Slurry Hydroconversion for Heavy Hydrocarbon Upgrading
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Solution Overview
Problem
The challenge lies in efficiently processing heavy hydrocarbons from oil sands for pipeline transport, as existing methods require substantial diluents, lead to high equipment costs, and result in coke formation that limits liquid yields and requires additional resources, while also posing disposal challenges due to the remote location of extraction sites.
Innovation Solution
A method involving slurry hydroconversion of heavy hydrocarbon feeds with a pitch recycle stream, which includes a substantial portion of 566° C.+ components, to produce a hydroconverted effluent with a high vacuum gas oil content and reduced coke formation, thereby minimizing the need for external diluents and equipment costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional coking methods are used to process heavy hydrocarbon feeds with substantial 566°C+ components, then processing capability is improved, but coke yield increases to 30 wt % or more, reducing liquid yields and creating disposal challenges
Solution Approach 1:
The patent changes the fundamental processing parameters by using slurry hydroconversion instead of thermal coking, operating at lower temperatures (300-450°C) with hydrogen atmosphere and catalyst particles. This parameter change transforms the reaction pathway from thermal cracking to catalytic hydroconversion, reducing coke formation from 30+ wt% to significantly lower levels while maintaining processing capability for heavy feeds with substantial 566°C+ components
Solution Approach 2:
The patent replaces the mechanical/thermal coking system with a chemical/catalytic hydroconversion system. Instead of relying on high-temperature thermal cracking, the invention uses catalyst particles in slurry form to facilitate hydroconversion reactions, substituting a chemical mechanism for a thermal-mechanical process and thereby reducing unwanted coke formation
2Loss of substance
If hydroprocessing is used to process feedstocks with substantial 566°C+ components, then liquid yield is improved compared to coking, but rapid fouling and degradation of hydroprocessing equipment occurs
Solution Approach 1:
The patent introduces catalyst particles as an intermediary medium that facilitates the conversion of heavy hydrocarbons. These catalyst particles act as a buffer between the aggressive heavy feedstock and the equipment, enabling the reaction to proceed under milder conditions that prevent direct contact and fouling of equipment surfaces while maintaining high liquid yields
Solution Approach 2:
The patent changes operating parameters by conducting hydroconversion at lower temperatures (300-450°C) compared to conventional hydroprocessing, and uses a slurry system with suspended catalyst particles. These parameter changes reduce the severity of the process, minimizing fouling and equipment degradation while maintaining reliability and liquid yield
3Ease of operation
If diluent is added to bitumen for pipeline transport, then transportability is improved, but the effective capacity of the pipeline is reduced due to large volume requirements
Solution Approach 1:
The patent performs preliminary hydroconversion of heavy hydrocarbon feeds at the extraction site before transport. By converting heavy components to lighter, less viscous products in advance, the need for large volumes of diluent is eliminated, allowing pipeline transport of the upgraded product with minimal or no diluent addition
4Object-generated harmful factors
If recycle stream with majority components boiling below 566°C is used to reduce 566°C+ content in reaction environment, then coke formation is reduced, but additional conversion to lower boiling products occurs and reactor productivity is reduced
Solution Approach 1:
The patent inverts the conventional approach by recycling a heavy bottoms stream that contains 50 wt% or more of 566°C+ components, rather than recycling a light distillate stream. This inversion allows the recycle stream to serve as additional feedstock for hydroconversion, maintaining reactor productivity while the catalytic action of the slurry system prevents excessive coke formation
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 enhances reactor productivity, reduces coke formation, and produces a 'bottomless' crude with a high vacuum gas oil content, suitable for pipeline transport with minimal additional diluent, while reducing capital and processing costs.
Implementation Method 1
exposing at least a portion of the first fraction and a pitch recycle stream to slurry hydroconversion conditions to form a hydroconverted effluent
Data Source
AI summary
Systems and methods are provided for partial upgrading of heavy hydrocarbon feeds to meet transport specifications, such as pipeline transport specifications. The systems and methods can allow for one or more types of improvement in heavy hydrocarbon processing prior to transport. In some aspects, the systems and methods can produce a partially upgraded heavy hydrocarbon product that satisfies one or more transport specifications while incorporating an increased amount of vacuum gas oil and a reduced amount of pitch into the partially upgraded heavy hydrocarbon product. In other aspects, the systems and methods can allow for increased incorporation of hydrocarbons into the fraction upgraded for transport, thereby reducing or minimizing the amount of hydrocarbons requiring an alternative method of disposal or transport. In still other aspects, the systems and methods can allow for reduced incorporation of external streams into the final product for transport while still satisfying one or more target properties.