Heavy Petroleum Feedstock Processing With Slurry-Phase Hydrocracking
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Solution Overview
Problem
Existing methods for processing heavy petroleum feedstocks, particularly those derived from heavy crude oils, face challenges such as equipment coking and sintering due to high asphaltene content, leading to inefficiencies and resource intensity, with a need for a stable and efficient method to derive valuable products like aromatic light gas oil and reduce resource consumption.
Innovation Solution
A method involving slurry phase hydrocracking with a coal additive, followed by solvent separation and vacuum distillation, then evaporating the residue to produce a concentrated hydrocracking residue suitable for catalytic cracking, using a dual-jacket thin-film evaporator to prevent coking and enhance separation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heavy petroleum feedstock is processed using conventional hydrocracking methods, then processing can be performed, but equipment coking and sintering occur due to high asphaltene content
Solution Approach 1:
The patent applies preliminary action by conducting slurry-phase hydrocracking before gas-phase hydrocracking. In the slurry phase, coal additive and catalyst are mixed with the feedstock to perform initial cracking that prevents asphaltene deposition in subsequent equipment, thereby preventing the harmful effect before it occurs
Solution Approach 2:
The patent uses coal additive as an intermediary substance that interacts with asphaltenes during slurry-phase hydrocracking. The coal additive serves as a mediator that prevents direct contact between asphaltenes and equipment surfaces, reducing coking and sintering while enabling successful processing
2Productivity
If heavy crude oil residues are processed to obtain valuable products, then product yield increases, but resource intensity increases
Solution Approach 1:
The patent applies parameter changes by transitioning from conventional gas-phase hydrocracking to slurry-phase hydrocracking. This parameter change in the physical state of the reaction medium improves conversion efficiency and product yield while reducing the resource intensity through better heat and mass transfer in the slurry phase
Solution Approach 2:
The patent implements self-service by using the heavy crude oil residues themselves as the feedstock for producing valuable aromatic light gas oil. The process transforms the problematic residues into useful products, making the system self-sufficient by utilizing its own waste streams
3Productivity
If combined hydrocracking process is used for heavy petroleum feedstock, then conversion efficiency improves, but stability of operation decreases
Solution Approach 1:
The patent applies segmentation by dividing the combined hydrocracking process into two distinct stages: slurry-phase hydrocracking followed by gas-phase hydrocracking. This segmentation allows each stage to be optimized independently, improving overall conversion efficiency while maintaining operational stability through controlled progression
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 method achieves stable operation with high conversion rates, producing a concentrated residue with reduced ash and sulfur content, suitable for sintering additives and aromatic gas oil production, enhancing the efficiency and reducing resource intensity.
Implementation Method 1
a combined hydrocracking process is the most effective process for processing heavy petroleum feedstocks
Implementation Method 2
separating the exhausted coal additive and the unconverted high-boiling residue by using a solvent
Implementation Method 3
supplying a mixture of the unconverted high-boiling residue and the solvent after the separation step to a vacuum column to obtain a separated heavy residue
Implementation Method 4
evaporating at least part of the separated heavy residue in an evaporator to obtain a concentrated hydrocracking residue and a heavy vacuum gas oil
Implementation Method 5
using a dual-jacket thin-film evaporator to prevent coking and enhance separation efficiency
Implementation Method 6
hydrocracking a feedstock in a slurry phase (slurry phase hydrocracking (SPH)), the slurry phase comprising the heavy petroleum feedstock and a coal additive
Data Source
AI summary
The invention relates to the field of petroleum processing, in particular to processes allowing the production of valuable products from heavy residues. A method for processing heavy petroleum feedstock is proposed, the method comprising hydrocracking a feedstock in a slurry phase (SPH) followed by separation into a stream of an SPH-subjected feedstock and a heavy residue stream, wherein the heavy residue stream is a slurry of an unconverted high-boiling residue and an exhausted coal additive; hydrocracking the SPH-subjected feedstock in gas phase, followed by fractionation of hydrocracking products; separating the exhausted coal additive and the unconverted high-boiling residue by using a solvent; supplying the mixture of the unconverted high-boiling residue and the solvent after the separation step to a vacuum column to obtain a separated heavy residue; evaporating at least part of the separated heavy residue in a thin-film evaporator to obtain a concentrated hydrocracking residue and a heavy vacuum gas oil (HVOG); and using at least a part of the HVOG to obtain the solvent. The technical result resides in ensuring the possibility of obtaining valuable products from difficult-to-utilize products, and in ensuring the stabilization of hydrocracking processes of heavy petroleum feedstock.