Split-Flow Hydroprocessing of Shale Oil Fractions
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional processes for upgrading whole shale oil face challenges such as severe fouling, plugging, and poor selectivity due to the wide boiling ranges and varying reactivities of its fractions, leading to inefficient hydroprocessing and high operating costs.
Innovation Solution
A split-flow hydroprocessing scheme that fractionates whole shale oil into different fractions, each processed in separate reactors with optimized conditions for diolefins saturation, hydrodemetallization, hydrodenitrogenation, hydrodesulfurization, and hydrodeoxygenation, minimizing fouling and improving product quality and on-stream efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If whole shale oil is processed in a single hydrotreating reactor, then the process is simple, but severe fouling and plugging occur due to widely varying reactivities of different fractions
Solution Approach 1:
The patent divides the single hydrotreating reactor into multiple reactors arranged in series, with each reactor handling a specific fraction of the shale oil based on its boiling range and reactivity characteristics. This segmentation allows optimized processing conditions for each fraction, reducing overall fouling and plugging while maintaining process manageability.
Solution Approach 2:
The patent applies different processing conditions and catalysts to different sections of the process, matching the specific requirements of each shale oil fraction. Lighter fractions receive milder treatment while heavier fractions undergo more severe hydroprocessing, optimizing each local processing zone for its specific feedstock characteristics.
2Device complexity
If whole shale oil is processed in a single reactor, then capital investment is lower, but operating costs increase due to poor selectivity and gas formation
Solution Approach 1:
The multi-reactor configuration segments the hydroprocessing into distinct stages, with each reactor optimized for specific reactions. This improves selectivity by preventing unwanted side reactions, reduces gas formation, and enhances overall productivity despite higher capital investment.
Solution Approach 2:
The patent varies processing parameters such as temperature, pressure, and catalyst type across different reactors to match the specific requirements of each shale oil fraction. This optimization improves reaction selectivity and reduces wasteful gas formation, thereby enhancing operating efficiency.
3Reliability
If multiple reactors are used to process different fractions, then fouling and plugging are reduced, but device complexity increases
Solution Approach 1:
The patent implements a segmented reactor system where each unit handles specific fractions, reducing fouling and plugging through targeted processing. The complexity is managed by organizing reactors in a logical sequence that follows the natural fractionation and processing requirements of the shale oil.
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 effectively upgrades whole shale oil by reducing fouling and improving product quality, leading to higher revenues and lower operating costs, despite the additional capital investment in equipment.
Implementation Method 1
separate the whole shale oil or partially hydrotreated whole shale oil into a plurality of fractions
Implementation Method 2
contacting the first fraction and hydrogen in a first-stage hydroprocessing reactor containing a hydrogenation catalyst to saturate diolefins
Implementation Method 3
containing catalysts to perform hydrodemetallization and saturation of mono-olefins
Implementation Method 4
having one or more beds of catalysts to perform hydrodenitrogenation, hydrodesulfurization, hydrodeoxygenation
Implementation Method 5
having one or more beds of catalysts to perform hydrodenitrogenation, hydrodesulfurization, hydrodeoxygenation
Implementation Method 6
having one or more beds of catalysts to perform hydrodenitrogenation, hydrodesulfurization, hydrodeoxygenation
Data Source
AI summary
Integrated processes for upgrading crude shale-derived oils, such as those produced by oil shale retorting or by in situ extraction or combinations thereof. Processes disclosed provide for a split-flow processing scheme to upgrade whole shale oil. The split flow concepts described herein, i.e., naphtha and kerosene hydrotreating in one or more stages and gas oil hydrotreating in one or more stages, requires additional equipment as compared to the alternative approach of whole oil hydrotreating. While contrary to conventional wisdom as requiring more capital equipment to achieve the same final product specifications, the operating efficiency vis a vis on-stream time efficiency and product quality resulting from the split flow concept far exceed in value the somewhat incrementally higher capital expenditure costs.