Solvent Deasphalting for Residue Upgrading
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Solution Overview
Problem
Current refining methods for upgrading crude residue are inefficient, leading to leftover naphtha and producing unwanted byproducts, while also causing environmental harm through high energy consumption and emissions.
Innovation Solution
A system and method involving hydrocarbon processing that includes distillation, deasphalting, hydroprocessing, and cracking to selectively separate and convert residues into more valuable products like olefins, reducing energy consumption and emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If vacuum distillation and coking are used for residue upgrading, then residue can be processed, but large amounts of CO and NOx emissions are generated
Solution Approach 1:
The invention extracts and removes asphaltenes from the residue through solvent deasphalting before further processing. This separation removes the problematic heavy components that would otherwise require high-temperature combustion processes, thereby eliminating the source of CO and NOx emissions while still enabling valuable product recovery from the deasphalted oil
Solution Approach 2:
The invention changes the processing parameters by using solvent-based deasphalting at relatively low temperatures instead of high-temperature thermal cracking or coking. This parameter change allows residue upgrading without the combustion reactions that produce harmful emissions, while still achieving effective separation and product recovery
2Productivity
If fired heaters are used in residue upgrading processes, then processing can be performed, but large amounts of energy are consumed
Solution Approach 1:
By extracting asphaltenes through solvent deasphalting, the invention eliminates the need for energy-intensive fired heating and thermal cracking processes. The deasphalted oil obtained is already a valuable product that can be directly used or further processed with minimal energy input, thereby dramatically reducing overall energy consumption
Solution Approach 2:
The solvent deasphalting process is self-service in that it uses the natural solubility differences between asphaltenes and other hydrocarbons in appropriate solvents. This spontaneous separation process requires minimal external energy input compared to thermal processes, allowing the system to perform residue upgrading with very low energy consumption
3Quantity of substance
If current refining methods are used to extract naphtha from residue, then some naphtha can be recovered, but the process is inefficient and leaves naphtha in the residue
Solution Approach 1:
The invention uses solvent deasphalting to extract and remove asphaltenes from residue, which simultaneously releases and recovers trapped naphtha and other lighter hydrocarbons. This extraction process is highly efficient because it targets the asphaltene-naphtha complex structure, completely removing asphaltenes and thereby fully recovering the associated naphtha without leaving it in the residue
Solution Approach 2:
By changing from thermal distillation parameters to solvent extraction parameters, the invention achieves superior naphtha recovery efficiency. The solvent system selectively interacts with asphaltenes, causing them to precipitate while carrying away associated naphtha, resulting in complete naphtha recovery and high extraction efficiency
4Productivity
If vacuum distillation and coking are used, then residue can be processed, but large capital costs and plot area are required
Solution Approach 1:
By removing asphaltenes through solvent deasphalting, the invention eliminates the need for complex vacuum distillation columns and coking units. The simple extraction process requires minimal equipment - primarily mixers, settlers, and filters - thereby dramatically reducing both capital costs and plot area while still achieving effective residue processing and valuable product recovery
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 system enhances the recovery of valuable hydrocarbon products, such as olefins, while minimizing environmental impact and reducing capital costs by improving the efficiency of residue upgrading processes.
Implementation Method 1
The residue can be mixed with a solvent to provide a mixture. The asphaltenes can be selectively separated from the mixture
Implementation Method 2
At least a portion of the distillate and at least a portion of the hydroprocessed hydrocarbon can be cracked to provide a cracked product comprising olefins
Data Source
AI summary
Systems and methods for processing hydrocarbons are provided. A hydrocarbon can be distilled to provide a distillate, a gas oil, and a residue. The residue can include, but is not limited to asphaltenes and non-asphaltenes. The residue can be mixed with a solvent to provide a mixture. The asphaltenes can be selectively separated from the mixture to provide a deasphalted oil. At least a portion of the deasphalted oil and at least a portion of the gas oil can be hydroprocessed to provide a hydroprocessed hydrocarbon. At least a portion of the distillate and at least a portion of the hydroprocessed hydrocarbon can be cracked in a first reaction zone to provide a first cracked product comprising C2 hydrocarbons, C3 hydrocarbons, C4 hydrocarbons, and naphtha.