Supercritical Water Petroleum Upgrading with Start-Up Agent
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Solution Overview
Problem
Conventional petroleum refining methods face limitations such as high hydrogen and catalyst consumption, coke production, and limited impurity removal, particularly when processing heavy and sour crude oils, leading to equipment plugging and reduced process efficiency.
Innovation Solution
The use of supercritical water mediated upgrading process, which includes a start-up agent to prevent coke and sludge formation, allowing for effective desulfurization and upgrading of petroleum feedstocks without external hydrogen or catalysts, and maintaining process line integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional hydrogenative methods are used for upgrading petroleum, then desulfurization conversion is improved, but hydrogen gas consumption increases and catalyst deactivation occurs frequently
Solution Approach 1:
The patent removes the catalyst component from the hydrogenative upgrading process, using pure supercritical water as the reaction medium. This eliminates catalyst deactivation issues while maintaining desulfurization effectiveness through water's inherent chemical reactivity at supercritical conditions.
Solution Approach 2:
The patent changes the physical state of water to supercritical conditions (temperature above 374°C and pressure above 22.1 MPa), which fundamentally alters water's properties to enable it to function as both solvent and reactant, replacing the need for external hydrogen gas and catalysts.
2Productivity
If thermal methods are used for upgrading petroleum, then processing of heavy fractions is improved, but coke production increases and impurity removal is limited
Solution Approach 1:
The patent uses supercritical water (temperature 300-650°C, pressure 20-30 MPa) instead of conventional thermal cracking conditions. The presence of water in supercritical state fundamentally changes the reaction pathway, enabling heavy fraction conversion while preventing coke formation through water's chemical interaction with hydrocarbon radicals.
Solution Approach 2:
Water acts as an intermediary substance that mediates the conversion of heavy hydrocarbons. It participates in the reaction mechanism by providing hydroxyl groups and facilitating hydrolysis reactions, which convert heavy fractions to lighter products while preventing unwanted side reactions that produce coke.
3Device complexity
If supercritical water upgrading is used without start-up agent, then process simplicity is improved, but equipment plugging occurs due to coke and sludge formation
Solution Approach 1:
The patent introduces a start-up agent before the main petroleum feedstock to prepare the system for supercritical water upgrading. This preliminary action conditions the reactor environment and prevents initial coke and sludge formation that would otherwise plug equipment lines during the transition to steady-state operation.
Solution Approach 2:
The start-up agent serves as a temporary, consumable substance used only during the initial phase of operation. It is sacrificed to prevent equipment plugging, after which it is replaced by the main feedstock processing, making it a disposable component that protects the overall system.
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 method achieves increased API gravity, middle distillate yield, reduced sulfur and nitrogen content, and decreased metal content in petroleum products, preventing equipment plugging and enhancing process efficiency and product quality.
Implementation Method 1
utilize supercritical water to upgrade and desulfurize a petroleum feedstock
Implementation Method 2
The methods described herein utilize a start-up agent, which is effective for preventing the formation of coke, coke precursors, and sludge
Implementation Method 3
supplying a heated and pressured water stream to a first mixing device, wherein the water stream is heated and pressurized to a temperature and pressure greater than the critical point of water
Implementation Method 4
the water stream is heated and pressurized to a temperature and pressure greater than the critical point of water
Implementation Method 5
mixing the heated and pressurized water stream and the heated and pressurized start-up agent stream in the first mixing device to produce a water and start-up hydrocarbon containing primer stream
Implementation Method 6
The treated primer stream is cooled to a temperature of less than about 150° C. and depressurized
Implementation Method 7
The treated primer stream is cooled to a temperature of less than about 150° C. and depressurized
Implementation Method 8
The cooled treated primer stream is then separated into treated primer gas and treated primer liquid phase streams
Data Source
AI summary
Provided is a process for the supercritical upgrading of petroleum feedstock, wherein the process includes the use of a start-up agent, wherein the use of the start-up agent facilitates mixing of the petroleum feedstock and water, thereby reducing or eliminating the production of coke, coke precursor, and sludge.