Solvent Deasphalting Integration with Resin Hydroprocessing
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Solution Overview
Problem
The existing solvent deasphalting process for heavy oils is limited in maximizing the yield of deasphalted oil (DAO), which restricts the production of valuable transportation fuels and increases the cost of downstream hydroprocessing, particularly due to the challenges posed by resin fractions.
Innovation Solution
A process integrating solvent deasphalting with resin hydroprocessing, where a solvent is added to a heavy hydrocarbon stream to separate asphaltenes and resins, followed by hydroprocessing the resin fraction to generate a hydroprocessed residue product, thereby increasing DAO yield and reducing hydroprocessing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If resin fraction is processed together with deasphalted oil in conventional hydroprocessing, then hydroprocessing costs increase, but DAO yield is maximized
Solution Approach 1:
The process segments the resin fraction separation from the DAO stream by introducing a precipitating agent that selectively precipitates resins at controlled temperatures. This allows resins to be removed before hydroprocessing, enabling the DAO to be processed separately at lower severity and reduced cost while maximizing DAO yield.
Solution Approach 2:
The resin fraction is extracted from the DAO stream through precipitation using agents such as methanol, ethanol, or n-paraffins. This extraction step removes the problematic resin components that would otherwise increase hydroprocessing costs, allowing the remaining DAO to be processed more economically.
2Ease of manufacture
If resin fraction is removed before solvent recovery, then hydroprocessing costs reduce, but process complexity increases
Solution Approach 1:
The resin precipitation step is merged with the existing solvent recovery sequence, utilizing the solvent-rich stream from the decanter as the feed for precipitation. This integration adds only one major unit operation (the precipitator) while leveraging existing equipment, thereby reducing process complexity compared to separate resin removal systems.
Solution Approach 2:
The precipitating agent acts as an intermediary substance that facilitates resin separation without requiring complex equipment. Simple chemicals like methanol, ethanol, or n-heptane are used to precipitate resins, which can then be separated by conventional decantation or filtration, avoiding the need for complex separation technologies.
3Reliability
If severe hydroprocessing is applied to treat resin fractions, then contaminant removal improves, but energy consumption increases
Solution Approach 1:
The resin fraction is removed in advance through precipitation before the DAO undergoes hydroprocessing. This preliminary action eliminates the need for severe hydroprocessing conditions to handle resin contaminants, thereby reducing energy consumption while maintaining effective contaminant removal from the DAO stream.
Solution Approach 2:
Resin fractions containing high concentrations of contaminants are extracted and removed from the DAO stream before hydroprocessing. This extraction step concentrates contaminants in the resin fraction, allowing the remaining DAO to be processed at lower severity with reduced energy input while still achieving the required contaminant removal levels.
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 enhances DAO yield, reduces coke production, and lowers hydroprocessing costs by selectively separating and treating the resin fraction, resulting in increased transportation fuel production and improved refinery efficiency.
Implementation Method 1
a solvent is added to a heavy hydrocarbon stream comprising asphaltenes, resin, and oil; removing the asphaltenes from the heavy hydrocarbon stream so as to produce a substantially solvent-free asphaltene stream and a substantially asphaltene-free solvent solution
Implementation Method 2
heating the solvent solution so as to precipitate the resin; separating the resin from the solvent solution, producing a resin product and a mixture comprising the oil and the solvent
Implementation Method 3
applying heat to the mixture so as to vaporize a fraction of the solvent; removing the vaporized solvent fraction from the mixture leaving a resin-free deasphalted oil product
Implementation Method 4
hydroprocessing the resin product so as to produce a residue product; integrating the resin recovery section with a hydroprocessing process; and hydroprocessing the resin-containing fraction in the hydroprocessing process to generate a hydroprocessed residue product
Data Source
AI summary
The invention is directed to a process that combines the solvent deasphalting with resin hydrotreatment so as to reduce the costs associated with performing each of the steps separately. The integrated process of the invention permits higher product yields coupled with lower energy and transportation costs.