Slurry Catalyst Hydrocracking for Heavy Oil Conversion
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Solution Overview
Problem
The petroleum industry faces challenges in effectively upgrading heavy oil feeds with high concentrations of asphaltenes and low API gravities, as existing systems require significant catalyst usage and recycling, leading to operational inefficiencies and equipment issues.
Innovation Solution
A process involving multiple contacting zones and separation zones is employed, using a slurry catalyst with an active metal catalyst in a hydrocarbon oil diluent, under hydrocracking conditions, to convert heavy oil feeds into lower boiling hydrocarbons, with a focus on minimizing catalyst usage and optimizing process efficiency through flexible operational modes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If spent slurry catalyst and unconverted heavy oil feeds are recycled back to the process, then heavy oil conversion is maximized, but catalyst usage increases and equipment plugging issues occur
Solution Approach 1:
The process divides the heavy oil feedstock into multiple contacting zones (first contacting zone, second contacting zone, etc.) where conversion occurs in stages. This segmentation allows unconverted oil to progress through multiple zones while fresh catalyst is introduced at each stage, improving overall conversion without requiring excessive catalyst recycling.
Solution Approach 2:
The system performs preliminary conversion in the first contacting zone before the effluent proceeds to subsequent zones. This staged approach ensures that catalyst is most effective when fresh, and unconverted material receives additional treatment in later zones without requiring full recycling of spent catalyst.
2Adaptability or versatility
If multiple contacting zones are used with permutable configuration, then process flexibility and throughput are improved, but device complexity increases
Solution Approach 1:
The contacting zones and separation zones are configured in a permutable fashion, allowing the system to operate in sequential mode, parallel mode, or combinations thereof. This dynamic reconfigurability provides operational flexibility to adapt to different feedstocks and production requirements while using standardized modular units.
Solution Approach 2:
Each contacting zone can function independently or in combination with others, and each separation zone can process effluent from any contacting zone. This multi-functionality allows the same equipment configuration to serve multiple operational modes, reducing overall system complexity despite the flexibility provided.
3Productivity
If slurry catalyst with particle size of at least 1 micron is used at concentration greater than 500 wppm, then hydrocracking efficiency is improved, but separation difficulty and equipment plugging increase
Solution Approach 1:
The process uses multiple separation zones arranged in series after the contacting zones. This segmentation of the separation process allows progressive removal of catalyst particles and unconverted oil, making the separation task more manageable despite the high catalyst concentration and particle size used for efficient hydrocracking.
4Quantity of substance
If heavy oil feedstock with high asphaltene concentration is processed, then feedstock utilization is improved, but equipment plugging and processing difficulty increase
Solution Approach 1:
The system performs preliminary hydrocracking in the first contacting zone to break down large asphaltene molecules before they can cause plugging in downstream equipment. This preliminary action converts problematic heavy asphaltenes into lighter, less problematic hydrocarbons, enabling effective processing of high-asphaltene feedstocks.
Solution Approach 2:
Multiple contacting zones provide staged conversion of asphaltene-rich feedstock, progressively breaking down complex molecules into lighter products. This segmented approach prevents asphaltene aggregation and plugging by maintaining lower concentrations of heavy residues at any single point in the system.
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 achieves high conversion rates of heavy oil feeds with reduced catalyst consumption, minimizing equipment downtime and plugging issues, while maintaining high throughput and product quality, with over 75% of heavy oil feed converted to lighter products and significant reductions in sulfur and nitrogen content.
Implementation Method 1
combining at least a portion of the hydrogen containing gas feed, at least a portion of the heavy oil feedstock, and at least a portion of the slurry catalyst in a first contacting zone under hydrocracking conditions at a sufficient temperature and a sufficient pressure to convert at least a portion of the heavy oil feedstock to lower boiling hydrocarbons
Implementation Method 2
sending a first effluent stream from the first contacting zone comprising a mixture of the upgraded products, the slurry catalyst, the hydrogen containing gas, and unconverted heavy oil feedstock as a feed to a first separation zone, wherein volatile upgraded products are removed with the hydrogen containing gas as a first overhead stream
Data Source
AI summary
A process for hydroprocessing heavy oil feedstock is disclosed. The process operates in once-through mode, employing a plurality of contacting zones and at least a separation zone to convert at least a portion of the heavy oil feedstock to lower boiling hydrocarbons, forming upgraded products. In the once-through upgrade system, little if any of the unconverted material and slurry catalyst mixture is recycled back to the system for further upgrading. The contacting zones operate under hydrocracking conditions, employing a slurry catalyst for upgrading the heavy oil feedstock. The slurry catalyst feed comprises an active metal catalyst having an average particle size of at least 1 micron in a hydrocarbon oil diluent, at a concentration of greater than 500 wppm of active metal catalyst to heavy oil feedstock.