Permutable Reactor Hydrocracking for Low-Sulfur Bunker Oil
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Solution Overview
Problem
Current refining processes for heavy hydrocarbon fractions, such as those used in maritime fuels, face challenges in achieving low sulphur and sediment content requirements, particularly for bunker oils, due to high conversion rates and sediment formation issues in existing hydrotreatment and hydrocracking processes.
Innovation Solution
A process incorporating a stage of hydrocracking in permutable reactors, allowing for increased conversion and sediment separation, which includes a hydrodemetallization stage, followed by fixed-bed hydrotreatment, hydrocracking in permutable reactors, and subsequent sediment precipitation and separation, enabling the production of heavy fractions with low sulphur and sediment content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high conversion rates are implemented in hydrotreatment and hydrocracking processes, then productivity and conversion efficiency are improved, but sediment formation increases and product quality deteriorates
Solution Approach 1:
The process is divided into multiple sequential stages: hydrodemetallization stage, fixed-bed hydrotreatment stage, and hydrocracking stage in permutable reactors. Each stage operates under optimized conditions to achieve progressive conversion while controlling sediment formation at each step, rather than attempting high conversion in a single stage.
Solution Approach 2:
The hydrodemetallization stage is implemented as a preliminary step before fixed-bed hydrotreatment and hydrocracking. This preliminary action removes metal impurities that would otherwise catalyze unwanted reactions and contribute to sediment formation during subsequent high-conversion stages.
2Ease of operation
If fixed-bed hydrotreatment is used, then process simplicity and ease of operation are improved, but conversion rate remains limited and product quality for bunker oil is insufficient
Solution Approach 1:
The process merges fixed-bed hydrotreatment (simple operation) with hydrocracking in permutable reactors (high conversion capability). The fixed-bed stage handles preliminary treatment with operational simplicity, while the permutable reactor stage achieves the high conversion rates needed for bunker oil quality, combining advantages of both approaches.
3Manufacturing precision
If sediment content is reduced to meet bunker oil specifications, then product quality is improved, but additional processing steps are required and process complexity increases
Solution Approach 1:
The hydrodemetallization stage is implemented as a preliminary step before fixed-bed hydrotreatment and hydrocracking. This preliminary action removes metal impurities that would otherwise catalyze unwanted reactions and contribute to sediment formation during subsequent high-conversion stages.
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 process achieves higher conversion rates and reduces sediment formation, resulting in fuel oils and bunker oils with sulphur content below 0.5% and sediment content after ageing of less than 0.1%, meeting stringent maritime fuel standards without degrading product quality.
Implementation Method 1
a hydrodemetallization stage in permutable reactors in which the hydrocarbon-containing feedstock and hydrogen are brought into contact on a hydrodemetallization catalyst
Implementation Method 2
a fixed-bed hydrotreatment stage b) of the effluent from stage a)
Implementation Method 3
a stage c) of hydrocracking in permutable reactors of the effluent from stage b)
Implementation Method 4
a stage e) of precipitation of the sediments in which the heavy liquid fraction from stage d) is brought into contact with a distillate cut
Data Source
AI summary
The invention relates to a process for the treatment of a hydrocarbon-containing feedstock making it possible to obtain a heavy hydrocarbon-containing fraction having a low sulphur content, said process comprising the following stages: a) a stage of hydrodemetallization in permutable reactors b) a stage of fixed-bed hydrotreatment of the effluent originating from stage a), c) a stage of hydrocracking in permutable reactors of the effluent originating from stage b), d) a stage of separation of the effluent originating from stage c), e) a stage of precipitation of the sediments, f) a stage of physical separation of said sediments from the heavy liquid fraction originating from stage d), g) a stage of recovery of the distillate cut used in stage e).