Residue Upgrading with SDA Resin Separation and SCW Treatment
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Solution Overview
Problem
Conventional solvent deasphalting processes for upgrading residue oil are limited by the production of low-value asphaltene pitch and require severe hydroprocessing conditions to process resin streams, leading to suboptimal yield and operational inefficiencies.
Innovation Solution
A process involving the separation of residue into asphaltene pitch, DAO, and resin streams, followed by treating the resin stream with supercritical water (SCW) to produce an upgraded resin stream, which is then hydroprocessed under mild conditions to enhance marketable product yield while minimizing asphaltene pitch production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the liquid yield of DAO is increased beyond 80 wt.%, then more residue oil is converted to valuable product, but severe hydroprocessing conditions (temperature >400°C, pressure >20 MPa) are required which increase operating costs
Solution Approach 1:
The invention segments the residue oil into three distinct streams: asphaltene pitch, resin, and DAO. By separating resin from DAO through controlled SDA conditions, the resin stream can be processed independently under milder conditions, allowing higher overall liquid yield without requiring severe hydroprocessing for the entire stream
Solution Approach 2:
The invention changes the processing parameters for different streams: resin is hydroprocessed at lower temperatures (300-400°C) and pressures (10-20 MPa) compared to conventional severe conditions, while DAO can be processed under optimized conditions. This parameter differentiation reduces overall energy consumption and operating costs
2Use of energy by stationary object
If the liquid yield of DAO is limited to ≤80 wt.%, then hydroprocessing can be conducted under milder conditions, but a substantial portion of residue oil is rejected as low-value asphaltene pitch
Solution Approach 1:
Instead of discarding resin as part of asphaltene pitch, the invention recovers it as a separate valuable stream through controlled SDA. The resin stream is then hydroprocessed to produce additional marketable products, converting what would be waste into valuable output and reducing overall substance loss
Solution Approach 2:
By segmenting the residue into three streams (asphaltene, resin, DAO), the invention enables selective processing where resin can be converted to useful products rather than being rejected as low-value pitch, thereby reducing substance loss while maintaining mild processing conditions
3Productivity
If resin is processed alone by hydroprocessing, then it can be converted to marketable products, but severe conditions are required due to high impurity content and high boiling point range
Solution Approach 1:
The invention changes the processing parameters for resin hydroprocessing: temperature is reduced to 300-400°C (below conventional 400°C+), pressure is reduced to 10-20 MPa (below conventional 20 MPa+), and catalyst selection is optimized for resin characteristics. These parameter changes enable productive resin processing under milder conditions
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 process increases the yield of marketable upgraded products by treating resin streams with SCW, allowing for efficient hydroprocessing under mild conditions and reducing the production of low-value asphaltene pitch.
Implementation Method 1
A-Muntaser Ameen A. et al. describe in 'Hydrothermal upgrading of heavy oil in the presence of water at sub-critical, near-critical and supercritical conditions' hydrothermal upgrading of high sulfur-content heavy oil at sub-critical, near-critical and supercritical water conditions
Implementation Method 2
treating the resin stream with supercritical water (SCW) to produce an upgraded resin stream
Implementation Method 3
hydroprocessing a portion of the upgraded resin stream and the DAO stream to produce the upgraded product
Implementation Method 4
a solvent deasphalting (SDA) process is employed by an oil refinery for the purpose of extracting valuable components from a residual oil
Data Source
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AI summary
Embodiments of the present disclosure are directed to a process for producing upgraded product from residue comprising atmospheric residue or vacuum residue upgrading comprising separating the residue through a Solvent Deasphalting (SDA) unit, wherein the SDA unit includes an asphaltene separator that separates the residue into asphaltene pitch and a stream comprising deasphalted oil (DAO) and resin, and a resin separator that subsequently separates the stream comprising DAO and resin into separate DAO and resin streams, treating the resin stream with supercritical water (SCW) to produce an upgraded resin stream, and hydroprocessing a portion of the upgraded resin stream and the DAO stream to produce the upgraded product.