Integrated Solvent Deasphalting and Oxidative Desulfurization Process
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Solution Overview
Problem
Current refining processes face challenges in achieving ultra-low sulfur levels in hydrocarbon fuels due to the difficulty in removing refractory sulfur-containing compounds, which are costly and require significant capital investments for retrofitting existing facilities to meet stringent environmental regulations.
Innovation Solution
An integrated process combining solvent deasphalting and gas phase oxidative desulfurization, optionally with hydrodesulfurization and hydrocracking, is employed to treat residual oil, utilizing a catalyst such as IB—MoO3/CuZnAl for gas phase oxidative desulfurization at elevated temperatures and pressures, effectively reducing sulfur content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional hydrodesulfurization processes are used to remove sulfur from hydrocarbon fuels, then sulfur content can be reduced, but the process requires high capital investment for retrofitting existing facilities and cannot achieve ultra-low sulfur levels below 10 ppmw
Solution Approach 1:
The patent employs oxidative desulfurization instead of conventional hydrodesulfurization, changing the chemical reaction mechanism from hydrogenation to oxidation. This parameter change allows achieving ultra-low sulfur levels below 10 ppmw without requiring high-pressure hydrogen environments or extensive facility retrofitting, thereby reducing capital investment while improving sulfur removal efficiency
Solution Approach 2:
The patent introduces an oxidative desulfurization unit as an intermediary process between solvent deasphalting and hydrodesulfurization. This intermediary unit uses oxidation catalysts to convert refractory sulfur compounds into removable forms, enabling ultra-low sulfur levels to be achieved without directly modifying existing hydrodesulfurization facilities, thus avoiding high retrofitting costs
2Manufacturing precision
If existing hydrotreating facilities are retrofitted to meet stringent sulfur specifications, then sulfur content can be reduced to below 10 ppmw, but the process requires higher temperature and pressure conditions that raise operational issues
Solution Approach 1:
The patent applies solvent deasphalting as a preliminary action before oxidative desulfurization to remove asphaltenes and heavy fractions containing refractory sulfur compounds. This preliminary separation reduces the burden on subsequent desulfurization steps, allowing ultra-low sulfur levels to be achieved at milder temperatures and pressures without requiring severe operational conditions
3Manufacturing precision
If refractory sulfur-containing compounds are removed using conventional methods, then sulfur content is reduced, but the process is costly and requires significant capital investments
Solution Approach 1:
The patent converts the challenge of refractory sulfur compounds into an opportunity by using oxidative desulfurization, which specifically targets and oxidizes these difficult-to-remove sulfur species. The oxidation process transforms refractory sulfur compounds into sulfones and sulfoxides that are easier to separate, thereby achieving effective removal of stubborn sulfur compounds without requiring proportionally high capital investment
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 integrated process significantly reduces sulfur content in hydrocarbon fuels, achieving a 68% total decrease in sulfur from residual oil, making it feasible to produce fuels with sulfur levels below 10 ppmw, thus meeting stringent environmental standards with minimal additional capital investment.
Implementation Method 1
utilizing a catalyst such as IB—MoO3/CuZnAl for gas phase oxidative desulfurization at elevated temperatures and pressures
Implementation Method 2
gas phase oxidative desulfurization
Implementation Method 3
solvent deasphalting
Data Source
AI summary
The invention is an integrated process for treating residual oil of a hydrocarbon feedstock. The oil is first subjected to solvent deasphalting then gas phase oxidative desulfurization. Additional, optional steps including hydrodesulfurization, and hydrocracking, may also be incorporated into the integrated process.