Selective Hydroprocessing System for Aromatic Fractionation

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Solution Overview

Problem

Current hydrocracking processes face challenges in efficiently producing clean transportation fuels from heavy hydrocarbon feeds, as they often result in lower yields and reduced quality due to the retention of aromatics, which affect key properties like smoke point and cetane number.

Innovation Solution

An integrated hydrocracking process that separates the feedstock into aromatic-rich and aromatic-lean fractions, processing each fraction in distinct hydroprocessing zones under optimized conditions to enhance hydrotreating and hydrocracking, thereby improving product quality and yield.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional hydrocracking processes retain aromatics in the product stream, then the process is simpler and more economical, but the product quality (smoke point and cetane number) is reduced

Engineering Contradiction:

Improveprocess simplicityVSAvoidproduct quality

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The hydrocracking process is segmented into two distinct reaction zones: a first zone for hydrotreating aromatic-rich fractions at severe conditions, and a second zone for hydrocracking aromatic-lean fractions at mild conditions. This segmentation allows each zone to be optimized for its specific function, enabling aromatic removal while maintaining product quality and process efficiency

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If severe hydrocracking conditions are applied to remove aromatics, then aromatic content is reduced, but the operational and capital costs increase

Engineering Contradiction:

Improvearomatic content reductionVSAvoidoperational and capital costs

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

Different local conditions are applied in different reaction zones: the first reaction zone operates under severe conditions (higher temperature, pressure, and catalyst activity) specifically for aromatic-rich feeds to maximize aromatic removal, while the second reaction zone operates under mild conditions for aromatic-lean feeds to minimize costs. This local optimization of process conditions reduces overall operational and capital costs while achieving the required aromatic content reduction

Inventive Principle:

Principle #3Local quality

3Productivity

If feedstock is separated into aromatic-rich and aromatic-lean fractions for separate processing, then hydroprocessing efficiency is improved, but the device complexity increases

Engineering Contradiction:

Improvehydroprocessing efficiencyVSAvoidprocess configuration

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The feedstock is pre-separated into aromatic-rich and aromatic-lean fractions before entering the hydroprocessing system. This preliminary separation action allows each fraction to be directed to the appropriate reaction zone optimized for its composition, significantly improving hydroprocessing efficiency and aromatic removal effectiveness while managing device complexity through integrated design

Inventive Principle:

Principle #10Preliminary action

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 approach allows for the efficient production of clean transportation fuels by targeting and reducing aromatic compounds, improving middle distillate yield and meeting transportation fuel specifications while reducing operational and capital costs.

Implementation Method 1

the feedstock is separated into an aromatic-rich fraction and an aromatic-lean fraction

Methodology Applied

Scientific EffectAromatic separation:

Implementation Method 2

operating under conditions effective to hydrotreat and/or hydrocrack at least a portion of aromatic compounds contained in the aromatic-rich fraction

Methodology Applied

Scientific EffectHydrotreating:

Implementation Method 3

operating under conditions effective to hydrotreat and/or hydrocrack at least a portion of aromatic compounds contained in the aromatic-rich fraction

Methodology Applied

Scientific EffectHydrocracking:

Implementation Method 4

operating under conditions effective to hydrotreat and/or hydrocrack at least a portion of paraffin and naphthene compounds contained in the aromatic-lean fraction

Methodology Applied

Scientific EffectHydrotreating:

Implementation Method 5

operating under conditions effective to hydrotreat and/or hydrocrack at least a portion of paraffin and naphthene compounds contained in the aromatic-lean fraction

Methodology Applied

Scientific EffectHydrocracking:

Implementation Method 6

the first hydroprocessing reaction zone effluent and the second hydroprocessing reaction zone effluent are fractionated to produce one or more product streams and one or more bottoms streams

Methodology Applied

Scientific EffectFractionation: Fractionation

Data Source

PatentUS9359566B2Selective single-stage hydroprocessing system and method

Publication Date: 2016.06.07 SAUDI ARABIAN OIL CO

AI summary

Aromatic extraction and hydrocracking processes are integrated to optimize the hydrocracking units design and/or performance. By processing aromatic-rich and aromatic-lean fractions separately, the hydrocracking operating severity and/or catalyst reactor volume requirement decreases.