 or more.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional single-step hydroprocessing is used, then processing cost is reduced, but the range of usable feedstocks is limited and product quality cannot be optimized
Solution Approach 1:
The hydroprocessing is divided into two distinct sequential steps: low-pressure hydroprocessing (5-15 bar) followed by high-pressure hydroprocessing (100-300 bar). Each step uses optimized conditions for specific transformations, allowing broad feedstock acceptance while achieving consistent high-quality brightstock output.
Solution Approach 2:
The process systematically varies pressure parameters between steps (low to high), temperature parameters (200-400°C range), and catalyst types to optimize for different feedstock viscosities and compositions, thereby expanding the range of acceptable feedstocks while maintaining product specifications.
2Productivity
If high pressure catalytic hydroprocessing is applied directly to high viscosity feedstock, then viscosity reduction is achieved, but viscosity index improvement is insufficient
Solution Approach 1:
Low-pressure hydroprocessing is performed first to partially reduce viscosity and modify feedstock composition before high-pressure hydroprocessing. This preliminary action prepares the feedstock for more effective viscosity index improvement in the second step, achieving both productivity and precision goals.
Solution Approach 2:
The two hydroprocessing steps are conducted in continuous sequence without interruption, maintaining cumulative transformation of the feedstock. This continuous action ensures progressive improvement in both viscosity reduction and viscosity index enhancement without losing intermediate benefits.
3Adaptability or versatility
If extended processing steps are used to broaden feedstock range, then feedstock versatility is improved, but processing time and cost increase
Solution Approach 1:
The process parameters (pressure, temperature, catalyst, residence time) are dynamically optimized for each of the two steps based on feedstock characteristics. This dynamic adaptation allows handling diverse feedstocks efficiently without requiring excessive processing time or additional steps.
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 method enables the production of naphthenic brightstock with reduced viscosity and increased viscosity index from a lower viscosity feedstock, expanding the usable feedstock range and potentially achieving a viscosity index of 100 or more, albeit with a lower yield.
Implementation Method 1
B1 low pressure catalytic hydroprocessing of the naphthenic feedstock based on naphthenic deasphalted oil, thereby obtaining a low pressure catalytically hydroprocessed liquid product
Implementation Method 2
low pressure catalytic hydroprocessing
Implementation Method 3
B2 high pressure catalytic hydroprocessing of the low pressure catalytically hydroprocessed liquid product leaving from the low pressure catalytic hydroprocessing step B1
Implementation Method 4
high pressure catalytic hydroprocessing
Implementation Method 5
B3 catalytic dewaxing of the high pressure catalytically hydroprocessed product leaving from the high pressure catalytic hydroprocessing step B2
Data Source
AI summary
A method of preparing a naphthenic brightstock from a naphthenic feedstock based on naphthenic deasphalted oil (DAO) is disclosed. The method includes a hydroprocessing step B, which step is sub-divided into three separate steps; B1 low pressure catalytic hydroprocessing, B2 high pressure catalytic hydroprocessing, and, B3 catalytic dewaxing. The naphthenic brightstock exhibits a reduced viscosity and increased viscosity index as compared to the naphthenic DAO feedstock, and the method allows for a broader range of naphthenic DAO feedstocks to be used for preparing the naphthenic brightstock.