Cross-Flow Slurry Catalyst Filtration for Carrier Conversion
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Solution Overview
Problem
Refineries face challenges in transitioning from petroleum-based to renewable-based liquid carriers in slurry hydrocracking processes due to environmental regulations and the need to minimize installation and operational costs, requiring a process to convert slurry catalysts with petroleum-based oil carriers to those with renewable-based carriers while minimizing contamination and carbon emissions.
Innovation Solution
A cross-flow filtration process using diafiltration separation units to convert slurry catalysts with petroleum-based oil carriers to those with renewable-based carriers, achieving less than 5 wt.% petroleum-based oil carrier content, by employing a series of diafiltration units and solvent extraction to generate a slurry catalyst enriched in renewable-based carriers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If refineries process renewable-based liquid carriers in existing refinery units, then installation and operational costs are minimized and revamp requirements are reduced, but the slurry catalyst will contain contamination from petroleum-based carriers
Solution Approach 1:
The patent applies extraction by removing the harmful petroleum-based carrier from the slurry catalyst system. Through phase separation and filtration processes, the petroleum-based carrier is extracted from the slurry, leaving behind a clean slurry catalyst that can be processed in existing refinery units without contamination. This resolves the contradiction by eliminating the harmful factor while maintaining ease of manufacture in existing infrastructure.
Solution Approach 2:
The patent introduces an intermediary separation process between the petroleum-based carrier and the slurry catalyst. This intermediary step allows the slurry catalyst to be processed in existing refinery units while preventing petroleum-based carrier contamination in the final product. The separation process acts as a mediator that enables both low-cost processing and contamination-free output.
2Object-generated harmful factors
If slurry catalyst is converted from petroleum-based to renewable-based liquid carrier, then carbon emissions and contamination are reduced, but a complex separation process is required
Solution Approach 1:
The patent applies segmentation by dividing the separation process into distinct stages: phase separation to separate the liquid carrier from the slurry catalyst, and filtration to remove any remaining petroleum-based carrier. This segmentation simplifies the overall process by breaking down the complex task of converting from petroleum-based to renewable-based carrier into manageable steps, reducing the apparent complexity while achieving the environmental goals.
Solution Approach 2:
The patent utilizes parameter changes in the separation process, specifically changing the physical parameters (temperature, pressure, density) to enable separation of the petroleum-based carrier from the slurry catalyst. By adjusting these parameters, the process achieves efficient separation without requiring complex equipment, thus reducing the complexity burden while minimizing carbon emissions and contamination.
3Quantity of substance
If cross-flow filtration is used to separate petroleum-based carrier from slurry catalyst, then renewable-based carrier content is increased, but process time and energy consumption increase
Solution Approach 1:
The patent applies partial action by implementing cross-flow filtration to achieve a specific target concentration of renewable-based carrier (less than 5 wt.% petroleum-based carrier), rather than attempting complete separation. This partial approach to filtration achieves the necessary purification level for environmental compliance while avoiding the excessive time and energy consumption that would result from attempting absolute separation. The process stops at the point of achieving the required purity threshold.
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 effectively replaces petroleum-based carriers with renewable-based carriers, reducing contamination and carbon emissions, allowing the use of renewable fuels without petroleum product contamination and enabling the reuse of petroleum-based carriers for new catalyst production.
Implementation Method 1
converting, in one or more cross-flow filtration separation units, a slurry catalyst comprising solid particles and a petroleum-based oil liquid carrier to a slurry catalyst comprising solid particles and a renewable-based liquid carrier
Implementation Method 2
generating, in a last diafiltration separation unit of a series of diafiltration separation units comprising three to five diafiltration separation units, a first retentate comprising the slurry catalyst comprising solid particles and a first amount of the renewable-based liquid carrier
Data Source
AI summary
A process including converting, in one or more cross-flow filtration separation units, a slurry catalyst containing solid particles and a petroleum-based oil liquid carrier to a slurry catalyst comprising solid particles and a renewable-based liquid carrier. The slurry catalyst containing solid particles and the renewable-based liquid carrier includes less than about 5 wt. % of the petroleum-based oil liquid carrier.