Deep Sulfur Removal
Treatment Process for Heavy Sour Crude Oils
The FlexUP process targets sulfur and other impurities in heavy sour crude oils. It uses oxydesulfurization technology with a proprietary catalyst system that oxidizes impurities under low-energy conditions. Unlike hydroprocessing, this method remains effective despite the presence of catalyst poisons.
Lower Emissions and Energy Demand
FlexUP reduces greenhouse gas emissions by approximately 65% compared to hydroprocessing. The process operates at lower temperatures and avoids high-pressure hydrogen, which helps decrease utility consumption. The compact equipment footprint allows for installation in areas where large hydroprocessing units are impractical.
Improving Feedstock Quality and API Gravity
The treatment raises API gravity, which enhances flow characteristics and improves compatibility with existing infrastructure. Depending on the feedstock, API values can increase by up to 20%. The process maintains hydrocarbon mass, ensuring consistent energy value after treatment.
Selective Oxidation and Separation of Impurities
The catalysts in FlexUP selectively oxidize sulfur and nitrogen compounds. These oxidized compounds undergo chemical cleavage and separation. The process isolates and removes the impurities, including metals and acid components, while preserving valuable hydrocarbons.
Performance Benefits
API Gravity Increase
Raising API gravity reduces or eliminates the need for external diluents. This change improves product quality and supports better transport efficiency.
Sulfur Control
Operators can adjust the system to meet specific sulfur targets based on output requirements, offering flexibility for regulatory compliance.
Reduction of TAN and Metals
The process lowers total acid number (TAN) and removes metals such as nickel and vanadium. As a result, the treated crude becomes suitable for a wider range of refineries.
Lower Hydrogen Use
FlexUP minimizes hydrogen use by relying on oxygen during oxidation. Refineries can reserve their hydrogen supply for other hydrogenation processes.
Application Focus: Upgrading Heavy Sour Feedstocks
FlexUP suits upstream applications where producers need to remove impurities from heavy oils. It improves product specifications and expands market options by reducing sulfur, metals, and acids without excessive energy or hydrogen demands.