Slurry Bubble Column Hydroconversion Reduces Hydrogen Consumption
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Solution Overview
Problem
Hydroconversion processes for heavy hydrocarbon oils result in incomplete conversion due to the formation of carbonaceous residues, which are difficult to dispose of and reduce economic viability, primarily because of high hydrogen incorporation in conversion products.
Innovation Solution
A hydroconversion process using a slurry bubble column reactor with a distillation unit under vacuum, where the hydrogen content in conversion products is reduced by operating at low concentrations of heavy gas oil and light gas oil, and by increasing the superficial velocity of vacuum residue to accelerate the extraction of these fractions, thereby minimizing hydrogen incorporation and achieving complete conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydroconversion is performed with high hydrogen incorporation to fully saturate conversion products, then product quality is improved, but hydrogen consumption increases and carbonaceous residue formation increases
Solution Approach 1:
The patent changes the hydrogen partial pressure parameter in the reaction zone to optimize the balance between hydrogen incorporation and carbonaceous residue formation. By controlling the hydrogen partial pressure, the process achieves adequate product saturation while minimizing excessive hydrogen consumption and coke generation.
Solution Approach 2:
The patent employs dynamic control of reaction conditions including temperature, pressure, and hydrogen flow rate during the hydroconversion process. This allows optimization of hydrogen incorporation at different conversion stages, achieving high product quality with reduced overall hydrogen consumption.
2Productivity
If hydroconversion is performed to maximize conversion of heavy hydrocarbon oils, then productivity is improved, but carbonaceous residue formation increases
Solution Approach 1:
The patent extracts or removes the harmful carbonaceous residue from the reaction system through optimized product separation and purification processes. This allows high conversion rates to be maintained while minimizing the accumulation and disposal problems of carbonaceous by-products.
Solution Approach 2:
The patent converts the carbonaceous residue formation into a beneficial process feature by controlling the reaction conditions to produce a manageable amount of coke that can be used as fuel or processed further, rather than treating it purely as waste.
3Stability of the object's composition
If hydrogen is introduced at the reactor base to achieve uniform distribution, then mixing is improved, but hydrogen diffusion into liquid phase is insufficient
Solution Approach 1:
The patent introduces an intermediary substance or phase enhancement mechanism to facilitate hydrogen transfer from the gas phase to the liquid reaction medium. This intermediary improves the solubility and availability of hydrogen in the liquid phase, ensuring adequate hydrogen supply for complete hydroconversion.
Solution Approach 2:
The patent optimizes the hydraulic and pneumatic parameters of hydrogen introduction, including flow rate, pressure, and distribution pattern. By controlling these parameters, the process achieves both uniform hydrogen distribution and sufficient hydrogen availability in the liquid phase.
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 production of low-hydrogen content products, reducing hydrogen consumption and eliminating carbonaceous residues, thereby enhancing the economic viability and completeness of the hydroconversion process.
Implementation Method 1
the flow of hydrogen which diffuses from the gas phase into the liquid phase brings an amount of hydrogen to the reaction liquid
Implementation Method 2
a distillation unit with final stage under vacuum for the extraction of the of high boiling conversion products
Data Source
AI summary
In the hydroconversion processes of heavy hydrocarbon oils, in which the hydrogen is introduced at the reactor base by bubbling, the low diffusion rate of hydrogen, from the gas phase to the reaction liquid, limits the degree of conversion. The process circumvents the obstacle of the limited amount of reactant hydrogen by using a slurry bubble column reactor which reduces the formation of light hydrocarbon products, and therefore the hydrogen required for the hydroconversion, allowing to operate at full conversion.