Wax Oil Hydrocracking via Segmented Catalyst Stages
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing hydrocracking processes for wax oil are limited in flexibility, as they typically produce tail oil products with specific properties depending on the catalyst used, making it difficult to produce multiple products with different specifications simultaneously using a single set of hydrocracking units.
Innovation Solution
A method and system that involves pre-hydrotreating wax oil with a catalyst, followed by two stages of hydrocracking using different catalysts, and then a hydrogenation isocracking process to further refine the products, allowing for the production of multiple products with varying specifications, such as naphtha, jet fuel, diesel oil, and tail oil, each with tailored properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single type of hydrocracking catalyst is used, then the production process is simple, but the product specifications are limited to one type
Solution Approach 1:
The hydrocracking process is divided into two separate stages: first hydrocracking and second hydrocracking. Each stage uses a different catalyst type (Y zeolite for first stage, isomerizing zeolite for second stage) to produce different product specifications. This segmentation allows the system to produce multiple product types (tail oil for steam cracking, lubricant base oil) from the same feedstock without requiring parallel processing units.
Solution Approach 2:
The same hydrocracking processing system is designed to perform multiple functions by sequentially applying different catalysts. The first hydrocracking unit produces intermediate products that can be further processed by the second hydrocracking unit with different catalysts to achieve different final product specifications, making the system universally applicable to multiple product requirements.
2Adaptability or versatility
If different hydrocracking catalysts are used to produce different product specifications, then product diversity increases, but the number of processing units must be increased
Solution Approach 1:
The process segments hydrocracking into two sequential stages with different catalysts, allowing one processing train to produce multiple product specifications. This avoids the need for parallel processing units while maintaining product diversity.
Solution Approach 2:
The first hydrocracking stage performs preliminary cracking to break down heavy molecules into smaller fractions. These intermediate products are then subjected to a second hydrocracking stage with different catalysts to achieve final product specifications. This preliminary action enables flexible product distribution without requiring complete parallel processing systems.
3Manufacturing precision
If Y zeolite catalyst is used for hydrocracking, then tail oil has low BMCI value suitable for steam cracking, but solidifying point is high
Solution Approach 1:
The process separates the functions of different catalysts into distinct stages. The first hydrocracking stage with Y zeolite optimizes for low BMCI value tail oil suitable for steam cracking. The second hydrocracking stage with isomerizing zeolite optimizes for low solidifying point lubricant base oil. This segmentation allows each catalyst to excel at its specific function without compromise.
Solution Approach 2:
By changing the catalyst type between stages (from Y zeolite to isomerizing zeolite), the process changes the chemical parameters of the tail oil. The first stage produces tail oil with low BMCI value, while the second stage produces tail oil with low solidifying point and high viscosity index, expanding product application range through parameter control.
4Manufacturing precision
If isomerizing zeolite catalyst is used for hydrocracking, then tail oil has low solidifying point suitable for lubricant base oil, but BMCI value is high
Solution Approach 1:
The process segments catalyst functions so that isomerizing zeolite is used only in the second hydrocracking stage to produce lubricant base oil with low solidifying point. The first stage with Y zeolite produces tail oil with low BMCI value for steam cracking. This segmentation ensures each catalyst type is used for its optimal application.
Solution Approach 2:
The process changes catalyst parameters between stages to control tail oil properties. The first stage produces tail oil with low BMCI value, while the second stage with isomerizing zeolite produces tail oil with low solidifying point and high viscosity index, enabling production of different product types from the same feedstock.
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 approach enables the flexible production of high-quality products with specific properties, including low solidifying points and high viscosity indices, by effectively allocating hydrocracked material flows through multiple processing steps, improving the operational flexibility and product diversity compared to traditional methods.
Implementation Method 1
pre-hydrotreating wax oil with a catalyst
Implementation Method 2
pre-hydrotreating wax oil with a catalyst
Implementation Method 3
first hydrocracking reaction
Implementation Method 4
contact with a first hydrocracking catalyst to have a first hydrocracking reaction
Implementation Method 5
second hydrocracking reaction
Implementation Method 6
contact with a second hydrocracking catalyst to have a second hydrocracking reaction
Implementation Method 7
hydrogenation isocracking reaction
Implementation Method 8
contact with a hydrogenation isocracking catalyst to have a hydrogenation isocracking reaction
Data Source
AI summary
A method of wax oil hydrocracking includes the steps of pre-hydrotreating wax oil to obtain a pre-hydrotreated material flow; controlling the pre-hydrotreated material flow and a hydrogen-containing material flow to contact with a first hydrocracking catalyst to obtain a first hydrocracked material flow, and dividing the first hydrocracked material flow into a first hydrocracked material flow A and a first hydrocracked material flow B; controlling the flow B and a hydrogen-containing material flow to contact with a second hydrocracking catalyst to obtain a second hydrocracked material flow, and then separating and fractionating the second hydrocracked material flow to obtain a hydrocracked tail oil product; controlling the flow A, at least a part of the hydrocracked tail oil product, and a hydrogen-containing material flow to contact with a hydrogenation isocracking catalyst to obtain a hydrogenation isocracked material flow, and then separating and fractionating the obtained hydrogenation isocracked material flow.