METHOD FOR IMPROVING A FEED FLOW

Description

/ 38 METHOD FOR IMPROVING A FEED FLOW Field

[001] The embodiments of the present disclosure relate generally to the field of hydrocarbon refining and upgrading and, in particular, to a method of upgrading hydrocarbons using a heat integration system and an electrified furnace. Background

[002] Ethylene is widely used as an intermediate in the petrochemical industry, and its production exceeds that of any other organic compound. Much of the ethylene production goes to the manufacture of ethylene oxide, ethylene dichloride, and polyethylene, which are precursors to a multitude of everyday consumer products. Despite various improvements over the years in thermal efficiency, reliability, and safety, steam cracking furnaces used to form hydrocarbons such as ethylene remain heavily dependent on the combustion of fossil fuels to provide process heat, leading to substantial greenhouse gas emissions.

[003] The steam cracking process for producing ethylene requires approximately half the energy needed in competing processes (e.g., direct C1 conversion technologies) and is projected to remain the most energy-efficient process. CO2 emissions from ethane cracking can reach 1 tonne of CO2 per tonne of ethylene produced, lower than those from naphtha steam cracking and alternative C1-based routes for ethylene. At projected ethylene production rates, CO2 emissions from conventional steam cracking could exceed 300 million tonnes of CO2 annually (Mta-CO2) in the coming years. Approximately 85% of CO2 emissions in the steam cracking process are emitted in the radiant combustion furnace section. In conventional radiant furnaces, Petition 870250091668, dated 07 / 10 / 2025, page 11 / 67 / 38 numerous fuel gas (methane) burners are deployed to efficiently radiate the heat from the combustion process through the walls of the tubular reactor containing fluid feedstocks (e.g., hydrocarbons and steam) and product gases, providing heat to perform the necessary endothermic chemical reactions. Summary

[004] Consequently, the growth and availability of renewable electricity create an opportunity to use renewable energy in ethylene production, eliminating the need to burn fossil fuels and enabling a process with lower emissions. Several electric heating technologies, such as impedance, induction, plasma, and microwave, can be used to replace combustion heating to efficiently generate and transfer heat to the radiant coils of steam cracking furnaces. However, there is still a need for systems that can produce ethylene and other high-value chemicals from hydrocarbon feedstocks, such as naphtha, using renewable electricity sources for heating.

[005] However, in the application of electric heating to large-scale steam cracking processes, large amounts of electric current and energy are required. One of the main challenges is how to apply direct electric heating efficiently and strategically to a large-scale steam cracker, through multiple conduits that require many hundreds of Megawatts of electrical energy. Reducing the required electric current results in increased efficiency for the process and associated electrical connections and support equipment. Furthermore, facilitating a heat injection rate adapted to the electrically conductive tubes increases the desired product yields.

[006] There is the possibility of further reductions in the total power demand required through effective system heat integration. A Petition 870250091668, dated 07 / 10 / 2025, page 12 / 67 / 38 heat integration of the system can occur by capturing and utilizing all the available heat within the process to effect the creation of the desired products. This should ideally be done within other process constraints, especially the minimization of fouling and secondary reactions that have a detrimental effect on the overall yield of the desired products.

[007] Consequently, improved hydrocarbon upgrading methods that minimize greenhouse gas emissions in a heat integration cycle are desired. Systems and methods of the present invention achieve the aforementioned objectives by using an electrified furnace for hydrocarbon upgrading and heat integration through steam recycling.

[008] For example, and in the embodiments described herein, steam can be used to effect heat transfer from the hotter steam to the cooler feed via heat exchangers at various locations in the system. The use of steam can reduce the electrical energy demand required by the electrified furnace to initially heat and then improve feed flow. Heat integration of the system can occur by recycling the condensed steam back to the steam source, where it can be used again to effect heat transfer in the system as an integrated cycle, thus utilizing all the available heat within the method. Furthermore, additional benefits can be obtained by the interaction of the condensed steam with the outlet side of the electrified furnace.In steam cracking, the improved hydrocarbons exit the furnace at a higher temperature than they had when they entered, even when fed by electric heating technology instead of conventional gas heaters. The condensed steam can interact with the improved hydrocarbons through another heat exchanger, thus heating the condensed steam (which can also be called "boiler feedwater") and cooling them. Petition 870250091668, dated 07 / 10 / 2025, page 13 / 67 / 38 improved hydrocarbons. The now reheated steam can then be recycled to the steam source, where it can be used in the integrated cycle. In this way, all the available heat within the system can be used to improve the hydrocarbons, and a minimum amount of heat and energy is lost or not used.

[009] Furthermore, the electrification of a process plant minimizes the use of steam as an energy source to power machines such as pumps and chillers. The conversion of steam enthalpy into mechanical shaft work can result in energy recovery on the order of 30 to 35%, and the implementation of electric drives can improve efficiency. Therefore, reducing steam export from an ethylene furnace can be beneficial and / or desirable. The use of steam at lower pressure than usual on the outlet side of the electrified furnace can result in even greater benefits due to the lower temperature and higher latent heat. In particular, lower pressure steam can result in faster cooling of the furnace effluent for a given length, size, or flow rate of a heat exchanger, reducing the amount of undesirable side reactions that can affect the desired yield of the process as a whole.Another advantage of designing the system for lower pressure steam can be more optimized preheating of liquid feeds. Preheating of liquid feed streams should ideally minimize the presence of the liquid fraction in contact with the hot tubes of the preheating heat exchangers. The remaining liquid film is exposed for a prolonged period to the temperature of the heated tube metal, which can lead to thermal reactions and therefore to fouling. This can traditionally be observed in gas furnaces, where heat is transferred from a hot combustion gas stream to the feed stream. Consequently, a lower pressure for the steam can result in cooler tubes, minimizing the extent of fouling. Petition 870250091668, dated 07 / 10 / 2025, page 14 / 67 / 38 thermal fouling reactions inside preheating heat exchangers.

[0010] According to one embodiment, a method of improving a feed stream may include introducing dilution steam into the feed stream, thereby forming a feed mixture, preheating the feed mixture, improving the feed mixture in an electrified hydrocarbon improvement furnace which includes one or more electric heating elements to form a cracked gas effluent, introducing the cracked gas effluent into a first heat exchanger, thereby cooling the cracked gas effluent to a temperature in the range of 500 °C to 700 °C and additionally treating the cracked gas effluent to form a cracked gas;A steam drum is in fluid communication with the first heat exchanger to transfer steam condensate to the first heat exchanger and saturated steam back to the steam drum, thus forming a closed heat exchange circuit, with the steam condensate transferred to the first heat exchanger at a pressure in the range of 1 bar to 50 bar.

[0011] According to another embodiment, a method of improving a feed stream may include introducing the feed stream into a second heat exchanger, thereby preheating the feed stream to a temperature in the range of 23 °C to 263 °C, introducing dilution steam into the feed stream, thereby forming a feed mixture, preheating the feed mixture, improving the feed mixture in an electrified hydrocarbon improvement furnace which includes one or more electric heating elements to form a cracked gas effluent, introducing the cracked gas effluent into a first heat exchanger, thereby cooling the cracked gas effluent to a temperature in the range of 500 °C to 700 °C and additionally treating the cracked gas effluent to form a cracked gas; wherein a Petition 870250091668, dated 07 / 10 / 2025, page 15 / 67 / 38 The steam drum is in fluid communication with the initial heat exchanger to transfer steam to the initial heat exchanger and steam condensate back to the steam drum, and is also in fluid communication with the first heat exchanger to transfer steam condensate to the first heat exchanger and saturated steam back to the steam drum, thus forming a closed heat exchange circuit, with the steam condensate transferred to the first heat exchanger at a pressure in the range of 1 bar to 50 bar.

[0012] Additional features and advantages of the embodiments described in the present invention will be presented in the detailed description below and, in part, will be readily apparent to those skilled in the art from this description or recognized by practice of the embodiments described, including the detailed description and claims that are provided below. Brief description of the drawings

[0013] The following detailed description of specific embodiments of the present disclosure can be better understood when read together with the following drawings in which: Figure 1 illustrates a process flow diagram for an exemplary process according to the modalities described herein; Figure 2 illustrates another process flow diagram for an exemplary process according to the modalities described herein; Figure 3 illustrates another process flow diagram for an exemplary process according to the modalities described herein; Figure 4 illustrates another process flow diagram for an exemplary process according to the modalities described herein; and Figure 5 illustrates the relationship between the heat of vaporization versus the pressure for vapor. Detailed description Petition 870250091668, dated 07 / 10 / 2025, page 16 / 67 / 38

[0014] The embodiments described herein refer to methods of improving a feed stream, such as a hydrocarbon feed stream including ethane or naphtha.

[0015] For the purposes of describing the simplified schematic illustrations and descriptions of the relevant figures, the numerous valves, temperature sensors, electronic controllers and the like that may be employed and that are well known to those skilled in the art of certain chemical processing operations are not included. Furthermore, associated components frequently included in typical chemical processing operations, such as air supply systems and catalyst hoppers, are not represented. Associated components present in typical upgrading units, such as drainage flows, spent catalyst discharge subsystems and catalyst replenishment subsystems, are also not shown. It should be understood that these components are within the spirit and scope of the present embodiments described.However, operational components, such as those described in this disclosure, may be added to the embodiments described in this disclosure.

[0016] It should also be noted that the arrows in the drawings refer to process streams. However, the arrows may equivalently refer to transfer lines that can serve to transfer process flows between two or more system components. Furthermore, arrows connected to system components define inputs or outputs at each given system component. The direction of the arrow generally corresponds to the main direction of movement of the materials in the stream contained within the transfer line indicated by the arrow. Additionally, arrows that do not connect two or more system components signify a flow exiting the illustrated system or a flow entering the illustrated system. Product streams may be Petition 870250091668, dated 07 / 10 / 2025, page 17 / 67 / 38 further processed in accompanying chemical processing systems or may be marketed as final products. System input streams may be streams transferred from associated chemical processing systems or may be unprocessed raw material streams. Some arrows may represent recycling streams, which are effluent streams from system components that are recycled back into the system. However, it should be understood that any recycling stream represented, in some embodiments, may be replaced by a system input stream of the same material and that a portion of a recycling stream may exit the system as a product.

[0017] In addition, the arrows in the drawings can schematically represent the steps in the transport process of a flow from one system component to another system component. For example, an arrow from one system component pointing to another system component can represent the “passage” of an effluent from one system component to another system component, which may include the contents of a process flow “leaving” or being “removed” from one system component and “introducing” the contents of that product flow into another system component.

[0018] It should be understood that, according to the embodiments presented in the relevant figures, an arrow between two system components may mean that the stream is not processed between the two system components. In other embodiments, the stream signified by the arrow may have substantially the same composition throughout its transport between the two system components. Furthermore, it should be understood that in the embodiments, an arrow may represent that at least 75% by weight, at least 90% by weight, at least 95% by weight, at least 99% by weight, at least 99.9% by weight, or even 100% by weight of the flow is transported between the system components. Thus, in Petition 870250091668, dated 07 / 10 / 2025, page 18 / 67 / 38 in some modalities, only part of the entire flow indicated by an arrow can be transported between the system components, as if a diversion flow were present.

[0019] It should be understood that two or more process streams are “mixed” or “combined” when two or more lines intersect in the schematic flow diagrams of the relevant figures. Mixing or combining may also include mixing by introducing two or more streams into a reactor, separation unit, or other similar system component. For example, it should be understood that when two streams are represented as being combined directly before entering a separation unit or reactor, in some embodiments, the streams may equivalently be introduced into the reactor and mixed within the reactor. Alternatively, when two streams are represented to enter a system component independently, they may, in embodiments, be mixed before entering that system component.

[0020] However, it should also be understood that when two or more process streams enter a heat exchanger, the streams are not mixed. Instead, the streams can communicate in terms of heat transfer from one stream to the other without coming into direct contact with each other.

[0021] The ranges may be expressed here as being “in the range of” a specific value up to another specific value. When such a range is expressed, another modality includes from a specific value and / or up to another specific value. It will further be understood that the extreme points of each of the ranges are significant both in relation to the other extreme point and independently of the other extreme point.

[0022] The additional features and advantages of the described modalities, some of which are illustrated in the attached drawings, will be presented in the detailed description below, and in part will be easily understood. Petition 870250091668, dated 07 / 10 / 2025, page 19 / 67 / 38 recognized by those skilled in the art based on this description or recognized by the practice of the described modalities, including the detailed description below, as well as the claims.

[0023] As used herein, references to pressure in “bar”, “Pascals” or any equivalent pressure units may be understood as being in absolute pressure units, rather than in gauge pressure units.

[0024] As stated previously, the embodiments mentioned herein refer to methods of improving a feed stream 102. The feed stream 102 may include hydrocarbon oils, refined hydrocarbons, bioderivative feed streams, circular feed streams (recycled hydrocarbons) or combinations thereof. The hydrocarbon oil may be selected from the group consisting of naphthas, natural gas condensates, Fischer-Tropsch derivatives, gas oils, pyrolysis oils or combinations thereof. Additionally or alternatively, the feed stream 102 may include hydrocarbon gases selected from the group consisting of ethane, propane, butane or combinations thereof.Now with reference to Figures 1 to 4, the methods in this document may include a system comprising an electrified hydrocarbon enhancement furnace 236; one or more heat exchangers 202, 204, 206, 208, 210, 212; one or more pumps 222, 224; one or more electronic heaters 234, 235, 242; or combinations thereof. The electrified hydrocarbon enhancement furnace 236, also referred to herein as the “furnace,” may include one or more electric heating elements 237 for enhancing a feed mixture 106. As used herein, “electric heating elements” or “electronic heater” may refer to one or more electric heating technologies, including but not limited to direct electric heating, indirect electric heating, plasma, shock wave, microwave, or. Petition 870250091668, dated 07 / 10 / 2025, page 20 / 67 / 38 combinations thereof.

[0025] The method also includes introducing dilution steam 104 into the feed stream 102, thereby forming a feed mixture 106. The method may also include preheating the feed mixture. The method may also include improving the feed mixture 106 in an electrified hydrocarbon enhancement furnace 236 to form a cracked gas effluent 108. The cracked gas effluent 108 may then be introduced into a first heat exchanger 202, in which the cracked gas effluent 108 may be cooled to a lower temperature than that of the cracked gas effluent 108 inside the electrified hydrocarbon enhancement furnace 236. The cracked gas effluent 108 may also be introduced into the fourth 208, fifth 210 and sixth 212 heat exchangers to further cool the cracked gas effluent 108. The cracked gas effluent 108 may then be further treated to form a cracked gas 114.Without being limited by theory, the main objective of cooling cracked gas effluent 108 may be to prevent other unwanted reactions.

[0026] The method may also include an initial step of introducing the feed stream 102 to a second heat exchanger 204. Introducing the feed stream 102 into the second heat exchanger 204 may initially preheat the feed stream 102, which may be necessary when the feed stream 102 includes hydrocarbon oils, refined hydrocarbons, bioderivative feed streams, or combinations thereof. Furthermore, initial preheating may not be necessary when the feed stream includes only hydrocarbon gases, as explained in more detail later in this document. Introducing the feed stream 102 into the second heat exchanger 204 may operate to vaporize at least a portion of the feed stream 102. Subsequently, introducing the Petition 870250091668, dated 07 / 10 / 2025, page 21 / 67 / 38 feed stream 102 in dilution vapor 104 may act to vaporize the remaining portion of feed stream 102, since the temperature of the feed mixture 106 may be above the dew point of the feed mixture 106. As mentioned earlier, this initial preheating step may not be necessary when the feed stream consists of hydrocarbon gases, since in this case the feed stream 102 would already be vaporized. The introduction of feed stream 102 into the second heat heater can initially preheat the feed stream to a temperature in the range of 23 °C to 263 °C, such as 23 °C to 50 °C, 50 °C to 70 °C, 70 °C to 100 °C, 100 °C to 120 °C, 120 °C to 140 °C, 140 °C to 160 °C, 160 °C to 190 °C, 190 °C to 210 °C, 210 °C to 230 °C, 230 °C to 263 °C, or any combination of ranges, or a smaller range within them.For example, in embodiments, feed stream 102 can be preheated in the range of 23 °C to 263 °C for hydrocarbon gas feed streams and from 70 °C to 263 °C for hydrocarbon oils, refined hydrocarbons, bioderivative feed streams, circular feed streams or combinations thereof.

[0027] As stated previously, the method may include preheating the feed mixture 106. Preheating the feed mixture 106 may include introducing the feed mixture 106 into a third heat exchanger 206, and thereby preheating the feed mixture 106 to a temperature in the range of 70 °C to 263 °C, such as 70 °C to 100 °C, 100 °C to 120 °C, 120 °C to 140 °C, 140 °C to 160 °C, 160 °C to 190 °C, 190 °C to 210 °C, 210 °C to 230 °C, 230 °C to 263 °C, or any combination of ranges or a smaller range contained therein.For example, in embodiments, the feed mixture 106 can be preheated in the range of 23 °C to 263 °C for hydrocarbon gas feed streams and from 70 °C to 263 °C for hydrocarbon oils, refined hydrocarbons, bioderivative feed streams, and other feed streams. Petition 870250091668, dated 07 / 10 / 2025, page 22 / 67 / 38 circular feed or combinations thereof. The preheating of the feed mixture 106 in the third heat exchanger 206 can generally be understood as preheating the feed mixture 106 to a temperature higher than that exiting the second heat exchanger 204.

[0028] Preheating the feed mixture 106 may also or alternatively include introducing the feed mixture 106 to a fourth heat exchanger 208. The fourth heat exchanger 208 may be positioned downstream of the first heat exchanger 202 on one side of the split gas effluent 108. The fourth heat exchanger 208 may also be positioned between the third heat exchanger 206 and the electrified hydrocarbon improvement furnace 236 on one side of the feed mixture 106. The fourth heat exchanger 208 may preheat the feed mixture 106 to a temperature in the range of 380 °C to 650 °C. Preheating the feed mixture 106 in the fourth heat exchanger 208 can generally be understood as preheating the feed mixture 106 to a temperature higher than that exiting the second heat exchanger 204, the third heat exchanger 206, or both.

[0029] The fourth heat exchanger 208 can also cool the cracked gas effluent 108 to a temperature lower than 700 °C up to greater than or equal to 150 °C, such as from lower than 700 °C to greater than or equal to 150 °C for hydrocarbon gas feed streams, or from lower than 700 °C to greater than or equal to 300 °C for hydrocarbon oils, refined hydrocarbons, bioderivative feed streams, circular feed streams, or combinations thereof. In particular, a cracked gas effluent temperature 108 exiting the cracked gas effluent side 108 of the fourth heat exchanger 208 can be lower than a cracked gas effluent temperature 108 exiting the first heat exchanger. Petition 870250091668, dated 07 / 10 / 2025, p. 23 / 67 / 38 of heat 202. In other words, the fourth heat exchanger 208 can additionally cool the cracked gas effluent 108 exiting the first heat exchanger 202.

[0030] The temperature of the cracked gas effluent 108 exiting the cracked gas effluent side 108 of the fourth heat exchanger 208 can generally be chosen to be high enough to prevent substantial fouling due to condensation of heavy components in the cracked gas effluent. When cracking gaseous feedstocks such as ethane, the cracked gas effluent can generally be cooled to between 150 and 250 °C, or to a temperature less than or equal to 250 °C, while liquid feedstocks such as naphtha can generally be cooled to temperatures above 300 °C.

[0031] Preheating the feed mixture 106 may also include introducing the feed mixture 106 into a first electronic heater 234, wherein the first electronic heater 234 may be positioned between the third heat exchanger 206 and the feed mixture 106 side of the fourth heat exchanger 208. The first electronic heater 234 may operate to preheat the feed mixture 106 to a temperature of 250 °C to 400 °C, so as to prevent fouling of the cracked gas effluent 108 in the fourth heat exchanger 208, as explained in more detail later in this document.

[0032] Preheating the feed mixture 106 may also or alternatively include introducing the feed mixture 106 to a sixth heat exchanger 210. The sixth heat exchanger 212 may be positioned downstream of the third heat exchanger 206 and upstream of the fourth heat exchanger 208 on the feed mixture 106 side. The sixth heat exchanger 212 may also be positioned downstream of the fourth heat exchanger 208 on the cracked gas effluent 108 side. The sixth heat exchanger 210 may preheat the feed mixture 106 to a temperature at Petition 870250091668, dated 07 / 10 / 2025, p. 24 / 67 / 38 range of 250 °C to 650 °C, as well as cooling the cracked gas effluent 108 to a temperature lower than 700 °C to greater than or equal to 150 °C, similar to the fourth heat exchanger 208, as greater than or equal to 150 °C or from 150 °C to 250 °C for hydrocarbon gas feed streams. Similarly, for hydrocarbon oils, refined hydrocarbons, bioderived feed streams, circular feed streams, or combinations thereof, the sixth heat exchanger 210 can cool the cracked gas effluent 108 to a temperature less than or equal to 350 °C, greater than or equal to 300 °C, or less than or equal to 350 °C.

[0033] It is assumed that there may be some risk in using the cracked gas effluent 108 in the fourth and sixth heat exchangers 208, 212, together with the feed mixture 106. For example, cooling the cracked gas effluent 108 on the “hot side” (cracked gas effluent side 108) of the fourth or sixth heat exchanger 208, 212 past the dew point of a significant fraction of heavy compounds in the cracked gas effluent 108 may result in excessive condensation of said heavy fractions of the cracked gas effluent 108 on the internal surfaces of the heat exchangers, also known as “scaling”. However, in some embodiments, this risk is minimized by preheating the feed mixture 106 to a temperature in the range of 250 °C to 400 °C, such as by using the first electronic heater 234, before entering the fourth or sixth heat exchanger 208, 212 on the 'cold side' (feed mixture side 106).

[0034] Preheating the feed mixture 106 may also include introducing the feed mixture 106 into a second electronic heater 235, wherein the second electronic heater 235 may be positioned between the fourth heat exchanger 208, on the feed mixture 106 side, and the electrified improvement furnace of Petition 870250091668, dated 07 / 10 / 2025, page 25 / 67 / 38 hydrocarbon 236, for example, immediately before (i.e., immediately upstream of) the electrified hydrocarbon improvement furnace 236. The second electronic heater 235 can operate to preheat the feed mixture 106 to a temperature in the range of 120 °C to 500 °C.

[0035] It is assumed that the use of the second electronic heater 235 can provide flexibility to the methods of the present invention, in terms of possible feed streams 102. For example, and in some embodiments, the temperature at which the feed mixture 106 is preheated may depend on the composition of the feed stream 102. As the average carbon content of the feed mixture 106 decreases, the temperature at which the feed mixture 106 needs to be heated to improve the feed stream to the cracked gas effluent 108 may, in turn, increase. This additional heating demand can be supported by the preheating methods or by the electrified hydrocarbon enhancement furnace 236.However, the potential heating load that furnace 236 can withstand may be limited by its dimensions, such that progressive reductions in carbon content, such as replacing the feed mixture from predominantly naphtha to predominantly ethane, may require a larger furnace to replace the comparatively smaller one. The time and cost of changing furnaces may, in turn, result in considerable economic losses for the method as a whole. Furthermore, the potential heating load that heat exchangers 202 and 204 can withstand may be limited by the temperature to which steam 150 can be heated.

[0036] The methods in this document may include a heat transfer fluid as well as a storage medium for a heat transfer fluid. The heat transfer fluid may include steam 150. The storage medium may include a steam drum 232 for the Petition 870250091668, dated 07 / 10 / 2025, page. 26 / 67 / 38 steam 150. The steam drum 232 can be in fluid communication with the first and second heat exchangers 202 and 204 to transfer steam 150 to the first and second heat exchangers 202 and 204 and steam condensate 152 back to the steam drum 232. The steam drum 232 can also be fluidly connected to the first heat exchanger 202 to transfer steam condensate 152 to the first heat exchanger 202 and saturated steam 154 back to the steam drum 232. The introduction of steam condensate 152 into the first heat exchanger 202 can heat the steam condensate 152, thus forming saturated steam 154 (saturated mixture of steam and water).

[0037] The connection of the steam drum 232 to each of the heat exchangers 202, 204, 206 can thus form a “closed heat exchange circuit”. As used herein, a “closed heat exchange circuit” may not be entirely independent. For example, and in embodiments, the steam drum 232 may additionally comprise a purge valve 158, which may also be commonly called a “discharge valve”. As will be understood in the technique, the purge valve 158 can operate to intentionally discard or 'drain' water and steam from the steam drum 232 through the purge valve 158 to prevent the concentration of impurities during continuous use and evaporation of the steam 150. The steam drum may also include a feed valve 156. The feed valve 156 can operate to introduce water into the steam drum 232 to replace the steam and water discharged from the purge valve 158.

[0038] As used herein, “film boiling” refers generally to a phenomenon that occurs when the flow of heat from a hot stream to a cold stream through the wall of a heat exchanger causes a film of the remaining liquid of the heating fluid to form, covering at least partially the heating surface. This liquid film is trapped between the bulk of the fluid and the surface of Petition 870250091668, dated 07 / 10 / 2025, page. 27 / 67 / 38 heating, significantly increasing the residence time of the boiling liquid and thus initiating thermal reactions that cause fouling.” For example, in this document, film boiling can cause the formation of feed stream fouling 102 inside the heat exchangers, thus reducing the effectiveness of the heat exchangers and, in severe cases, resulting in critical failures of the heat exchanger materials.

[0039] In some embodiments, the method may also include exporting excess steam 160 from the steam drum 232, not otherwise sent to 204 or 206, from the cracking furnace section to another part of the plant / installation for use as process heating applications. Furthermore, excess steam 160 may first be sent to a third electronic heater 242. The introduction of excess steam 160 into the third electronic heater 242 may operate to form a superheated steam 162.Superheated steam 162 can be exported for use in any of a number of additional downstream units, including process heating applications. Electrification of the cracking furnace 237 and the use of lower pressure steam to help integrate heat between the feed stream and the effluent, as disclosed herein, drastically reduces the amount of thermodynamic work, so that all major steam turbines in the downstream section of the cracking plant can be electrified. The third electronic heater 242 can heat excess steam 160 from the steam drum 232 to a temperature in the range of 120 °C to 500 °C. It is contemplated that one use for exported steam 160 could be in heating and / or vaporizing dilution steam 104.

[0040] In additional embodiments, the system may include a fifth heat exchanger 210. The method may include introducing excess steam 160 from the steam drum 232 into the fifth heat exchanger 210. The fifth heat exchanger 210 may be positioned downstream of the first and fourth heat exchangers on one side of the cracked gas effluent 108. The fifth Petition 870250091668, dated 07 / 10 / 2025, page. The 28 / 67 / 38 heat exchanger 210 can also contribute to the heating service of the third electronic heater 242 in the production of the superheated flow 162. In particular, the fifth heat exchanger 210 can heat the excess steam 160 from the steam drum 232 to a temperature in the range of 120 °C to 500 °C, thus producing the superheated steam 162. Furthermore, the fifth heat exchanger 210 can also cool the cracked gas effluent 108 to a temperature lower than 700 °C up to or greater than 150 °C, or from lower than 700 °C to greater than or equal to 150 °C for hydrocarbon gas feed streams, or from lower than 700 °C to greater than or equal to 350 °C for hydrocarbon oils, refined hydrocarbons, and feed streams. bio-derived products, circular feed streams, or combinations thereof.Specifically, the temperature of the cracked gas effluent 108 exiting the cracked gas effluent side 108 of the fifth heat exchanger 208 may be lower than the temperature of the cracked gas effluent 108 exiting the first heat exchanger 202, the third heat exchanger 208, or both. In other words, the fifth heat exchanger 210 may additionally cool the cracked gas effluent 108 exiting the first heat exchanger 202, the third heat exchanger 208, or both.

[0041] As noted earlier, the methods in this document may include one or more pumps 222, 224. For example, and in some embodiments, each of the second through third heat exchangers 202, 204 may additionally include pumps, or the pumps may be a separate unit. For example, and in embodiments, pumps 222 and 224 may be interposed between the downstream end of the second and third heat exchangers 202 and 204 and the steam drum 232. Pumps 222 and 224 may operate to transport the steam condensate 152 exiting the second and third heat exchangers 202 and 204 back to the steam drum 232, wherein the steam condensate 152 may be reheated for reuse as the Petition 870250091668, dated 07 / 10 / 2025, page 29 / 67 / 38 steam 150, as by transfer to the first exchanger 202 to cool the cracked gas effluent 108.

[0042] As stated previously, the introduction of steam condensate 152 into the first heat exchanger 202 can heat the steam condensate 152, thus forming saturated steam 154. However, the introduction of steam condensate 152 into the first heat exchanger 202 can also operate to cool the cracked gas effluent 108, as described previously. Without adhering to theory, the cracked gas effluent 108 may undergo additional reactions due to its high temperature upon exiting the electrified hydrocarbon enhancement furnace 236. These additional reactions may form undesirable byproducts, so it is desirable that the cracked gas effluent be cooled as quickly as possible to preserve the desired products.Without being limited by theory, most of these secondary reactions can be suppressed at temperatures below approximately 600-650 °C, although at least a portion of the secondary reactions can be suppressed at temperatures between 650 °C and 700 °C. Consequently, the introduction of steam condensate 152 to rapidly cool the cracked gas effluent 108 can rapidly cool and / or suppress at least a portion of the secondary reactions of the cracked gas effluent 108.

[0043] In some embodiments, the steam 150, the steam condensate 152 or the excess steam 160 introduced into the heat exchangers 202, 204, 206 and 210 may be at a pressure in the range of 1 bar to 50 bar, such as 1 bar to 5 bar, 5 bar to 10 bar, 10 bar to 15 bar, 15 bar to 25 bar, 25 bar to 30 bar, 32 bar to 35 bar, 35 bar to 38 bar, 38 bar to 40 bar, 40 bar to 50 bar, or any combination of ranges or a smaller range contained therein, such as 1 bar to 40 bar, so that the steam condensate 52 may be considered “lower pressure steam”. Specifically, the pressure range could preferably be from 10 bar to 35 bar or from 10 bar to 15 bar. Petition 870250091668, dated 07 / 10 / 2025, page 30 / 67 / 38 hydrocarbon gas feed streams and 32 to 38 bar for hydrocarbon oil feed streams. Without delving into theory, the steam used in hydrocarbon upgrading processes is typically “high-pressure steam,” in the range of 80 to 180 bar and, more commonly, 100 to 120 bar. This is likely because high-pressure steam is typically exported to downstream steam turbines to perform thermodynamic work and drive various large compression units and steam turbines in downstream processes. However, when the exported steam is not otherwise desired, as in a fully electrified cracking process as provided herein, the steam condensate 152 used in the first heat exchanger 202, as well as the steam 150 used in heat exchangers 204 and 206, and the excess steam 160 used in heat exchanger 210, may be lower pressure steam.Lower pressure steam used in steam condensate 152, steam 150 or excess steam 160 can have numerous process benefits, as further explained later in this document and in the examples section.

[0044] For example, lower-pressure steam may have a higher heat of vaporization than relatively higher-pressure steam. “Heat of vaporization,” also called “enthalpy of vaporization,” is generally understood as the amount of heat required to transform 1 gram of a liquid (steam condensate in this case) into a vapor, without increasing the temperature of the liquid. This is illustrated, for example, in Figure 5, which shows the heat of vaporization of steam as a function of steam pressure. As shown in Figure 5, as the steam pressure increases, the heat of vaporization decreases. Conversely, as the steam pressure decreases, the heat of vaporization increases. Consequently, it is predicted that lower-pressure steam can transfer heat more effectively for a given exposure length of a heat exchanger, or for a given flow rate. Petition 870250091668, dated 07 / 10 / 2025, p. 31 / 67 / 38 inside the same.

[0045] Without delving into theory, this can apply both when the steam condensate 152 is partially vaporized in the heat exchanger 202 during the cooling of the cracked gas effluent 108, and when steam 150 is condensed to preheat the feed stream 102 in the second or third heat exchangers 204 and 206. In other words, lower pressure steam can be considered a denser energy carrier to effect heat transfer. Furthermore, lower pressure steam may have a lower saturation temperature compared to higher pressure steam, as also shown in Figure 5. The lower temperature of the condensate and steam at saturation can additionally increase the heat transfer rate in 202 when used to cool the cracked gas effluent 108, for example, by increasing the temperature difference between the hot and cold sides of the heat exchanger.The net effect can be a combination of the advantages of higher heat of vaporization and lower saturation temperature, thus contributing to unexpected gains in rapid cooling efficiency and suppression of side reactions.

[0046] Finally, the lower pressure and therefore the temperature of the steam 150 reduces the temperature gradient across the heat exchangers 204 / 206 when it is condensed to form the steam condensate 152. This reduced temperature gradient can decrease the probability of film boiling in 204 / 206, as well as suppress the occurrence of secondary reactions of the feed stream 102 and the feed mixture 106.

[0047] As shown in the Examples later in this document, the use of 1 bar to 50 bar of steam condensate 152 and preferably 10 bar to 40 bar of steam in the first heat exchanger 202 can enable the cooling of the cracked gas effluent 108 to a temperature in the range of 500 °C to 700 °C with a shorter residence time. Petition 870250091668, dated 07 / 10 / 2025, page 32 / 67 / 38 for equivalent heat exchangers than for 100 bar to 120 bar of steam condensate 152. In embodiments, any remaining cooling of the cracked gas effluent 108 necessary to recover heat and additionally suppress the remaining side reactions can then be performed by introducing the cracked gas effluent 108 into the fourth heat exchanger 208, as in embodiments disclosed herein. The net result can be an increase in the amount of desired products in the cracked gas effluent 108 with a corresponding minimization in the amount of side reactions that produce undesired products therein.

[0048] As stated previously, the cracked gas effluent 108 can be further treated to form a cracked gas 114. The further treatment may include exposing the cracked gas effluent 108 to a rapid cooling fluid 110 in a rapid cooling tower 238, thereby forming a cooled cracked gas mixture 112. In embodiments involving hydrocarbon gases, the rapid cooling fluid 110 may include water. Alternatively, in some embodiments involving hydrocarbon oil, refined hydrocarbons or bio-derived feed streams, the rapid cooling fluid 110 may include diesel oil, gas oil or both. The further treatment may also include introducing the rapidly cooled cracked gas mixture 112 into a separator 240, thereby forming a recovered fluid 116 and a cracked gas 114.The recovered fluid 116 may include tar in the case of diesel oil and / or gas oil-based rapid cooling fluids 110, and additional water in the case of water-based rapid cooling fluids 110. The cracked gas 114 may include olefins as well as other hydrocarbon fractions. The rapid cooling tower 238 may be any rapid cooling tower generically understood in the art. The recovered fluid 116 may be further treated to recycle the rapid cooling fluid 110 for reuse in the rapid cooling tower 238. Petition 870250091668, dated 07 / 10 / 2025, page 33 / 67 / 38 including by any method generically understood in the technique.

[0049] In some embodiments, and as stated previously, the methods of the present invention can be implemented to reduce the energy / electrical energy demand required to improve a feed flow 102 by using an electrified hydrocarbon improvement furnace and heat integration method. The methods described herein can reduce the energy demand compared to conventional methods, including a convection-based hydrocarbon improvement furnace, by at least 35%. The methods of the present invention can also reduce the energy demand, compared to comparative methods without heat integration circuits, by at least 10%. This is also shown and illustrated in the Examples below. Examples

[0050] The simulations of the feed flow improvement process, according to the modalities of this document, were performed using ASPEN PLUS® V11 software, using APV110 ethylene and APV110 PURE physical property databases, with Soave-Redlich-Kwong equations of state. Example 1 - Naphtha cracker

[0051] In Example 1, a naphtha flow of 20,000 kg per hour (as feed flow 102) was improved according to the embodiment illustrated in Figure 3. The naphtha was first preheated to a temperature of 120 °C in the second heat exchanger 204 by steam condensation to provide the heat and vaporize at least a portion of the naphtha. The naphtha was then mixed with dilution steam at 10,000 kg per hour 104 at 180 °C and 7 bar to form the feed mixture 106 at 125 °C and, as discussed earlier, vaporize the remaining portion of the naphtha. The feed mixture 106 was then introduced into the third heat exchanger 206 to preheat the feed mixture to a temperature of approximately 212 °C. A Petition 870250091668, dated 07 / 10 / 2025, page 34 / 67 / 38 feed mixture 106 was then preheated to a temperature of 300 °C and 535.7 °C in the first electronic heater 234 and in the fourth heat exchanger 208, respectively.

[0052] The second electronic heater 235 further preheats the feed mixture 106 to 600 °C before upgrading in the electrified hydrocarbon upgrading furnace 236. The cracked gas effluent exiting the electrified hydrocarbon upgrading furnace 236 was at 847 °C and approximately 2.1 bar. The cracked gas effluent 108 was then rapidly cooled to 600 °C in the third heat exchanger by partial vaporization of the steam condensate 152 at 36 bar. Specifically, the steam condensate 152 absorbed the excess heat from the cracked gas effluent 108 so that a fraction of the condensate forms a saturated steam mixture 154. The cracked gas effluent was then further cooled to 360 °C in the fourth heat exchanger 208. The cracked gas effluent 108 was then further treated to form the cracked gas 114, as shown in Figure 3.

[0053] The results of this method were then compared with a similar system (Comparative Project 1) using a combustion-based hydrocarbon upgrading furnace, wherein the high-pressure steam is formed by cooling the cracked gas in one or more heat exchangers in the transfer line using high-pressure steam condensate and superheated by the combustion gas from the combustion furnace, which also preheats the feed stream. The superheated high-pressure steam is exported in Comparative Project 1 and used to generate mechanical work in the downstream section of the plant. It was considered that the mass flow rates, temperature, and pressure of the feed stream, dilution steam, and effluent exiting the furnace were identical, i.e., that the performance of the conventional and electric furnaces was the same in the hydrocarbon feed stream reaction. The mass flow balance, as well as the use of Petition 870250091668, dated 07 / 10 / 2025, page 35 / 67 / 38 energy in comparison, are shown below in Table 1. For the conventional oven, the firebox efficiency is 42% and the overall efficiency is 94%.

[0054] The naphtha feed stream composition and cracking yields were, at least partially, based on those of SM Sadrameli & AES Green, Systematics and modeling representations of naphtha thermal cracking for olefin production, Journal of Analytical and Applied Pyrolysis, 305-313 (Volume 73, Issue 2, 2005). The heat of reaction estimate was calculated by comparing the composition of the cracked gas product with the initial naphtha composition, using ASPEN PLUS® v11 software. Table 1: Mass Flow Balance and Service Comparison Units Comparative Project 1 Example Project 1 Mass Flow Feed Rates Naphtha Feed Flow (60 °C, 6 bar) Kg / h 20,000 20,000 Dilution Steam (180 °C, 7 bar) Kg / h 10,000 10,000 Boiler Feedwater (120 °C, 130 bar) Kg / h 25,117 0 Boiler Feedwater (120 °C, 36 bar) Kg / h 0 4083 Saturated and Superheated Steam Exported Steam Flow Rate (500 °C, 110 bar) Kg / h 24,683 0 Steam Flow Rate (242 °C, 36 bar) Kg / h 0 3841 Work Produced from Turbine Shaft kW 7307 0 Comparison of working hours: Methane (20 °C, 1 bar) kg / h 2915 0 Combustion air (20 °C, 1 bar) kg / h 55,713 0 Combustion gas (154 °C, 1 bar) kg / h 58,627 0 CO2 emissions kg / h 7997 0 Electric furnace service kW 0 17016 Electric heater service kW 0 3438 Supplementary shaft work kW 0 7307 Total furnace service kW 40,511 28,968

[0055] As shown in Table 1, Comparative Project 1 produced approximately 7307 kW of excess shaft work in the combustion furnace, which can normally be exported to processes of Petition 870250091668, dated 07 / 10 / 2025, page 36 / 67 / 38 downstream cracking for utilization. Example 1, in contrast, did not produce any excess shaft work due to the electrified design and lower pressure steam. Consequently, for a true comparison of total service in the Examples, an additional supplementary shaft work of 7307 kW was produced in the electrified furnace. Consequently, the electrified heating furnace required significantly less net energy (28,968 kW to 40,511 kW) than the equivalent system using the combustion-based hydrocarbon improvement furnace. Furthermore, the lower pressure steam design (36 bar) also resulted in significantly less boiler feedwater flow needing to be fed to the steam drum to maintain the operational method.The lower pressure steam design (36 bar) also resulted in better initial rapid cooling of the cracked gas effluent 108 (faster cooling) as shown below in Table 2.

[0056] In particular, for the lower pressure steam design, shorter residence time, shorter heat exchanger length, and lower steam condensate flow rate were required to cool the cracked gas effluent to 600 °C than an equivalent higher pressure steam design (110 bar). As discussed earlier, faster cooling can act to prevent undesirable side reactions in the cracked gas effluent, which can improve the yield of desired products (ethylene, propylene, butylene, etc.). For the design of the heat exchangers, ASPEN Exchanger Design and Rating (EDR) v11 software was used, with a single double-pipe exchanger (outer tube diameter 96 mm, thickness 8 mm) to cool 1200 kg / h of cracked gas effluent relative to saturated liquid water with a steam quality of 10% of the steam mixture exiting the heat exchanger. Petition 870250091668, dated 07 / 10 / 2025, page 37 / 67 / 38 Table 2: Comparison of rapid cooling of low and high pressure steam designs for the naphtha cracker of Example 1 Steam condensate pressure at 3rd TLHE Steam condensate temperature at 3rd TLHE Steam condensate flow rate Heat exchanger length Average residence time in heat exchanger Bar °C kg / h meters seconds 110 309 7536 6.59 0.058 36 242 5404 5.55 0.049

[0057] The composition of the naphtha feed stream and the resulting composition of the cracked gas effluent after cooling, according to Example 1, are shown below in Table 3. Table 3: Compositions of the feed stream and effluent_______________ Compound Weight Fraction Compound Weight Fraction Naphtha Feed Flow Cracked Gas Effluent Naphtha Feed Flow Cracked Gas Effluent HYDROGEN 0 0.0108 METHYL-ACETYLENE 0 0.0095 METHANE 0 0.1666 1-BUTENE 0 0.0416 ETHANE 0 0.0641 1,3-BUTADIENE 0 0.0456 PROPANE 0 0.005 CYCLOPENTADIENE 0 0.0325 N-BUTANE 0.0453 0.0025 BENZENE 0.0217 0.0592 N-PENTANE 0.2252 0 TOLUENE 0.0037 0.0272 N-HEXANE 0.1202 0 O-XYLENE 0.0044 0.0066 N-HEPTANE 0.0169 0 ETHYLBENZENE 0 0.0005 N-OCTANE 0.0063 0 STYRENE 0 0.0082 N-NONANE 0.0007 0 ISOPROPYLBENZENE 0 0.0048 ISOBUTANE 0.0012 0 NAPHTHALENE 0 0.0321 2-METHYLBUTANE 0.1648 0 CYCLOPENTANE 0.0738 0 2-METHYLPENTANE 0.1217 0 CYCLOHEXANE 0.07112 0 2-METHYLHEPTANE 0.002 0 CARBON MONOXIDE 0 0.003 ETHYLENE 0 0.3195 CARBON DIOXIDE 0 0.0005 ACETYLENE 0 0.0063 2,2-DIMETHYL-BUTANE 0.003 0 PROPYLENE 0 0.1437 2,3-DIMETHYL-BUTANE 0.0118 0 Example 2 - Ethane cracker

[0058] In Example 2, an ethane feed flow of 20,000 kg Petition 870250091668, dated 07 / 10 / 2025, page 38 / 67 / 38 per hour (35 °C, 10 bar) was improved according to the embodiment illustrated in Figure 2. Ethane was first preheated to a temperature of 163 °C in the second heat exchanger 204. The ethane was then mixed with 6,000 kg per hour of dilution steam 104 at 180 °C and 7 bar to form the feed mixture 106 at 167 °C and 5.9 bar. The feed mixture 106 was then heated to a temperature of 620 °C in the fourth heat exchanger 208. The second electronic heater 235 preheated the feed mixture to 690 °C before improvement in the electrified hydrocarbon improvement furnace 236.

[0059] The cracked gas effluent exiting the electrified hydrocarbon improvement furnace 236 was at 850 °C and approximately 2.0 bar. The cracked gas effluent 108 was then rapidly cooled to 650 °C in the first heat exchanger with steam condensate 152 at 13.5 bar, where the steam condensate 152 absorbs heat from the cracked gas effluent 108 to form a mixture of condensate and saturated steam 154. The cracked gas effluent was then further cooled to 220 °C in the fourth heat exchanger 208. The cracked gas effluent 108 was then further treated to form cracked gas 114, as shown in Figure 2.

[0060] The results of this method were then compared with a similar system (Comparative Project 2) using a combustion-based ethane improvement furnace, wherein the high-pressure steam is formed by cooling cracked gas in one or more heat exchanger lines using high-pressure steam condensate and superheated by the combustion gas from the combustion furnace, which also preheats the feed stream. The superheated high-pressure steam is exported in Comparative Project 2 and used to generate mechanical work in the downstream section of the plant. The mass flow rates, temperature, and pressure of the feed stream, dilution steam, and effluent were considered. Petition 870250091668, dated 07 / 10 / 2025, page 39 / 67 / 38. The results from the furnace were identical, meaning that the performance of the conventional and electric furnaces was the same in the hydrocarbon feed stream reaction. The mass flow balance, as well as the energy use in the comparison, are shown below in Table 4. For the conventional furnace, the firebox efficiency is 42% and the overall efficiency is 93%.

[0061] Similar to naphtha cracking, ethane cracking yields were adapted from yields reported in Chapter: Ethylene (p. 477, Table 3) by H. Zimmermann and R. Walzl in Ullman's Encyclopedia of Industrial Chemistry 2012 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim and shown in Table 5. The estimated heat of reaction was calculated by comparing the composition of the cracked gas product with the initial composition of ethane, using ASPEN PLUS® v11 software. Table 4: Mass flow balance and service comparison ____________ Comparative Project Units 2 Example Project 2 Mass Flow Rates Ethane feed flow (35 °C, 10 bar) kg / h 20,000 20,000 Dilution steam (180 °C, 7 bar) kg / h 6,000 6,000 Boiler feed stream water (120 °C, 130 bar) kg / h 33,505 0 Boiler feed stream water (120 °C, 15 bar) kg / h 0 6,009 Saturated and superheated steam exported Steam flow rate (500 °C, 108 bar) kg / h 32,892 Steam flow rate (194 °C, 13.5 bar) kg / h 0 5,831 Work produced from turbine shaft kW 9,749 0 Journey comparison Methane (60 °C, 1 Combustion air (25°C, 1 bar) kg / h 3.496 0 Combustion gas (180°C, 1 bar) kg / h 68.458 0 Combustion gas (180°C, 1 bar) kg / h 71.954 0 CO2 emissions kg / h 9.591 0 Electric furnace service kW 0 20.410 Electric heater service kW 0 1798 Supplementary shaft work kW 0 9.749 Total furnace service kW 48.486 32.575 Petition 870250091668, dated 07 / 10 / 2025, p. 40 / 67 / 38

[0062] As shown in Table 4, Comparative Design 2 produced approximately 9749 kW of excess shaft work in the combustion furnace, which can normally be exported to downstream refinery processes for utilization. Example 2, in contrast, did not produce any excess shaft work due to the electrified design. Consequently, for a true comparison of total service in the Examples, an additional 9749 kW of excess shaft work was produced in the electrified furnace. Consequently, the electrified heating furnace required significantly less net energy (32,575 kW to 48,486 kW) than the equivalent system using the combustion-based hydrocarbon improvement furnace. Furthermore, the lower pressure steam design (13.5 bar) also resulted in significantly less boiler feedwater flow needing to be fed to the steam drum to maintain the operational method.The lower pressure steam design (13.5 bar) also resulted in better initial rapid cooling of the cracked gas effluent 108, similar to Example 1. In particular, for the lower pressure design, less residence time was required to cool the cracked gas effluent 108 to 650 °C than the higher pressure steam design (110 bar). Table 5: Compositions of feed stream and effluent (dry basis) Compound Weight Fraction Compound Weight Fraction Ethane Feed Stream Cracked Gas Effluent Naphtha Feed Stream Cracked Gas Effluent Hydrogen 0 0.0409 Butadiene 0 0.0179 Methane 0 0.0319 1-Butene 0 0.0018 Acetylene 1 0.0054 Butane 0 0.0021 Ethylene 0 0.5285 Benzene 0 0.0038 Ethane 0 0.3499 Toluene 0 0.0006 Methylacetylene 0 0.0002 Styrene 0 0.0002 Propylene 0 0.0106 Naphthalene 0 0.0040 Propane 0 0.0012 Carbon Monoxide 0 0.0003 Vinylacetylene 0 0.0005 Carbon dioxide 0.0001 Petition 870250091668, dated 07 / 10 / 2025, page 41 / 67 / 38 IJJI carbon|||

[0063] In the previous simulations (Examples 1 and 2), a heat loss of 2% was assumed in all heat exchangers. Shaft work was calculated by passing steam 154 through a turbine with an isentropic efficiency of 0.8, a mechanical efficiency of 1, to a condensate effluent pressure of 2 in-Hg. Steam drum discharge was calculated as 2% of the condensate and fresh boiler feedwater to the steam drum. The steam condensate flow rate was adjusted to achieve a steam quality of 10% at the outlet of heat exchanger 202.

[0064] It is observed that references in the present disclosure to a component of the present disclosure that is “operable” or “sufficient” in a specific way, to embody a specific property, or to function in a specific way, are structural references, as opposed to references to intended use. More specifically, references in the present disclosure to the manner in which a component is “operable” or “sufficient” denote an existing physical condition of the component and, as such, should be considered a definite reference to the structural characteristics of the component.

[0065] The singular forms “a”, “an”, “the”, and “the” include plural referents unless the context clearly indicates otherwise.

[0066] Throughout this disclosure, ranges are provided. It is foreseen that each distinct value covered by the ranges will also be included. Additionally, the ranges that can be formed by each distinct value covered by the explicitly disclosed ranges are also foreseen.

[0067] As used in this disclosure and the appended claims, the words “comprise”, “have” and “include” and all grammatical variations thereof are intended to have an open, non-limiting meaning that does not exclude additional elements or steps.

[0068] As used in this revelation, terms such as “first,” “second,” “third,” etc., are assigned arbitrarily and are intended Petition 870250091668, dated 07 / 10 / 2025, page 42 / 67 / 38 only to differentiate between two or more instances or components. It should be understood that the words “first”, “second”, “third”, etc. serve no other purpose and do not form part of the name or description of the component, nor do they necessarily define a location, position, or relative order of the component. Furthermore, it should be understood that the mere use of the term “first”, “second”, or “third” does not require that there be a “fourth” component, although that possibility is foreseen within the scope of this disclosure.

[0069] For the purposes of describing and defining these modalities, it is noted that the terms “substantially” and “approximately” are used in this document to represent the inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement, or other representation. The terms “substantially” and “approximately” are also used in this document to represent the degree to which a quantitative representation may vary from a stated reference without resulting in a change in the basic function of the subject matter.

[0070] According to a first aspect, a method for improving a feed stream may include introducing dilution steam into the feed stream, thereby forming a feed mixture; preheating the feed mixture; improving the feed mixture in an electrified hydrocarbon improvement furnace to form a cracked gas effluent, wherein the electrified hydrocarbon improvement furnace comprises one or more electric heating elements to improve the feed mixture; introducing the cracked gas effluent into a first heat exchanger, thereby cooling the cracked gas effluent to a temperature in the range of 500 °C to 700 °C; and further treating the cracked gas effluent to form a cracked gas, wherein: a steam drum is in fluid communication with the first heat exchanger to transfer the steam condensate to the first Petition 870250091668, dated 07 / 10 / 2025, page 43 / 67 / 38 heat exchanger and saturated steam back to the steam drum, thus forming a closed heat exchange circuit, with the steam condensate transferred to the third heat exchanger at a pressure in the range of 1 bar to 50 bar.

[0071] A second aspect may include the first aspect and may further include that the feed stream additionally comprises hydrocarbon gases selected from the group consisting of ethane, propane, butane or combinations thereof.

[0072] A third aspect may include the first aspect and may further include that the feed stream comprises hydrocarbon oils, refined hydrocarbons, bioderivative feed streams or combinations thereof, the hydrocarbon oils being selected from the group consisting of naphthas, gas oils, pyrolysis oils or combinations thereof.

[0073] A fourth aspect may include any of the previous aspects and may additionally include introducing the feed stream into a second heat exchanger before introducing the dilution steam into the feed stream, thereby preheating the feed stream to a temperature in the range of 23 °C to 263 °C, and the steam drum also being in fluid communication with the second heat exchanger to transfer steam to the second heat exchanger and the steam condensate back to the steam drum.

[0074] A fifth aspect may include any of the preceding aspects and may further comprise preheating the feed mixture by introducing the feed mixture into a third heat exchanger, thereby preheating the feed mixture to a temperature in the range of 70 °C to 263 °C; and the steam drum is in fluid communication with the third heat exchanger to transfer steam to the third heat exchanger and steam condensate back to the steam drum. Petition 870250091668, dated 07 / 10 / 2025, p. 44 / 67 / 38

[0075] A sixth aspect may include any of the preceding aspects, and may additionally include preheating the feed mixture comprising introducing the feed mixture into a first electronic heater; and the first electronic heater preheats the feed mixture to a temperature of 250 °C to 400 °C.

[0076] A seventh aspect may include any of the preceding aspects, and may additionally comprise preheating the feed mixture comprising introducing the feed mixture into a first electronic heater; the fourth heat exchanger is positioned downstream of the first heat exchanger on a cracked gas effluent side of the fourth heat exchanger; a cracked gas effluent temperature exiting the cracked gas effluent side of the fourth heat exchanger is lower than a cracked gas effluent temperature exiting the first heat exchanger; the fourth heat exchanger preheats the feed mixture to a temperature in the range of 380 °C to 650 °C and cools the cracked gas effluent to a temperature less than 700 °C to greater than or equal to 150 °C.

[0077] An eighth aspect may include any of the foregoing aspects and may further comprise preheating the feed mixture comprising introducing the feed mixture into a second electronic heater, wherein the second electronic heater is positioned immediately upstream of the electrified hydrocarbon improvement furnace; and the second electronic heater further preheats the feed mixture to a temperature in the range of 500 °C to 700 °C.

[0078] A ninth aspect may include any of the preceding aspects and may further comprise that further treating the cracked gas effluent comprises exposing the cracked gas effluent to a fast-cooling fluid in a fast-cooling tower, thereby forming a rapidly cooled cracked gas mixture; and the fast-cooling fluid comprises water or at least one of diesel oil and Petition 870250091668, dated 07 / 10 / 2025, p. 45 / 67 / 38 diesel.

[0079] A tenth aspect may include the ninth aspect and may further comprise that further treating the cracked gas effluent further comprises introducing the cooled cracked gas mixture into a separator, thereby forming a recovered fluid and a cracked gas, wherein the cracked gas comprises olefins.

[0080] An eleventh aspect may include any of the preceding aspects and may additionally include that the second and third heat exchangers comprise one or more pumps interposed between the downstream end of the second and third heat exchangers and the steam drum.

[0081] A twelfth aspect may include any of the preceding aspects and may further include that the method further comprises introducing excess steam from the steam drum into a third electronic heater, thereby forming superheated steam for export; and the second electronic heater heats the steam from the steam drum to a temperature in the range of 120 °C to 500 °C.

[0082] A thirteenth aspect may include any of the first to eleventh aspects and may additionally include the introduction of excess steam from the steam drum into a fifth heat exchanger, the fifth heat exchanger being positioned downstream of the first heat exchanger on a cracked gas effluent side of the fifth heat exchanger; heating the excess steam from the steam drum to a temperature in the range of 120 °C to 500 °C in the fifth heat exchanger, thereby forming superheated steam for export; and cooling the cracked gas effluent to a temperature less than 700 °C to greater than or equal to 150 °C in the fifth heat exchanger, wherein a temperature of the cracked gas effluent exiting the cracked gas effluent side of the fifth heat exchanger is less than a temperature of the cracked gas effluent exiting the first heat exchanger. Petition 870250091668, dated 07 / 10 / 2025, pp. 46 / 67 / 38

[0083] A fourteenth aspect may include any of the preceding aspects, and may further comprise preheating the feed mixture comprising introducing the feed mixture into a sixth electronic heater; the sixth heat exchanger is positioned downstream of the first heat exchanger on a cracked gas effluent side of the sixth heat exchanger; and the sixth heat exchanger preheats the feed mixture to a temperature in the range of 250 °C to 650 °C and cools the cracked gas effluent to a temperature less than or equal to 350 °C.

[0084] According to a fifteenth aspect, a method of improving a feed stream may include introducing the feed stream into a second heat exchanger, thereby preheating the feed stream to a temperature in the range of 100 °C to 263 °C; introducing dilution steam into the feed stream, thereby forming a feed mixture; further preheating the feed mixture; improving the feed mixture in an electrified hydrocarbon improvement furnace to form a cracked gas effluent, wherein the electrified hydrocarbon improvement furnace comprises one or more electric heating elements to improve the feed mixture; introducing the cracked gas effluent into a first heat exchanger, thereby cooling the cracked gas effluent to a temperature in the range of 500 °C to 700 °C;and additionally treat the cracked gas effluent to form cracked gas, wherein: a steam drum is in fluid communication with the second heat exchanger to transfer steam to the second heat exchanger and the steam condensate back to the steam drum, and is also in fluid communication with the first heat exchanger to transfer the steam condensate to the first heat exchanger and the saturated steam back to the steam drum, thus forming a closed heat exchange circuit; Petition 870250091668, dated 07 / 10 / 2025, page 47 / 67 / 38: condensate of steam transferred to the third heat exchanger is at a pressure in the range of 1 bar to 50 bar.

[0085] Having described the subject matter of the present disclosure in detail and by reference to specific embodiments, it is noted that the various details disclosed in the present disclosure should not be interpreted as implying that those details refer to elements that are essential components of the various embodiments described in the present disclosure. Furthermore, it will be evident that modifications and variations are possible without departing from the scope of the present disclosure, including, but not limited to, embodiments defined in the appended claims. Petition 870250091668, dated 07 / 10 / 2025, pp. 48 / 67

Claims

1 / 5 CLAIMS 1. A method for improving a feed stream, characterized in that it comprises: introducing dilution steam into the feed stream, thereby forming a feed mixture; preheating the feed mixture; improving the feed mixture in an electrified hydrocarbon improvement furnace to form a cracked gas effluent, wherein the electrified hydrocarbon improvement furnace comprises one or more electric heating elements for improving the feed mixture;at least one of the following: introducing the feed stream into a second heat exchanger before introducing the dilution steam into the feed stream, wherein the steam drum is in fluid communication with the second heat exchanger to transfer steam to the second heat exchanger and the steam condensate back to the steam drum; or introducing the feed mixture into a third heat exchanger, thereby preheating the feed mixture, wherein the steam drum is in fluid communication with the third heat exchanger to transfer the steam to the third heat exchanger and the steam condensate back to the steam drum;and introduce the cracked gas effluent into a first heat exchanger, thus cooling the cracked gas effluent to a temperature in the range of 500 °C to 700 °C, wherein: the steam drum is in fluid communication with the first heat exchanger to transfer the steam condensate to the first heat exchanger and saturated steam back to the steam drum, thus forming a closed heat exchange circuit, together with the second heat exchanger, with the third heat exchanger, or with both, and wherein the steam condensate transferred to the first heat exchanger is at a pressure in the range of 1 bar to 50 bar.

2. A method according to claim 1, characterized in that the feed stream additionally comprises hydrocarbon gases selected from the group consisting of ethane, propane, butane, or combinations thereof.

3. Method according to claim 1, characterized in that the feed stream comprises hydrocarbon oils, refined hydrocarbons, bioderivative feed streams, circular feed streams or combinations thereof, wherein the hydrocarbon oils are selected from the group consisting of naphthas, gas oils, pyrolysis oils, Fischer-Tropsch derivatives, natural gas condensates or combinations thereof.

4. A method according to any of the preceding claims, characterized in that the step of introducing the feed stream into a second heat exchanger comprises preheating the feed stream to a temperature in the range of 23 °C to 263 °C.

5. A method according to any of the preceding claims, characterized in that the step of introducing the feed mixture into a third heat exchanger comprises preheating the feed mixture to a temperature in the range of 70 °C to 263 °C.

6. A method according to any of the preceding claims, characterized in that it further comprises introducing the feed mixture into a first electronic heater, wherein the first electronic heater preheats the feed mixture to a temperature of 250 °C to 400 °C.

7. A method according to any of the preceding claims, characterized in that it further comprises: Petition 870250091668, dated 10 / 07 / 2025, page 63 / 67 3 / 5 introducing the feed mixture into the third heat exchanger; and introducing the feed mixture into a fourth heat exchanger, wherein: the fourth heat exchanger is positioned downstream of the first heat exchanger on a cracked gas effluent side of the fourth heat exchanger; a cracked gas effluent temperature exiting the cracked gas effluent side of the fourth heat exchanger is lower than a cracked gas effluent temperature exiting the first heat exchanger; The fourth heat exchanger preheats the feed mixture to a temperature in the range of 380 °C to 650 °C and cools the cracked gas effluent from a temperature below 700 °C to greater than or equal to 150 °C.

8. A method according to any of the preceding claims, characterized in that it further comprises introducing the feed mixture into a second electronic heater, wherein the second electronic heater is positioned immediately upstream of the electrified hydrocarbon improvement furnace, wherein the second electronic heater further preheats the feed mixture to a temperature in the range of 500 °C to 700 °C.

9. A method according to any of the preceding claims, characterized in that it further comprises exposing the cracked gas effluent to a rapid cooling fluid in a rapid cooling tower, thereby forming a rapidly cooled cracked gas mixture, wherein the rapid cooling fluid comprises: water; or diesel oil, gas oil, or both. Petition 870250091668, dated 10 / 07 / 2025, pp. 64 / 67 4 / 5 10. Method according to claim 9, characterized in that it further comprises introducing the cooled cracked gas mixture into a separator, thereby forming a recovered fluid and a cracked gas comprising olefins.

11. A method according to any of the preceding claims, characterized in that the second and third heat exchangers additionally comprise one or more pumps interposed between the downstream end of the second and third heat exchangers and the steam drum.

12. A method according to any of the preceding claims, characterized in that it further comprises introducing the feed mixture into a sixth heat exchanger, wherein: the sixth heat exchanger is positioned downstream of the first heat exchanger on a cracked gas effluent side of the sixth heat exchanger; the sixth heat exchanger preheats the feed mixture to a temperature in the range of 250 °C to 650 °C; and the sixth heat exchanger cools the cracked gas effluent to a temperature less than or equal to 350 °C.

13. Method for improving a feed stream characterized in that it comprises: introducing the feed stream into a second heat exchanger, thereby preheating the feed stream to a temperature in the range of 23 °C to 263 °C; introducing dilution steam into the feed stream, thereby forming a feed mixture; preheating the feed mixture; improving the feed mixture in an electrified hydrocarbon improvement furnace to form a cracked gas effluent, Petition 870250091668, dated 07 / 10 / 2025, p.65 / 67 5 / 5 wherein the electrified hydrocarbon improvement furnace comprises one or more electric heating elements to improve the feed mixture; introducing the cracked gas effluent into a first heat exchanger, thereby cooling the cracked gas effluent to a temperature in the range of 500 °C to 700 °C; and further treating the cracked gas effluent to form a cracked gas, wherein: a steam drum is in fluid communication with the second heat exchanger to transfer steam to the heat exchanger and steam condensate back to the steam drum, also being in fluid communication with the first heat exchanger to transfer steam condensate to the first heat exchanger and saturated steam back to the steam drum, thus forming a closed heat exchange circuit, and wherein the steam condensate transferred to the first heat exchanger is at a pressure in the range of 1 bar to 50 bar.Petition 870250091668, dated 07 / 10 / 2025, pp. 66 / 67.

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