Oxidative Desulfurization of Oil Fractions Using FCC Unit
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Solution Overview
Problem
Conventional methods for desulfurization and denitrogenation of hydrocarbon feedstocks face challenges such as inefficiency in removing sterically hindered sulfur compounds, high energy consumption, catalyst deactivation, and production of coke byproducts, which hinder the production of ultra-low sulfur fuels that meet stringent regulatory standards.
Innovation Solution
A method involving oxidative desulfurization and denitrogenation using a fluid catalytic cracking (FCC) unit, where a hydrocarbon feedstock is oxidized with an oxidizing agent in the presence of a catalyst, followed by solvent extraction and subsequent processing in a FCC unit to recover and crack oxidized sulfur and nitrogen compounds, thereby reducing sulfur and nitrogen content and producing usable hydrocarbons.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional hydrotreating or hydrogenation is used to reduce sulfur and aromatics content, then sulfur content is reduced, but fuel lubricity is reduced causing excessive wear of fuel pumps and injectors
Solution Approach 1:
The patent changes the chemical parameter of sulfur compounds by oxidizing them to sulfones and sulfoxides, which have different physical and chemical properties. This allows sulfur removal through extraction rather than hydrogenation, preserving fuel lubricity while achieving ultra-low sulfur content
Solution Approach 2:
The patent extracts oxidized sulfur compounds (sulfones and sulfoxides) from the fuel using selective solvents or adsorbents. This extraction method removes sulfur without the harsh hydrogenation conditions that degrade fuel lubricity, thus maintaining fuel pump and injector performance
2Manufacturing precision
If chemical hydrotreating is used to reduce sulfur content to meet regulatory standards, then sulfur content is reduced, but energy consumption increases and catalyst deactivation occurs
Solution Approach 1:
The patent changes the approach from hydrogenation (high energy, high pressure) to oxidation followed by extraction. This parameter change allows sulfur removal at milder conditions with lower energy consumption and without catalyst deactivation issues associated with conventional hydrotreating
3Manufacturing precision
If oxidative desulfurization is used to remove sulfur compounds, then sulfur content is reduced, but oxidized sulfur compounds (sulfones) are produced that require disposal
Solution Approach 1:
The patent extracts sulfones and other oxidized sulfur compounds from the fuel using selective solvents or adsorbents. This separation step removes the harmful oxidized sulfur compounds from the fuel stream, allowing the fuel to meet sulfur specifications without contamination from extraction solvents
Solution Approach 2:
The patent discards or recovers the oxidized sulfur compounds (sulfones and sulfoxides) as separate waste streams after extraction. This allows the main fuel product to achieve ultra-low sulfur content while the harmful oxidized compounds are handled separately through disposal or recovery processes
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 method effectively reduces sulfur and nitrogen levels in hydrocarbon feedstocks under mild conditions, enhancing the yield and quality of hydrocarbons while allowing for the recovery and disposal of oxidized sulfur and nitrogen compounds, thus meeting stringent fuel standards with reduced energy consumption and catalyst degradation.
Implementation Method 1
contacting the hydrocarbon feedstock with an oxidizing agent in the oxidation reactor under conditions sufficient to selectively oxidize sulfur compounds and nitrogen compounds present in the hydrocarbon feedstock to produce an oxidized hydrocarbon stream that includes hydrocarbons, oxidized sulfur compounds, and oxidized nitrogen compounds
Implementation Method 2
separating the hydrocarbons, the oxidized sulfur compounds, and the oxidized nitrogen compounds in the oxidized hydrocarbon stream by solvent extraction with a polar solvent to produce an extracted hydrocarbon stream and a mixed stream
Implementation Method 3
supplying the first residue stream to a fluid catalytic cracking unit, and wherein the fluid catalytic cracking unit is operative to catalytically crack the oxidized sulfur and the oxidized nitrogen to produce regenerated catalyst and gaseous and liquid products
Data Source
AI summary
Embodiments provide a method and apparatus for recovering components from a hydrocarbon feedstock. According to at least one embodiment, the method includes supplying a hydrocarbon feedstock to an oxidation reactor, wherein the hydrocarbon feedstock is oxidized in the presence of a catalyst under conditions sufficient to selectively oxidize sulfur compounds and nitrogen compounds present in the hydrocarbon feedstock, separating the hydrocarbons, the oxidized sulfur compounds, and the oxidized nitrogen compounds by solvent extraction, collecting a residue stream that includes the oxidized sulfur compounds and the oxidized nitrogen compound, and supplying the first residue stream to a fluid catalytic cracking unit. The first residue stream is further supplied through a hydrotreater prior to supplying the first residue stream to the fluid catalytic cracking unit.