Integrated Oxidative Desulfurization Fluid Catalytic Cracking
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Solution Overview
Problem
Conventional refining processes struggle to efficiently and cost-effectively achieve ultra-low sulfur levels in hydrocarbon fuels, particularly with refractory sulfur-containing compounds, due to the need for costly upgrades and yield losses in existing hydrodesulfurization units, and separate operations for desulfurization and fluid catalytic cracking.
Innovation Solution
An integrated process combining oxidative desulfurization and fluid catalytic cracking, where a hydrocarbon feedstock is treated with oxygen and a heated cracking catalyst, optionally with heterogeneous or homogeneous catalyst additives, to oxidize and cleave sulfur compounds, thereby facilitating simultaneous desulfurization and cracking without requiring substantial additional equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional hydrodesulfurization processes are used to achieve ultra-low sulfur levels, then sulfur content can be reduced, but substantial capital investment and facility upgrades are required
Solution Approach 1:
The patent combines oxidative desulfurization and fluid catalytic cracking into a single integrated process unit. The oxidative desulfurization reactor is integrated with the FCC unit, allowing sulfur removal and hydrocarbon cracking to occur simultaneously in one facility rather than requiring separate desulfurization and cracking units. This merging eliminates the need for substantial additional equipment while achieving ultra-low sulfur levels.
Solution Approach 2:
The integrated process performs multiple functions simultaneously: oxidative desulfurization removes sulfur compounds while the fluid catalytic cracking converts heavy hydrocarbons into lighter fractions. The same reactor system handles both desulfurization and cracking operations, making the facility multi-functional and avoiding the need for dedicated separate units for each process.
2Object-affected harmful factors
If existing hydroprocessing facilities are retrofitted to meet stringent sulfur specifications, then sulfur reduction is achieved, but yield losses occur
Solution Approach 1:
The process uses oxidative desulfurization which changes the chemical mechanism from hydrodesulfurization to oxidation-based sulfur removal. This parameter change in the desulfurization mechanism allows for effective sulfur removal without the severe operating conditions and yield losses associated with conventional hydroprocessing retrofits. The oxidation process occurs under milder conditions that preserve hydrocarbon yield.
3Reliability
If separate desulfurization and fluid catalytic cracking operations are performed, then each process can be optimized independently, but process complexity and capital investment increase
Solution Approach 1:
The patent merges separate desulfurization and cracking operations into one integrated process. The oxidative desulfurization reactor is combined with the FCC unit, allowing both processes to occur in sequence within the same facility. This eliminates the need for separate standalone units while maintaining the ability to optimize each process step through controlled operating parameters and catalyst selection.
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 integrated approach effectively reduces sulfur content by up to 50% while maintaining hydrocarbon yield, optimizing existing refinery operations and reducing capital expenditures by integrating desulfurization and cracking processes within existing facilities.
Implementation Method 1
oxidize at least a portion of organosulfur compounds in the hydrocarbon feedstock to form oxidized organosulfur compounds
Implementation Method 2
cleave carbon-sulfur bonds of oxidized organosulfur compounds to form sulfur-free hydrocarbon compounds and sulfur oxide
Implementation Method 3
combining the hydrocarbon feedstock, an effective amount of oxygen containing gas, an effective amount of heated cracking catalyst
Data Source
AI summary
A process for catalytically cracking and oxidatively desulfurizing a hydrocarbon feedstock containing organosulfur compounds is provided. Oxygen containing gas is introduced with a cracking catalyst and the feed to form a suspension. At least a portion of organosulfur compounds in the hydrocarbon feedstock are oxidized to form oxidized organosulfur compounds, carbon-sulfur bonds of oxidized organosulfur compounds are cleaved to form sulfur-free hydrocarbon compounds and sulfur oxides, and oxidized and unoxidized compounds are catalytically cracked into hydrocarbon compounds of lower boiling points. Cracked components and the cracking catalyst particles are separated and recovered for regeneration and reuse.