Method and system for optimizing mechanical and / or thermal vapor compression in a multi-stage process

Abstract

This invention utilizes mechanical vapor compression and / or thermal vapor compression, integrating compression loops across multiple process stages. A sequential network of compressors is used to increase the pressure and condensation temperature of vapor within each process stage as an internal vapor flow, and as an inter-vapor flow branching between process stages. Because available vapor is shared between compressor stages, the number of compressors can be reduced, improving economics. By separating vapor between compressor stages to balance the vapor mass flow rate across multiple process stages in the incremental compressor stages, the entire vapor compression system can be customized to individual process energy requirements and adapt to dynamic fluctuations in process conditions.

Description

[0001] Priority data

[0002] This international patent application claims priority to U.S. Provisional Patent Application No. 63 / 052,202, filed July 15, 2020; U.S. Provisional Patent Application No. 63 / 172,150, filed April 8, 2021; U.S. Provisional Patent Application No. 63 / 172,151, filed April 8, 2021; and U.S. Patent Application No. 17 / 374,962, filed July 13, 2021, each of which is hereby incorporated herein by reference. Invention Field

[0003] This invention generally relates to methods and systems for reducing carbon intensity associated with refineries and biorefineries. Background of the Invention

[0005] Industrial processes utilizing reaction, separation, and evaporation typically separate multi-component mixtures into pure materials or specific blends. Common feedstocks include fossil hydrocarbons and renewable bio-based natural matrices. The feedstocks undergo refining processes, in which the crude mixture is typically separated, fractionated, reacted, and / or purified to produce a finished product with specific qualities. Generally, “refineries” utilize fossil hydrocarbons (such as crude oil or coal), while “biorefineries” utilize biomass (such as lignocellulosic feedstocks).

[0006] Typical refining processes utilize liquid-gas phase transitions to induce the separation of complex mixtures. A significant amount of process heat is required to drive this endothermic phase transition. Organizing the boiling point differences of the processed materials at different stages of the refinery process allows for cascading heat from the highest to the lowest temperature process, enabling heat reuse and reducing overall process energy. The heat of vaporization is far greater than the heat required to move the process flow without vaporization, where only the sensible heat capacity of the mixture needs to be considered. Therefore, the vaporization stage has the greatest energy requirement of the entire process.

[0007] Unrefined hydrocarbons from plant-based or petroleum-based fossil sources are mixtures of complex organic molecules with varying molecular structures and boiling points. Hydrocarbons, along with triglycerides and various other renewable feedstocks, exist in aliphatic, olefinic, and aromatic subclasses. Refining process stages separate mixtures into subcomponents or break down complex, longer molecules into smaller molecules and / or reform them into larger molecules. Refineries always produce mixtures that require purification through further processing and separation. Refining processes can utilize reaction vessels to induce chemical changes, producing mixtures of products, followed by separation processes to purify the reaction products. Typical refining processes employ more than one process stage, with each stage producing different products for different markets and uses. These multiple stages in processing typically operate sequentially, with each process stage coinciding with other continuous process stages, producing products of varying value.

[0008] Refineries and other industrial processing plants frequently require fractionation to recover and refine finished products. The plant's process energy consumed in fractionation typically constitutes the largest energy demand throughout the production lifecycle of such products. Standard refining practice involves each process stage operating independently, with thermal energy applied as heat to each stage, and the vapor produced by the process ultimately entering a condenser, which acts as a non-contact heat exchanger, reducing the temperature and pressure of the gas phase to the conditions required for a phase change to a liquid. The condenser typically transfers the heat of condensation of the vapor or gas to a liquid, such as cooling water supplied via a cooling tower, or to a cooling gas, such as air in the atmosphere. Therefore, the heat applied to the feed stream of the process is ultimately lost to the cooling medium in the condenser. Typically, multi-process systems will have multiple condensers. Each of these process stages requires energy, where the total process energy is the sum of the energy of all process stages. Similarly, the latent heat lost in the condenser approximates the sum of the process energy applied to each stage.

[0009] To reduce overall process energy, standard industrial practice for optimizing multiple sequential process stages involves cascading heat from one stage to another within a multi-stage process. The cascading approach is achieved by arranging multiple stages so that heat can be transferred as multiple effects from higher-temperature process stages to lower-temperature process stages. This approach reduces overall process energy, but new efforts are underway to further reduce process energy requirements to even lower energy levels to improve efficiency and reduce carbon footprint.

[0010] Vapor compression can be applied to process stages to reduce total process energy to below what is achievable through simple thermal cascading, thus providing additional opportunities to reduce the process carbon footprint in multi-stage processes. The concept of mechanical vapor compression in fractionation has been disclosed in patents and used to reduce process energy requirements for decades. Mechanical vapor compression is widely used in water treatment, food processing, pharmaceuticals, and brewing. Its primary application is in evaporation processes. When applied, mechanical vapor compression is typically categorized as recovering energy within a single process stage.

[0011] Commercially, there is a need for improved methods and systems to reduce energy requirements and process carbon intensity in a wide range of industrial and biorefineries. Invention Overview

[0013] Some variations of the present invention provide a multi-stage energy integration process comprising:

[0014] (a) Providing a common configuration for converting raw materials into one or more products in a continuous or semi-continuous manner, wherein the multiple process stages utilize gas-liquid phase change;

[0015] (b) Providing a vapor compression system, wherein the vapor compression system comprises at least a first vapor compressor and a second vapor compressor, wherein the first vapor compressor is a mechanical vapor compressor or a hot vapor compressor, and wherein the second vapor compressor is a mechanical vapor compressor or a hot vapor compressor;

[0016] (c) The first and second vapor compressors are arranged sequentially to increase the pressure and condensation temperature of the first vapor in the first process stage and the second vapor in the second process stage downstream of the first process stage, thereby providing compressed first vapor and compressed second vapor;

[0017] (d) directing at least a portion of the compressed first vapor to (i) the second stage, (ii) a process stage downstream of the second stage, if any, (iii) a process stage upstream of the first stage, if any, or (iv) a combination thereof.

[0018] (e) Optionally, at least a portion of the compressed second vapor is directed to (i) the first process stage, (ii) a process stage upstream of the first stage, if any, (iii) a process stage downstream of the second stage, if any, or (iv) a combination thereof.

[0019] (f) Optionally, at least a portion of the compressed first vapor is directed back to the first stage; and

[0020] (g) Optionally, at least a portion of the compressed second vapor is directed back to the second stage.

[0021] Raw materials may include fossil hydrocarbons, renewable bio-based natural matrices, or combinations thereof.

[0022] In some embodiments, at least one of steps (e), (f), and (g) is performed, or at least two of steps (e), (f), and (g) are performed, or all of steps (e), (f), and (g) are performed.

[0023] For example, multiple process stages can be at least three process stages.

[0024] In some embodiments, at least one of the first or second process stages is selected from distillation, evaporation, stripping, molecular sieve treatment, chemical reactions, and combinations thereof. When the process involves chemical reactions, the chemical reactions may be selected from the group consisting of, for example, oxidation, reduction, hydrolysis, condensation, transesterification, oligomerization, polymerization, crystallization, isomerization, reforming, cracking, dehydrogenation sulfidation, hydrotreating, alkylation, hydrogenation, dehydrogenation, dehydration (olefin formation), cyclization, coking, catalyst regeneration, and combinations thereof.

[0025] In some embodiments, the third steam compressor is configured to compress a heat exchange medium that does not come into contact with the third steam in the third process stage, and wherein the third steam compressor is a mechanical steam compressor or a thermal steam compressor.

[0026] Multi-stage energy integration processes can be implemented, for example, in biorefineries, oil refineries, chemical plants, petrochemical plants, biochemical plants, natural gas refineries, shale oil refineries, coal-derived product refineries, or syngas-derived product plants.

[0027] Other variations of the invention provide a multi-stage energy integration system comprising:

[0028] (a) A plurality of process subsystems configured to continuously or semi-continuously convert feedstocks into one or more products, wherein the plurality of process subsystems are configured to utilize a gas-liquid phase change; and

[0029] (b) A vapor compression subsystem, wherein the vapor compression subsystem comprises at least a first vapor compressor and a second vapor compressor, wherein the first vapor compressor is a mechanical vapor compressor or a hot vapor compressor, and wherein the second vapor compressor is a mechanical vapor compressor or a hot vapor compressor.

[0030] The first and second vapor compressors are arranged and configured sequentially to increase the pressure and condensation temperature of the first vapor in the first process subsystem and the second vapor in the second process subsystem, wherein the second process subsystem is physically separated from the first process subsystem but is in fluid communication with it;

[0031] The first steam compressor is in fluid communication with the second or third process subsystem via a first compressed steam pipeline, wherein the first compressed steam pipeline is equipped with a first control valve;

[0032] Optionally, the second steam compressor is in fluid communication with the first process subsystem, the third process subsystem, or the fourth process subsystem via a second compressed steam line, wherein the second compressed steam line is equipped with a second control valve;

[0033] Optionally, the first vapor compressor is in fluid communication with the first process subsystem; and

[0034] Optionally, the second steam compressor is in fluid communication with the second process subsystem.

[0035] In some embodiments, the first vapor compressor is in fluid communication with the second process subsystem. In these or other embodiments, the first vapor compressor is in fluid communication with the third process subsystem.

[0036] In some embodiments, the second vapor compressor is in fluid communication with the first process subsystem. In these or other embodiments, the second vapor compressor is in fluid communication with a third and / or fourth process subsystem.

[0037] Alternatively or additionally, the first steam compressor may be in fluid communication with the first process subsystem. The second steam compressor may be in fluid communication with the second process subsystem.

[0038] For example, multiple process subsystems can be at least three process subsystems.

[0039] At least one of the first or second process subsystems may be selected, for example, from a distillation unit, an evaporation unit, a stripping unit, a molecular sieve unit, a chemical reactor, or a combination thereof.

[0040] In some embodiments, the third steam compressor is configured to compress a heat exchange medium that does not come into contact with a third steam within the third process subsystem, wherein the third steam compressor is a mechanical steam compressor or a thermal steam compressor.

[0041] Multi-stage energy integration systems can be, for example, part or all of a biorefinery, oil refinery, chemical plant, petrochemical plant, biochemical plant, natural gas refinery, shale oil refinery, coal derivatives refinery, or syngas derivatives plant. Attached Figure Description

[0042] Figure 1This illustrates a process (conventional technology) in which precursors are transported to a multi-stage process. The process stages are arranged in a configuration where the product of each stage flows from a higher temperature to a lower temperature. There is no heat reuse between stages.

[0043] Figure 2 A multi-stage process (conventional technology) is illustrated, in which each process stage is organized such that an upstream process stage, having a higher temperature than a downstream process stage, can transfer heat from the upstream process stage to the downstream process stage via a non-contact heat exchanger. The last stage in the cascade chain has a condenser in which process heat from the final process stage is discharged.

[0044] Figure 3 This is a schematic diagram illustrating an exemplary multi-stage process, in which vapor from each stage is mechanically compressed to a certain pressure, causing the condensation temperature to rise to a point that allows the heat of vaporization to be returned to the process stage via a heat exchanger and / or transferred to the next process stage.

[0045] Figure 4 This is a schematic diagram illustrating an exemplary multi-stage process, in which steam from each stage is mechanically compressed by multiple compressors configured in parallel to a level that allows the heat of vaporization to be returned to the process stage via a heat exchanger and / or transferred to the next process stage. Multiple parallel mechanical compressors allow for greater variation in the flow from each stage. The amount of steam moving within a single stage and the amount of steam exchanged between process stages can be selected with better control. Multiple compressors within a single process stage and across multiple process stages form a network of series and parallel steam flows through the multi-stage process.

[0046] Figure 5 This is a schematic diagram illustrating an exemplary multi-stage process, in which vapor from each stage is thermally compressed to a pressure such that the condensation temperature rises to a point that allows the heat of vaporization to be returned to the process stage via a heat exchanger and / or transferred to the next process stage. Multiple thermal compressors within the multiple process stages form parallel vapor flows through the multi-stage process.

[0047] Figure 6 This is a schematic diagram illustrating an exemplary multi-stage process, in which steam from each stage is thermally compressed by multiple compressors configured in parallel to a level that allows the heat of vaporization to be returned to the process stage via a heat exchanger and / or transferred to the next process stage. Multiple parallel thermal compressors allow for greater variation in the flow from each stage, thereby allowing for better control over the selection of the amount of steam moving within a single stage and the amount of steam exchanged between process stages. Multiple compressors within a single process stage and across multiple process stages form a series and parallel steam flow network through the multi-stage process.

[0048] Figure 7This is a schematic diagram illustrating an exemplary multi-stage process, in which vapor from each stage is mechanically compressed to a pressure such that the condensation temperature rises to a point that allows the heat of vaporization to be returned to the sourcing process stage and / or transferred to the next process stage via a heat exchanger. Multiple mechanical compressors within the multiple process stages form a valve-controlled parallel vapor flow through the multi-stage process.

[0049] Figure 8 This is a schematic diagram illustrating an exemplary multi-stage process, in which vapor from each stage is mechanically compressed and controlled by valves and multiple compressors configured in parallel and series to a pressure that allows the heat of vaporization to return to the process stage via a heat exchanger and / or be transferred to the next process stage. Multiple parallel mechanical compressors controlled by valves allow for greater variation in the flow from each stage, where the amount of vapor moving within a single stage and the amount of vapor exchanged between process stages can be selected with better control. Multiple compressors within a single process stage and across multiple process stages use control valves to form a network of series and parallel vapor flows through the multi-stage process.

[0050] Figure 9 This is a schematic diagram illustrating an exemplary multi-stage process, in which vapor from each stage is thermally compressed to a pressure such that the condensation temperature rises to a point that allows the heat of vaporization to be returned to the source process stage via a heat exchanger and / or transferred to the next process stage. Multiple thermal compressors within the multiple process stages form a parallel vapor flow controlled by valves through the multi-stage process.

[0051] Figure 10 This is a schematic diagram illustrating an exemplary multi-stage process, in which steam from each stage is thermally compressed by multiple compressors configured in a networked parallel and series configuration to a level that allows the heat of vaporization to be returned to the source process stage and / or transferred to the next process stage via a heat exchanger. Multiple parallel thermal compressors allow for greater variation in the flow from each stage via control valves, where the amount of steam moving within a single stage and the amount of steam exchanged between process stages can be selected with better control. Multiple compressors within a single process stage and across multiple process stages form a network of series and parallel steam flows, where mass flow through the multi-stage process is varied via control valves.

[0052] These and other embodiments, features, and advantages of the present invention will become more apparent to those skilled in the art when referred to the following detailed description. Detailed Implementation

[0053] Certain embodiments of the invention will now be described in more detail in a manner that allows those skilled in the art to make and use the invention. All references to "invention" herein should be construed as referring to the non-limiting embodiments disclosed in this patent application.

[0054] Unless otherwise indicated, all numerical values ​​used in the specification and claims to indicate conditions, concentrations, yields, etc., should be understood to be modified by the term "about" in all cases. Therefore, unless otherwise indicated, the numerical parameters listed in the following specification and appended claims are approximations, which may vary at least depending on the specific analytical technique. Any numerical value inherently contains a certain degree of error, which necessarily arises from the standard deviation present in its corresponding experimental measurement.

[0055] As used in this specification and the appended claims, unless the context clearly indicates otherwise, the singular forms “a / an” and “the” include the plural indicators. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. If any definition listed in this section contradicts or otherwise is inconsistent with definitions listed in patents, published patent applications, and other publications incorporated by reference, the definitions listed in this specification shall prevail over those incorporated herein by reference.

[0056] The term "comprising," synonymous with "including," "containing," or "characterized in," is inclusive or open-ended and does not exclude additional, unlisted elements or method steps. "Comprising" is a specialized term used in claims language to mean that the specified claim element is essential, but other claim elements may be added and still constitute a concept within the scope of the claims.

[0057] As used herein, the phrase “consisting of” excludes any element, step, or ingredient not specified in the claims. When the phrase “consisting of” (or variations thereof) appears in a clause of the body of a claim rather than immediately following the preamble, the phrase limits only the element set forth in that clause; other elements are not excluded from the claims as a whole. As used herein, the phrase “substantially constitutes” limits the scope of the claims to the specified elements or method steps, plus those that do not substantially affect the basis of the claimed subject matter and one or more novel features.

[0058] Regarding the terms “comprising,” “consisting of,” and “substantially consisting of,” when one of these three terms is used herein, the currently disclosed and claimed subject matter may include the use of either of the other two terms. Thus, in some embodiments not otherwise explicitly enumerated, any instance of “comprising” may be replaced by “consisting of” or alternatively by “substantially consisting of.”

[0059] In industrial processes, when applying mechanical vapor compression and / or thermal vapor compression, conventional practice tends to optimize isolated compression loops at each process stage. The inventors have recognized that conventional methods sacrifice efficiency. The disclosed method, which integrates compression loops across multiple process stages, is more efficient.

[0060] This invention utilizes mechanical vapor compression and / or thermal vapor compression, integrating compression loops across multiple process stages. A sequential network of compressors is used to increase the pressure and condensation temperature of vapor within each process stage as an internal vapor flow, and as an inter-vapor flow branching between process stages. Because available vapor is shared between compressor stages, the number of compressors can be reduced, improving economics. By separating vapor between compressor stages to balance the vapor mass flow through incremental compressor stages across multiple process stages, the entire vapor compression system can be customized to individual process energy requirements and adapt to dynamic fluctuations in process conditions.

[0061] This invention is at least in part based on incorporating multiple compressors in an integrated network design including series and / or parallel branches, wherein vapor flow control valves balance compressed vapor within and between process stages. The integrated design optimizes process energy use by increasing the pressure and temperature of condensable vapor to a level that allows for the reintroduction of condensation heat into an integrated system across multiple process stages, where all or part of the vapor is returned to the vapor source process stage and / or the next process stage, while simultaneously meeting process requirements for mass flow and pressure / temperature dynamic operating ranges.

[0062] Traditional plant designs typically cascade heat from process stages operating at higher temperatures and their associated pressures, transferring all or part of the process heat to process stages operating at lower temperatures and their associated pressures in order to improve efficiency by reducing overall plant energy requirements. This approach often relies on the thermal energy introduced into the process through fuel combustion. The heat cascading between process stages increases the temperature range to which useful energy can be supplied, but ultimately results in condensation heat loss of the heat carrier when the vapor from the lower-temperature process stage is then cooled and returned to liquid form. Passive cascading of heat between process stages involves conditioning process conditions by restricting mass flow and / or increasing process heat, leading to condensation of the lowest-level flow (lowest temperature and pressure) and the loss of condensation heat of that flow.

[0063] In contrast, the inventors have discovered that integrating multiple process stages via intra- and inter-stage integrated compression provides a means to significantly improve the process energy efficiency of existing process stages (e.g., distillation columns and reaction vessels) and optimize process conditions, as well as to increase flexibility in adapting to process dynamics. This integrated system with internal / inter-compression vapor control allows for the customization of process conditions to reduce fouling, alter process water balance, and meet other operational objectives that are not achievable with simpler process designs that utilize only cascaded heat between process stages. Capturing the heat carrier in vapor form prior to condensation and increasing its pressure and temperature through compression allows condensation to occur at higher condensation temperatures in the heat exchanger, thus allowing for the return of condensation heat under conditions that can be reused throughout the process. This configuration recovers process heat that would otherwise be lost to cooling towers and / or the atmosphere.

[0064] Traditional applications of vapor compression within process stages, such as in single-stage evaporation, lack the more complex balancing and system design challenges of multi-stage integrated systems. While conventional recompression methods offer high efficiency at individual process stages, they limit the total potential cumulative benefits of a "whole plant" approach, as disclosed in this paper, which leverages process synergies to expand available design options across intra- and inter-process stages.

[0065] The more sophisticated methods disclosed herein allow for process optimization to meet environmental, economic, or efficiency objectives, or a combination of these objectives. However, the complexity of this invention is not beyond the skill of a chemical engineer, as will be understood by a person skilled in the art who reads this disclosure. Advanced control systems, including the use of network optimization algorithms, can support the efficient control of the more complex compressor arrays of this invention in integrated system designs. For example, linear programming or stochastic Monte Carlo simulations can use system design conditions and / or probability distributions describing how system process conditions change over time to optimize process performance by adjusting the vapor compression subsystem. Increasing the speed and power of individual compressors, shutting down or opening parallel compressors, and adjusting flow valves to control system mass flow rates provide methods for system performance tuning, allowing for the achievement of various potential objectives, including (but not limited to) reducing carbon intensity, increasing process efficiency, or reducing operating costs.

[0066] According to embodiments of the invention, a meaningful and substantial reduction in the thermal energy use of industrial processes will also significantly reduce the carbon intensity attributable to the plant process. In a standard refinery without mechanical vapor compression, the energy demand of the process stages accounts for the majority of the total process energy, with a small amount of additional electrical process energy used for pumping, agitation, and fan operation.

[0067] When used in separation process stages, mechanical vapor compression recovers process heat via a closed-loop heat pump method, as described in U.S. Patent No. 6,375,803 to Razzaghi et al., issued April 23, 2002, which is incorporated herein by reference. See also WO 2013 / 116789 A1 to Batty et al., published August 8, 2012, which is also incorporated herein by reference. In systems using best mechanical vapor compression design practices, the mechanical energy required for compression is equivalent to approximately 10% to 20% of the discharged heat energy compared to the mechanical energy required for the same process stage without compression. The advantage of the compression loop is limited to the temperature difference within the cycle, where smaller temperature differences produce the greatest advantage.

[0068] This invention provides the integration of mechanical vapor compression and / or thermal vapor compression in multiple vapor processing units to reduce process energy in industrial refining or other industrial processes. Several examples are provided to demonstrate possible configurations for using mechanical or thermal vapor compression in liquid-gas fractionation or other vapor processing for general refining or biorefining processes.

[0069] The term "process energy" in this article refers to the thermal energy required to generate process steam by burning fuel, the electrical energy required to directly heat the process by burning fuel, and the electrical energy required for mechanical power, such as the electrical energy used for pumping.

[0070] The term "process stage" in this document refers to a unit operation within an entire process or system (e.g., a refinery). Generally, a process employs multiple separate process stages. Unless otherwise indicated, the term "process" refers to the entire process of converting feedstock into a final product. A process stage can be viewed as a step within the entire process. A process stage can also be viewed as a subsystem of the entire system. That is, depending on the context, a process stage can refer to a process step or a physical subsystem; unless otherwise indicated, a process stage will refer to a process step. A process stage as a physical subsystem can be a steam processing unit. Steam processing units may include, but are by no means limited to, distillation units, stripping units, flash evaporators, single-effect evaporators, multi-effect evaporators, molecular sieve units, and chemical reactors.

[0071] When the steam processing unit is a chemical reactor (e.g., a catalytic reactor), such a reactor can be used for chemical reactions selected from the group consisting of: for example, oxidation, reduction, hydrolysis, transesterification, condensation, oligomerization, polymerization, crystallization, isomerization, reforming, cracking, dehydrogenation sulfidation, hydrotreating, alkylation, hydrogenation, dehydrogenation, dehydration (olefin formation), cyclization, coking, catalyst regeneration, and combinations thereof.

[0072] The term "multi-stage process" (equivalent to "multi-stage process") used herein refers to methods and systems for converting precursor feedstocks into a mixture of components that require separation, purification, and / or refining to separate the finished product. The sufficiently purified finished product has value as a precursor for further reaction processes or commercial value in its natural state. A multi-stage process comprises at least two process stages, such as 2, 3, 4, 5, 6, 7, 8, 9, 10, or more. For example, refineries typically employ multiple fractionation to purify multiple product streams. Exemplary multi-stage process methods and systems include, but are not limited to, biorefineries, oil refineries, petrochemical plants, natural gas refineries, shale oil refineries, coal-derived product refineries, and syngas-derived product plants. Unless otherwise indicated, "refinery" is a generic term and also encompasses biorefineries.

[0073] The use of vapor compression provides a means to increase the temperature and pressure of vapors so that their heat of condensation can be used for upstream and downstream processing. Standard practice involves using cooling water to condense vapors at low temperatures when forming final products or intermediate process sub-products, losing the heat of condensation to the cooling water and thus preventing the reintroduction and reuse of this heat. Vapor compression allows the reuse of the heat of condensation when the increased pressure raises the condensation temperature to a level higher than required for use in the process. Vapor compression has long been established in single-process applications such as seawater desalination and evaporation.

[0074] For decades, the concept of mechanical vapor compression in distillation has been used to reduce process requirements in refining. This concept has also been widely applied in seawater desalination and process evaporation. When used in distillation, mechanical vapor compression recycles the heat of distillation via a closed-loop heat pump, as disclosed in, for example, the following U.S. Patent Nos.: 4,340,446, 4,422,903, 4,539,076, 4,645,569, 4,692,218, 4,746,610, 5,294,304, 7,257,945, 8,101,217, 8,101,808, 8,114,255, 8,128,787, 8,283,505, 8,304,588, 8,535,413, and 8,614,077, which are hereby incorporated herein by reference. When used for distillation, evaporation, dehydration, and drying, the latent heat of the hot vapor is recirculated via a closed-loop heat pump, as disclosed, for example, in U.S. Patent Nos. 5,772,850, 4,536,258, and 4,585,523, which are hereby incorporated herein by reference.

[0075] In this disclosure, mechanical vapor recompression (MVR) and / or thermal vapor recompression (TVR) are preferably used to produce steam that meets the required conditions to best integrate and optimize energy recovery between process stages and reduce total process heat energy usage in the refinery. The condensation heat of the compressed steam provides energy that can be used to integrate other parts of the refinery. Multi-effect, thermal vapor recompression, and / or mechanical vapor recompression heat exchangers are used to balance process conditions to meet process design requirements by increasing or decreasing steam energy.

[0076] All instances of “vapor compression,” “vapor recompression,” MVR, TVR, etc., mean mechanical vapor recompression, thermal vapor recompression, or a combination thereof. Thermal vapor recompression may also be referred to as thermal compression or vapor compression. Also included is the commonly owned U.S. Patent Application No. 15 / 711,699, filed September 21, 2017 (and published February 1, 2018 as US 2018 / 0028934A1), whose description of mechanical vapor compression, thermal vapor compression, and other features applicable to some embodiments of the present invention is hereby incorporated by reference.

[0077] Some variations of the present invention provide a multi-stage energy integration process comprising:

[0078] (a) Providing a common configuration for converting raw materials into one or more products in a continuous or semi-continuous manner, wherein the multiple process stages utilize gas-liquid phase change;

[0079] (b) Providing a vapor compression system, wherein the vapor compression system comprises at least a first vapor compressor and a second vapor compressor, wherein the first vapor compressor is a mechanical vapor compressor or a hot vapor compressor, and wherein the second vapor compressor is a mechanical vapor compressor or a hot vapor compressor;

[0080] (c) The first and second vapor compressors are arranged sequentially to increase the pressure and condensation temperature of the first vapor in the first process stage and the second vapor in the second process stage downstream of the first process stage, thereby providing compressed first vapor and compressed second vapor;

[0081] (d) directing at least a portion of the compressed first vapor to (i) the second stage, (ii) a process stage downstream of the second stage, if any, (iii) a process stage upstream of the first stage, if any, or (iv) a combination thereof.

[0082] (e) Optionally, at least a portion of the compressed second vapor is directed to (i) the first process stage, (ii) a process stage upstream of the first stage, if any, (iii) a process stage downstream of the second stage, if any, or (iv) a combination thereof.

[0083] (f) Optionally, at least a portion of the compressed first vapor is directed back to the first stage; and

[0084] (g) Optionally, at least a portion of the compressed second vapor is directed back to the second stage.

[0085] Raw materials may include fossil hydrocarbons, renewable bio-based natural matrices (which may be mechanically or chemically pretreated), or combinations thereof.

[0086] In some embodiments, at least one of steps (e), (f), and (g) is performed, or at least two of steps (e), (f), and (g) are performed, or all of steps (e), (f), and (g) are performed.

[0087] For example, multiple process stages can be at least three process stages.

[0088] In some embodiments, at least one of the first or second process stages is selected from distillation, evaporation, stripping, molecular sieve treatment, chemical reactions, and combinations thereof. When the process involves chemical reactions, the chemical reactions may be selected from the group consisting of, for example, oxidation, reduction, hydrolysis, condensation, transesterification, oligomerization, polymerization, crystallization, isomerization, reforming, cracking, dehydrogenation sulfidation, hydrotreating, alkylation, hydrogenation, dehydrogenation, dehydration (olefin formation), cyclization, coking, catalyst regeneration, and combinations thereof.

[0089] The compressed first vapor contains process vapor (e.g., hydrocarbons or alcohols) and may further contain steam. The compressed second vapor also contains process vapor and may further contain steam. In a preferred embodiment, the compressed first vapor consists of more than just steam, and the compressed second vapor consists of more than just steam.

[0090] In some embodiments, the third steam compressor is configured to compress a heat exchange medium that does not come into contact with the third steam in the third process stage (becoming compressed third steam), and wherein the third steam compressor is a mechanical steam compressor or a thermal steam compressor. The compressed third steam comprises process steam and may further comprise steam. In a preferred embodiment, the compressed third steam consists of more than just steam.

[0091] Multi-stage energy integration processes can be implemented, for example, in biorefineries, oil refineries, chemical plants, petrochemical plants, biochemical plants, natural gas refineries, shale oil refineries, coal-derived product refineries, or syngas-derived product plants.

[0092] Other variations of the invention provide a multi-stage energy integration system comprising:

[0093] (a) A plurality of process subsystems configured to continuously or semi-continuously convert feedstocks into one or more products, wherein the plurality of process subsystems are configured to utilize a gas-liquid phase change; and

[0094] (b) A vapor compression subsystem, wherein the vapor compression subsystem comprises at least a first vapor compressor and a second vapor compressor, wherein the first vapor compressor is a mechanical vapor compressor or a hot vapor compressor, and wherein the second vapor compressor is a mechanical vapor compressor or a hot vapor compressor.

[0095] The first and second vapor compressors are arranged and configured sequentially to increase the pressure and condensation temperature of the first vapor in the first process subsystem and the second vapor in the second process subsystem, wherein the second process subsystem is physically separated from the first process subsystem but is in fluid communication with it;

[0096] The first steam compressor is in fluid communication with the second or third process subsystem via a first compressed steam pipeline, wherein the first compressed steam pipeline is equipped with a first control valve;

[0097] Optionally, the second steam compressor is in fluid communication with the first process subsystem, the third process subsystem, or the fourth process subsystem via a second compressed steam line, wherein the second compressed steam line is equipped with a second control valve;

[0098] Optionally, the first vapor compressor is in fluid communication with the first process subsystem; and

[0099] Optionally, the second steam compressor is in fluid communication with the second process subsystem.

[0100] In some embodiments, the first vapor compressor is in fluid communication with the second process subsystem. In these or other embodiments, the first vapor compressor is in fluid communication with the third process subsystem.

[0101] In some embodiments, the second vapor compressor is in fluid communication with the first process subsystem. In these or other embodiments, the second vapor compressor is in fluid communication with a third and / or fourth process subsystem.

[0102] Alternatively or additionally, the first steam compressor may be in fluid communication with the first process subsystem. The second steam compressor may be in fluid communication with the second process subsystem.

[0103] For example, multiple process subsystems can be at least three process subsystems.

[0104] At least one of the first or second process subsystems may be selected, for example, from a distillation unit, an evaporation unit, a stripping unit, a molecular sieve unit, a chemical reactor, or a combination thereof.

[0105] In some embodiments, the third steam compressor is configured to compress a heat exchange medium that does not come into contact with a third steam within the third process subsystem, wherein the third steam compressor is a mechanical steam compressor or a thermal steam compressor.

[0106] Multi-stage energy integration systems can be, for example, part or all of a biorefinery, oil refinery, chemical plant, petrochemical plant, biochemical plant, natural gas refinery, shale oil refinery, coal derivatives refinery, or syngas derivatives plant.

[0107] Certain embodiments of the present invention will now be described in more detail to enable those skilled in the art to make and use the invention. It should be noted that all references to "invention" herein should be interpreted as references to embodiments of the invention.

[0108] Figures 1 to 10 Each diagram illustrates a typical process flow of a refinery, comprising multiple process stages producing products A, B, C, and D (without limitation on the quantity of any specific product produced). Each of these diagrams features a feedstock described as a precursor, which can be, for example, petroleum, petrochemical products, biochemical products, or renewable streams (e.g., derived from biomass). The typical refining process stages are configured to extract mixtures of compounds using conventional refining methods. The compounds may be fed to reactor vessels, where they undergo chemical reactions or processing to produce portions of the products, which are then separated through process stages such as distillation, evaporation, or countercurrent flow.

[0109] Figure 1 This illustrates the process of transporting precursors to a multi-stage process. The process stages are arranged in a configuration where the product of each stage flows from a higher temperature to a lower temperature. Figure 1 A standard process is described, in which there is no heat reuse between stages. Each process stage has a condenser, through which the process heat of each stage is discharged.

[0110] Figure 2 A multi-stage process is illustrated, where each stage is organized such that an upstream stage, having a higher temperature than the downstream stage, can transfer heat from the upstream stage to the downstream stage via a non-contact heat exchanger. The final stage in the cascade chain has a condenser in which process heat from the final stage is discharged.

[0111] Figure 1 Multiple process stages are described, without the benefits of thermal cascading or mechanical vapor compression. Figure 2 With Figure 1The same process configuration is understood to mean that each subsequent process stage is at a higher temperature than the next process stage, and that the process heat is partially or completely cascaded to the next process. Figure 1 and Figure 2 Each includes a multi-stage process for reacting and / or separating the mixture into sub-components. Figure 1 Multiple process stages for forming a mixture and separating it into sub-components are shown, each driven by steam generated by boiler heat from a combustion boiler or steam and steam condensed in a condenser. Figure 2 The same process stages are shown, arranged in sequence from the highest temperature process stage to the lowest temperature process stage, wherein steam from each process stage is transferred to the next process stage, and the heat of condensed steam is cascaded to the next process stage, wherein the final process stage transfers the heat of condensation of steam to a single condenser. Figure 1 and Figure 2 It represents traditional technology.

[0112] Figure 3 This is a schematic diagram illustrating a multi-stage process, in which vapor from each stage is mechanically compressed to a pressure such that the condensation temperature rises to a point where the heat of vaporization can be returned to the process stage via a heat exchanger and / or transferred to the next process stage. Multiple mechanical compressors within the multiple process stages form parallel vapor flows through the multi-stage process. The final process stage in the multi-stage process can transfer a portion of the vapor to the final condenser to balance the total process heat flux.

[0113] Figure 4 This is a schematic diagram illustrating a multi-stage process where vapor from each stage is mechanically compressed by multiple compressors configured in parallel to a level that allows the heat of vaporization to return to the process stage and / or be transferred to the next process stage via a heat exchanger. Multiple parallel mechanical compressors allow for greater variation in the flow from each stage. The amount of vapor moving within a single stage and the amount of vapor exchanged between process stages can be selected with better control. Multiple compressors within a single process stage and across multiple process stages form a network of series and parallel vapor flows through the multi-stage process. The ability to close parallel branches provides a wider operating range to accommodate higher mass flow variability. The final process stage in a multi-stage process can transfer a portion of the vapor to the final condenser to balance the total process heat flux.

[0114] Figure 5This is a schematic diagram illustrating a multi-stage process, in which vapor from each stage is thermally compressed to a pressure such that the condensation temperature rises to a point that allows the heat of vaporization to be returned to the process stage via a heat exchanger and / or transferred to the next process stage. Multiple thermal compressors within the multiple process stages form parallel vapor flows through the multi-stage process. The final process stage in the multi-stage process can transfer a portion of the vapor to the final condenser to balance the total process heat flux.

[0115] Figure 6 This is a schematic diagram illustrating a multi-stage process where vapor from each stage is thermally compressed by multiple compressors configured in parallel to a level that allows the heat of vaporization to be returned to the process stage via a heat exchanger and / or transferred to the next process stage. Multiple parallel thermal compressors allow for greater variation in the flow from each stage, thus allowing for greater control over the selection of the amount of vapor moving within a single stage and the amount of vapor exchanged between process stages. Multiple compressors within a single process stage and across multiple process stages form a network of series and parallel vapor flows in a multi-stage process. The ability to close parallel branches provides a wider operating range to accommodate higher mass flow variability. The final process stage in a multi-stage process can transfer a portion of the vapor to a final condenser to balance the total process heat flux.

[0116] It should be understood that, although Figure 3 and Figure 4 And most of the content in this specification, when using mechanical vapor compression, refers to balanced mechanical vapor compression within a single process stage and between multiple process stages. The path of the compressed vapor can alternatively be driven by multiple compressors configured in series and / or parallel paths to achieve optimal reuse of process heat throughout the group of process stages. Similarly, it will also be understood that, although Figure 5 and Figure 6 Much of this specification, when referring to the use of hot vapor compression, refers to hot vapor compression balanced within a single process stage and between multiple process stages. The path of the compressed vapor can alternatively be driven by multiple compressors configured in series and / or parallel paths to achieve optimal reuse of process heat throughout the group of process stages. In some embodiments, any instance of a single compressor can be replaced by multiple compressors.

[0117] Figures 3-6 Each of these includes a multi-stage process for reacting and / or separating the mixture into sub-components. Figure 3 and Figure 4 Mechanical vapor compression is described, while Figure 5 and Figure 6 The compression of hot steam is described. Figures 3-6 In each of these processes, a portion of the steam returns process heat to the process stage via a reboiler, and another portion of the steam is transferred to other integrated process stages. Figure 4 and Figure 6 By utilizing the complex structure of the compressor, in which steam can be delivered via a network of series or parallel stages, more options are available for the combination of paths that steam can share throughout the process.

[0118] In some embodiments, the available mass flow is distributed between different process stages, and each vapor can be directly condensed for heat recovery within the source process stage. Alternatively or additionally, each vapor can be condensed to produce another vapor composition by using a heat exchanger that drives another process stage.

[0119] For example, a schematic flowchart ( Figure 1-10 Each of the multi-stage processes described in the document is typically a refining process that produces a mixture of products purified by countercurrent fractionation and / or evaporation separation processes. Multi-stage processes are not limited by the number of different process stages (at least two process stages will exist).

[0120] In some embodiments, multiple process steps or stages are described as follows:

[0121] 1) Precursor feedstocks, such as petroleum, natural agricultural products, or petrochemical precursors, are fed into an initial refining process stage with separation / purification processing; the initial refining process stage may include transferring subclasses of chemicals to a reaction vessel, where downstream components are separated or purified to produce feedstock materials.

[0122] 2) Countercurrent fractionation physically separates the raw material into multiple sub-product streams, each of which is rich in a subset of components;

[0123] 3) In the separation stage, components with lower boiling point temperatures are vaporized in the countercurrent reaction / separation / evaporation multi-stage subsystem (note that "separation" can include "fractional distillation");

[0124] 4) The separation stage then condenses the components with higher boiling point temperatures as liquid components that move downwards into the reaction / separation / evaporation multi-stage subsystem;

[0125] 5) Fractional separation is driven by boiling higher-temperature boiling point components at the bottom of the reaction / separation / evaporation multi-stage subsystem, as the higher-temperature boiling point components move upward as vapor, while the countercurrent liquid moves downward to the reaction / separation / evaporation multi-stage subsystem.

[0126] 6) The countercurrent reaction / separation / evaporation multi-stage subsystem dynamically forms a temperature gradient with the highest temperature at the bottom and the lowest temperature at the top along the vertical length of the subsystem;

[0127] 7) The heat driving the multi-stage reaction / separation / evaporation subsystem enters from the bottom and exits from the top as vapor containing a subset of components from the feedstock;

[0128] 8) The bottom component of the reaction / separation / evaporation multi-stage subsystem can be boiled by burning fuel to drive fractionation, wherein the top product is condensed and / or the top vapor is compressed to a higher pressure, raising the condensation temperature to a temperature higher than the bottom boiling temperature to recover heat from the fractionation system, or the heat from the condensation of the top product can be transferred to a separate medium (e.g., steam or ammonia vapor) through a non-contact reboiler, wherein the medium is compressed to a certain temperature to allow the heat from the fractionation system to be recycled to the bottom product via a reboiler of a specific stage, and / or a portion of the vapor can be transferred to the process stage before or after a specific stage;

[0129] 9) Valve control allows compressed vapor to return between the source process stage and the next process stage, thereby allowing for a balance of vapor flow within / between stages;

[0130] 10) Multiple fractionation / evaporation for separation is used in complex refining stages where many components are purified into the final product; and

[0131] 11) Multiple fractionation / evaporation can be employed, in which the product mixture is refined in multiple stages driven by combustion fuel and / or driven by compression of the top product vapor from the fractionation / evaporation stages.

[0132] A typical multi-stage process generally refers to one or more reaction / separation / evaporation stages, each requiring energy in the form of thermal / fuel or mechanical / electrical energy. Thermal and mechanical energy provide heat to drive the separation of the mixture into a set of refined products or a series of stages that produce a final, high-quality product. The energy portion provided by fuel combustion can be adjusted and / or balanced with the heat portion provided by mechanical vapor compression and / or thermal vapor compression from electric and / or thermally driven compressors to meet the energy management requirements of each stage of the process.

[0133] The mechanical and / or thermal energy required by the compressor in a closed loop will be less than the thermal energy recovered in the process energy distribution of the multi-stage reaction / separation / evaporation subsystem as described above. In standard multi-stage processes, the thermal process energy of each stage constitutes the largest energy consumption, thus offering the greatest potential opportunity to reduce the total process energy. Figure 3 and Figure 4 Two schematic diagrams illustrate examples of different options for using mechanical vapor compression in a multi-stage process, depicting the thermal and electromechanical distribution of energy in this part of the multi-stage process. Figure 5 and Figure 6 The schematic diagram illustrates the thermal vapor compression in a multi-stage process, which describes the thermal distribution of energy in each part of the multi-stage process. Figure 7 and 8This demonstrates the use of mechanical vapor compression with valves to control vapor flow in a multi-stage process. Figure 9 and 10 This demonstrates the use of valved thermal vapor compression to control vapor flow in a multi-stage process.

[0134] Now will describe further. Figures 1-6 The specific components. Each of these process flow diagrams has similar stages and product flow structures, describing a process path starting with a precursor feedstock (including, for example, natural products, petroleum, or petrochemical fractions). The liquid effluent flows via pipe 1 along with a mixture of components to the initial fuel combustion heater vaporizer 2, where the precursor is vaporized. The vaporized mixture is conveyed via pipe 3 to a manifold leading to several process stages, the first of which is pipe 4 leading to reaction vessel 5, where reagent reactants are added via pipe 6. Reaction vessel 5 may, for example, consist of oxidation, reduction, molecular fracturing, or reforming processes. The resulting product mixture from the reaction process in vessel 5 is then... Figure 1 Pipe 7 in the middle conveys to the condenser 8. Figure 1 It has a condenser 8, in which cooling water is condensed and the heat of the first stage is discharged by the liquefaction of product A, which is conveyed via pipe 9. Figure 2 Vapor is condensed in a non-contact heat exchanger 8, where heat from the first-stage process is cascaded to the second-stage process. In all figures, the condensed product A is conveyed via pipe 9, whereby product A can be conveyed as a finished product via pipe 9, and the remainder of product A is conveyed via pipe 10 to container 11 for further processing.

[0135] The reaction vessel 5 can be configured to perform processes such as oxidation, reduction, hydrocracking, molecular fractionation, reforming, transesterification, isomerization, or hydrolysis, or combinations thereof.

[0136] Figure 1 It has a condenser 8 in which the process heat of the first stage is discharged. Figure 2 It has a heat exchanger 8, in which the process heat of the first stage is cascaded to the second process stage, and the container 5 is under a sufficiently high pressure to allow the vapor to pass through the heat exchanger above the condensation temperature. Figure 3 It has a mechanical compressor 7-1-1 and Figure 5 It has a heat compressor 7-1-1, which compresses the vapor from container 5 through pipe 7 to a pressure higher than the condensation conditions in heat exchanger 8, allowing container 5 to have lower pressure and temperature, while the compressor 7-1-1 reaches a sufficiently high pressure to allow the vapor in pipe 7-1-2 to condense in heat exchanger 8. Figure 4 and Figure 6 With Figure 3 and Figure 5The same compression circuit via compressor 7-1-1 is described, while having an additional parallel compressor 7-2-1, in Figure 4 In the case of a mechanical steam compressor, while Figure 5 In this case, it is a hot steam compressor.

[0137] Figure 3 and Figure 5 Each has a compressor 7-1-1, which transmits balanced and distributed compressed vapor between container 5 and heat exchanger 8 via pipe 7-1-2 and between compressor 13-1-1 via pipe 7-1-3. Figure 3 and Figure 5 The amount of vapor product A condensed in heat exchanger 8 can be changed, with the remainder being transferred to the second stage, compressor 13-1-1, via pipe 7-1-3. Figure 4 and Figure 6 Having similar Figure 3 and Figure 5 The compressor 7-1-1 has the same conditions for recompressing vapor in the heat exchanger 8, but the additional compressor 7-2-1 configured in parallel with the compressor 7-1-1 allows for greater variation in the flow when the two compressors are running at different speeds. Figure 4 and Figure 6 A second mechanical compressor 7-2-1 is shown, wherein compressed vapor is delivered to heat exchanger 8 via pipe 7-2-2, and the amount of vapor delivered to the next stage of the process via pipe 7-2-3 can be optionally balanced.

[0138] Figure 5 and Figure 6 Each has a portion of the liquid condensate from exchanger 8 returned to the hot steam compressor drive heater 7-1-5 to generate motive steam to drive the hot compressor via pipe 7-1-4. The generated steam is then transferred to the hot steam compressor 7-1-1 via pipe 7-1-6, and... Figure 6 The system also drives a parallel hot steam compressor 7-2-1, wherein the hot steam compressor 7-1-1 is driven by the hot steam compressor 7-2-1 via pipe 7-2-6.

[0139] In each of the attached figures, steam from container 5 is transmitted through pipe 7. Figure 1 Condensation occurs in condenser 8, or... Figures 2-6 The liquid condensate is condensed in heat exchanger 8. The liquid condensate is transferred via pipe 9, and a portion of product A is discharged from the system or transferred via pipe 10 to container 11.

[0140] Figure 1 The process stages are shown to operate independently of each other, as process heat is dissipated from each process stage. Figure 2The diagram illustrates the process stages, where the temperature of each stage is higher than that of the next stage, a portion of the process heat is cascaded to the next stage, and the final stage removes the remaining heat. Figure 3 , 4 In steps 5 and 6, each process stage does not require decreasing (stage-to-stage) condensing pressure and temperature in the downstream stage. This is because mechanical and / or thermal compressors can be configured to regulate conditions between each stage sufficiently to transfer the desired process heat between stages. Figure 3 , 4 Figures 5 and 6 illustrate the various process stages in which process heat from each stage (e.g., reaction, fractionation, separation, or evaporation) is transferred forward to the next process stage and / or returned to the original process stage.

[0141] Figures 1-6 Each shows a second-stage container 11 driven by steam from pipe 12. Figure 1 The second-stage container 11 is shown, which is driven by steam from vaporizer 2 through pipe 3 and then through pipe 12. Figures 2-6 Each is shown as a container 11 driven by steam via pipe 12, wherein the liquid precursor is conveyed via pipes 1-12 to a heat exchanger 8, where the liquid is vaporized and conveyed via pipe 12 to container 11. Figures 1-6 Each of them shows steam from the second-stage container 11 being conveyed via pipe 13. Figure 1 The diagram shows steam being transferred from pipe 13 to condenser 14, while Figure 2 The diagram shows steam being transferred from pipe 13 to heat exchanger 14. Figure 3 and Figure 4 Pipe 13 leading to mechanical compressor 13-1-1 is shown. Figure 5 and Figure 6 Pipe 13 leading to heat compressor 13-1-1 is shown. Figure 4 It has an additional mechanical compressor 13-2-1. Figure 6 An additional heat compressor 13-2-1 is provided, which leads to pipe 13-1-2. Figure 4 and Figure 6 Each has an additional pipe 13-2-2, which delivers compressed steam to heat exchanger 14 via pipe 13-1-2. Figures 3-6 Each is shown as pipe 13-1-3, which provides the option to transfer a portion of the steam to the next process stage, wherein Figure 4 and Figure 6 The additional pipe 13-2-3 from the parallel compressor path is shown.

[0142] Figures 1-6Each of them shows the second-stage vapor condensate B conveyed via pipe 15, such that a portion of the liquid can be separated between the final product and the container 17 conveyed via pipe 16 to the third-stage process.

[0143] Figure 5 and Figure 6 Each has an additional condensate diversion from exchanger 14, which delivers liquid back to the hot steam compressor drive heater 13-1-5, which generates motive steam to drive the hot compressor via pipe 13-1-4. The generated steam is delivered to the hot steam compressor 13-1-1 via pipe 13-1-6, and... Figure 6 In the case of the same situation, the hot steam compressor 13-2-1 is also driven in parallel, wherein the hot steam compressor 13-1-1 is driven by the hot steam compressor 13-2-1 via pipe 13-2-6.

[0144] Figures 1-6 Each of them shows a third-stage container 17 driven by steam from pipe 18. Figure 1 The third-stage container 17 is shown, which is driven by steam from vaporizer 2 through pipe 3 via pipe 18. Figures 2-6 Each is shown as a container 17 driven by steam via pipe 18, wherein the liquid precursor is conveyed via pipes 1-18 to heat exchanger 14, where the liquid is evaporated and conveyed via pipe 18 to container 17. Figures 1-6 Each of them shows steam from the third-stage container 17 being conveyed via pipe 18. Figure 1 The diagram shows steam from pipe 19 being transferred to condenser 20, while... Figure 2 The steam from pipe 18 is shown being transferred to heat exchanger 20. Figure 3 and Figure 4 The diagram shows that pipe 19 delivers steam to mechanical compressor 19-1-1, and... Figure 4 It is then transferred to an additional mechanical compressor 19-2-1. Figure 5 and Figure 6 Each sends its steam to the heat compressor 19-1-1. Figure 4 In the middle, an additional pipe 19-2-2 conveys the compressed steam to the heat exchanger 20. Figure 6 In the middle, the additional heat compressor 19-2-1 sends steam to pipe 19-1-2. Figures 3-6 Each of these shows pipe 19-1-3, which provides the option to transfer a portion of the steam to the next process stage, in which Figure 4 and Figure 6 The additional pipe 19-2-3 from the parallel compressor path is shown.

[0145] Figures 1-6Each of them shows the third-stage vapor condensate B conveyed via pipe 21, where a portion of the liquid can be balanced between the final product and the container 23 conveyed via pipe 22 to the fourth-stage process.

[0146] Figure 5 and Figure 6 Each shows an additional portion of the condensate from exchanger 20, returning the liquid to the hot steam compressor drive heater 19-1-5 to generate motive steam to drive the hot compressor via pipe 19-1-4. The generated steam is then conveyed to the hot steam compressor 19-1-1 via pipe 19-1-6, and... Figure 6 The system also drives a parallel hot steam compressor 19-2-1, wherein the hot steam compressor 19-1-1 is driven by the hot steam compressor 19-2-1 via pipe 19-2-6.

[0147] Figures 1-6 Each of them shows a fourth-stage container 23 driven by steam from pipe 24. Figure 1 The fourth stage container 23 is shown, which is driven by steam from vaporizer 2 through pipe 3 via pipe 24. Figures 2-6 Each is shown as a container 23 driven by steam via pipe 24, wherein the liquid precursor is conveyed via pipes 1-24 to heat exchanger 20, where the liquid is evaporated and conveyed via pipe 24 to container 23. Figures 1-6 Each of them shows the steam from the fourth-stage container 23 being delivered via pipe 25. Figures 1-6 Each of these also shows vapor from pipe 25 being conveyed to condenser 26 to transfer product D via pipe 27. The fourth product D can be... Figures 3-6 One of them is balanced with the steam from pipe 25, which is then conveyed to Figure 3 and Figure 4 The mechanical compressor 25-1-1 in the middle, or transmitted to Figure 5 and Figure 6 The heat compressor 25-1-1 in the middle, or transmitted to Figure 4 Additional mechanical compressor 25-2-1 in the middle, or transferred to Figure 6 Additional heat compressor 25-2-1 in the middle, or transferred to Figure 4 or Figure 6 Pipe 25-1-2 in the middle, and / or conveyed to Figure 6 Additional pipes 25-2-2 in the process convey compressed vapor to heat exchanger 28, where the condensed product is conveyed as product D via pipe 29, and heat from the fourth process stage evaporates the precursor liquid in heat exchanger 28 via pipes 1-30, where the vapor passes through pipe 30 and the vapor returns to drive the process stage of the entire process. Figures 3-6Each is shown as pipe 25-1-3, which provides the option to transfer a portion of the steam to the next process stage, wherein Figure 4 and Figure 6 The additional pipe 25-2-3 from the parallel compressor path is shown.

[0148] Figure 5 and Figure 6 Additional portions of the liquid condensate from exchanger 28 are shown, returning the liquid to the hot steam compressor drive heater 25-1-5 to generate motive steam to drive the hot compressor via pipe 25-1-4. The generated steam is then conveyed to the hot steam compressor 25-1-1 via pipe 25-1-6, and... Figure 6 The system also drives a parallel hot steam compressor 25-2-1, wherein the hot steam compressor 25-1-1 is driven by the hot steam compressor 25-2-1 via pipe 25-2-6.

[0149] Figure 7 and Figure 8 Mechanical vapor compression is shown, and Figure 9 and Figure 10 The diagram illustrates hot vapor compression, in which a compression output control valve directs the flow of a portion of the vapor to transfer process heat back to the process stage via a reboiler, and / or balances the remaining flow when all or part of the vapor is transferred to other integrated process stages. Figure 8 and Figure 10 The complex structure of the compressor is shown, in which control valves guide the compressed output vapor, which can be delivered in series and / or parallel to the process stages, thus providing more options for the path combinations of vapor flow shared throughout the process stages.

[0150] Figure 7 This is a schematic diagram illustrating a multi-stage process, in which vapor from each stage is mechanically compressed to a pressure such that the condensation temperature rises to a point where the heat of vaporization can be returned to the source process stage via a heat exchanger and / or transferred to the next process stage. Multiple mechanical compressors within the multiple process stages form a valve-controlled parallel vapor flow through the multi-stage process. The final process stage in the valve-controlled multi-stage process can transfer a portion of the vapor to the final condenser to balance the total process heat flux, optionally discharging the portion of vapor that did not return to the process stage.

[0151] Figure 8This is a schematic diagram illustrating a multi-stage process where vapor from each stage is mechanically compressed and controlled by valves and multiple compressors configured in parallel and series, to a pressure that allows the heat of vaporization to be returned to the process stage and / or the next process stage via a heat exchanger. Multiple parallel mechanical compressors controlled by valves allow for greater variation in the flow from each stage, where the amount of vapor moving within a single stage and the amount of vapor exchanged between process stages can be selected with better control. Multiple compressors within a single process stage and across multiple process stages form a network of series and parallel vapor flows through the multi-stage process using control valves. The ability to control flow through valves with parallel branches provides a wider operating range to accommodate higher mass flow variability. The final process stage in a multi-stage process can transfer a portion of the vapor via control valves to the final condenser to balance the total process heat flux.

[0152] Figure 9 This is a schematic diagram illustrating a multi-stage process where vapor from each stage is thermally compressed to a pressure such that the condensation temperature rises to a point that allows the heat of vaporization to be returned to the source process stage via a heat exchanger and / or transferred to the next process stage. Multiple thermal compressors within the multiple process stages form a parallel vapor flow through the multi-stage process, controlled by valves. The final process stage in the valve-controlled multi-stage process can transfer a portion of the vapor to the final condenser to balance the total process heat flux.

[0153] Figure 10 This is a schematic diagram illustrating a multi-stage process where steam from each stage is thermally compressed by multiple compressors in a networked parallel and series configuration to a level that allows the heat of vaporization to be returned to the source process stage and / or transferred to the next process stage via a heat exchanger. Multiple parallel thermal compressors allow for greater variation in the flow from each stage via control valves, where the amount of steam moving within a single stage and the amount of steam exchanged between process stages can be selected with better control. Multiple compressors within a single process stage and across multiple process stages form a network of series and parallel steam flows, where mass flow across the multi-stage process is altered via control valves. The ability to control parallel branches via control valves provides a wider operating range to accommodate higher mass flow variability. As regulated by one or more control valves, the final process stage in a multi-stage process can transfer a portion of the steam to the final condenser to balance the total process heat flux.

[0154] The present invention is shown in some embodiments, in Figure 7 , Figure 8 , Figure 9 ,and Figure 10The process path, which begins with a precursor feedstock (composed of natural products, petroleum, or petrochemical fractions) and exhibits similar stages and product flow structures, is described. The liquid effluent flows via pipe 1, where a mixture of components is conveyed to an initial fuel combustion heater vaporizer 2, where the precursor is vaporized. The vaporized mixture is then conveyed via pipe 3 to a manifold leading to several process stages, with the first manifold being pipe 4 leading to reaction vessel 5. Reagent reactants are added to the reaction vessel via pipe 6. Reaction vessel 5 may be composed of, for example, oxidation, reduction, molecular fracturing, or reforming processes. The resulting product mixture from the reaction process stages in vessel 5 is then... Figure 7 , Figure 8 , Figure 9 and Figure 10 Pipe 7 in the middle conveys to the condenser 8.

[0155] Figure 7 and Figure 8 The mechanical compressor 7-1-1 is shown and Figure 9 and Figure 10 A heat compressor 7-1-1 is shown, which compresses vapor from container 5 via pipe 7 to a pressure higher than the condensation conditions in heat exchanger 8, allowing container 5 to have lower pressure and temperature, while compressor 7-1-1 reaches a sufficiently high pressure to allow vapor in pipe 7-1-2 to condense in heat exchanger 8. Figure 7 , Figure 8 , Figure 9 and Figure 10 Control valves 7-1-2-1 and 7-1-3-1 on the high-pressure side of compressor 7-1-1 are depicted, wherein steam control can be balanced to send compressed steam back to heat exchanger 8 as a source process stage or a subsequent process stage. Figure 8 and Figure 10 With Figure 7 and Figure 9 The same compression circuit via compressor 7-1-1 is also provided with an additional parallel compressor 7-2-1, which has a control valve on the high-pressure side of the parallel compressor 7-2-1. Figure 8 Including mechanical steam compressors and Figure 10 (Including hot steam compressors). Figure 8 and Figure 10 The diagram shows compressed steam controlled by valves 7-2-2-1 and 7-2-3-1 to balance the steam between heat exchangers 8, where heat is returned to the source process stage and / or heat is transferred to the next process stage via pipe 13.

[0156] Figure 8 and Figure 10A compressor 7-1-1, connected in parallel with compressor 7-2-1, is shown that delivers compressed steam in a balanced and distributed manner between container 5 and heat exchanger 8 via pipe 7-1-2 and between compressor 13-1-1 via pipe 7-1-3. Figure 8 As shown, compressed steam is controlled via parallel valves 7-1-2-1 / 7-1-3-1 and 7-2-2-1 / 7-2-3-1, and Figure 10 The amount of vapor product A condensed in heat exchanger 8 can be changed, with the remainder being transferred via pipe 13 to the second stage, compressor 13-1-1 / 13-2-1. Figure 8 and Figure 10 Having similar Figure 7 and Figure 9 The parallel compressor 7-1-1 has the same conditions for recompressing vapor in the heat exchanger 8. An additional compressor 7-2-1 is configured to operate in parallel with compressor 7-1-1 to allow for greater flow rate variations when the two compressors are running at different speeds. Parallel control valves 7-1-2-1 / 7-1-3-1 and 7-2-2-1 / 7-2-3-1 are present.

[0157] Figure 9 and Figure 10 A portion of the liquid condensate from exchanger 8 is returned to the hot steam compressor drive heater 7-1-5 to generate motive steam to drive the hot compressor via pipe 7-1-4. The generated steam is then transferred to the hot steam compressor 7-1-1 via pipe 7-1-6. Figure 10 It also drives a parallel hot steam compressor 7-2-1, wherein the hot steam compressor 7-1-1 is driven by the hot steam compressor 7-2-1 via pipe 7-2-6.

[0158] exist Figure 7 , Figure 8 , Figure 9 and Figure 10 In each of the containers, vapor from container 5 is condensed in condenser 8 via pipe 7. Liquid condensate is transferred via pipe 9, and a portion of product A is discharged from the system or transferred to container 11 via pipe 10.

[0159] Figure 7 , Figure 8 , Figure 9 and Figure 10 A container 11 driven by steam via pipe 12 is shown, wherein a liquid precursor is conveyed via pipes 1-12 to a heat exchanger 8, where the liquid is evaporated and conveyed via pipe 12 to the container 11. Figure 7 , Figure 8 , Figure 9 and Figure 10 The steam from the second-stage container 11 is shown being transported via pipe 13. Figure 7 and Figure 8 The pipe 13 leading to the mechanical compressor 13-1-1 is shown, and Figure 9 and Figure 10 Pipe 13 leading to heat compressor 13-1-1 is shown. Figure 8 An additional mechanical compressor 13-2-1 is shown, and Figure 10 An additional heat compressor 13-2-1 leading to pipe 13-1-2 is shown. Figure 8 and Figure 10 An additional conduit 13-2-2 is shown, which delivers compressed steam via conduit 13-1-2 to heat exchanger 14. Figure 8 and Figure 10 Pipe 13-1-3 is shown, which provides the option to transfer a portion of the steam to the next process stage, as well as an additional pipe 13-2-3 from the parallel compressor path.

[0160] Figure 7 , Figure 8 , Figure 9 and Figure 10 The second-stage vapor condensate B, conveyed via pipe 15, is shown, allowing a portion of the liquid to be separated between the final product and the container 17, which is conveyed via pipe 16 to the third-stage process.

[0161] Figure 9 and Figure 10 The diagram illustrates an additional diversion of condensate from exchanger 14, which returns liquid to the hot steam compressor drive heater 13-1-5, generating motive steam to drive the hot compressor via pipe 13-1-4. The generated steam is then conveyed to the hot steam compressor 13-1-1 via pipe 13-1-6. Figure 10 The system also drives a parallel hot steam compressor 13-2-1, wherein the hot steam compressor 13-1-1 is driven by the hot steam compressor 13-2-1 via pipe 13-2-6.

[0162] Figure 7 , Figure 8 , Figure 9 and Figure 10 The steam generated by container 14 is shown being returned via pipe 18 to drive a previous steam source process stage. Figure 7 , Figure 8 , Figure 9 and Figure 10 A heat exchanger 14 is shown, in which liquid is evaporated and transported via pipe 18, and the generated vapor is returned to the source process vessel 11 and vessel 5 via pipe 18. Figure 7 and Figure 8 This shows that steam from pipe 19-1-2-2 is transferred to heat exchanger 20, while Figure 8 and Figure 10 The pipe 19-2-2-2 is shown to transfer steam to the heat exchanger 20. Figure 7 It has a mechanical compressor 19-1-1, and Figure 8 It has an additional mechanical compressor 19-2-1; Figure 9 It has a heat compressor 19-1-1, and Figure 10 It has an additional heat compressor 19-2-1. Figure 7 , Figure 8 , Figure 9 and Figure 10 Compressed steam is passed through pipe 19-1-2 and Figure 8 and Figure 10 The parallel compressors in the process transfer compressed vapor to heat exchanger 20 via an additional pipe 19-2-2, where the vapor balance controlled by valves 19-1-2-1 and 19-1-3-1 transfers the compressed vapor back to the source process stage or condenser 24 via heat exchanger 20. Figure 8 and Figure 10 The parallel compressor 19-2-2 is shown to transfer steam via pipe 19-1-3 controlled by valve 19-1-3-1 and pipe 19-1-3-2, thereby providing the option to transfer a portion of the steam to condenser 24.

[0163] It should be noted that, regarding the process flow diagram, specific unit operations may be omitted in some embodiments, and other unit operations not explicitly shown may be included in these or other embodiments. Various valves, pumps, instruments, sensors, sampling ports, etc., are not shown in these block flow diagrams. Furthermore, multiple devices (in series or in parallel) can be used for any unit operation. Additionally, solid, liquid, and gaseous flows generated or present within the process can be independently recycled, passed to subsequent steps, or removed / purged from the process at any point.

[0164] In various embodiments specifically involving biorefining plants, the starting biomass feedstock may be selected from crops and / or agricultural residues. In some embodiments, the crops are selected from starch-containing feedstocks such as corn, wheat, cassava, rice, potato, millet, sorghum, or combinations thereof. In some embodiments, the crops are selected from sucrose-containing feedstocks such as sugarcane, sugar beets, or combinations thereof. Lignocellulosic biomass can also be used as a biomass feedstock. Lignocellulosic biomass includes, for example, plants and plant-derived materials, vegetation, agricultural waste, forestry waste, wood waste, paper waste, animal-derived waste, poultry-derived waste, and municipal solid waste.

[0165] Some embodiments incorporate a process control subsystem configured for the automated control of the steam processing unit and the steam compression subsystem. The process control subsystem may utilize artificial intelligence, such as one or more machine learning algorithms, one or more deep learning algorithms, one or more neural networks, or a combination thereof.

[0166] Production volumes or processing capacities can vary widely from small laboratory-scale units to fully commercial-scale refineries (including any pilot, demonstration, or semi-commercial-scale systems). In various embodiments, processing capacities are at least about 1 kg / day, 10 kg / day, 100 kg / day, 1 tonne / day (all tons are metric tons), 10 tons / day, 100 tons / day, 1000 tons / day, 10000 tons / day, or higher.

[0167] A refinery can be a retrofit of an existing plant. In other embodiments, the refinery is a newly built plant. Some embodiments employ a mechanical vapor compression system in conjunction with a standard thermally driven process in the original system to capture synergies. Some embodiments provide retrofitting or expanding a standard refinery (which can be a newly built or existing refinery) with an integrated mechanical vapor compression system. Retrofitting can provide the option of transferring vapor (from a standard thermally driven process) to a mechanical or thermal vapor compression system integrated into the refinery.

[0168] As will be understood by those skilled in the art, the principles of this disclosure can be applied to many refinery or industrial plant configurations other than those explicitly disclosed or described in the accompanying drawings. Various combinations are possible and embodiments selected from several variations can be utilized or modified to obtain additional variations that do not necessarily include all the features disclosed herein.

[0169] In this detailed description, reference has been made to various embodiments of the invention, as well as non-limiting examples and drawings illustrating how the invention can be understood and practiced. Other embodiments, not all of which provide for all the features and advantages set forth herein, may be utilized without departing from the spirit and scope of the invention. The invention encompasses routine experimentation and optimization of the methods and systems described herein. Such modifications and variations are considered to fall within the scope of the invention as defined by the claims.

[0170] All publications, patents, and patent applications referenced in this specification are incorporated herein by reference in their entirety as if each publication, patent, or patent application had been expressly and separately set forth herein. This specification hereby incorporates, by reference, commonly owned U.S. Patent No. 9,925,476, issued March 27, 2018, and U.S. Patent No. 9,925,477, issued March 27, 2018, and U.S. Patent Application No. 15 / 711,699, filed September 21, 2017 (published as U.S. Patent Application Publication No. 2018 / 0028934A1 on February 1, 2018).

[0171] When the above methods and steps indicate that certain events occur in a certain order, those skilled in the art will recognize that the order of certain steps can be modified, and such modifications are made according to variations of the invention. Furthermore, where possible, some of these steps can be performed simultaneously in parallel processes or sequentially.

[0172] Therefore, with regard to variations of the invention, those found within the spirit of this disclosure or equivalent to those in the appended claims, it is intended that this patent also cover those variations. The invention should be defined only by the claims.

[0173] This invention is not for a single steam processing unit for a single process stage, wherein a single steam processing unit has a continuous compressed flow that does not branch into other process stages or other processes.

Claims

1. A multi-stage energy integration process, comprising: (a) Providing a common configuration for converting raw materials into one or more products in a continuous or semi-continuous manner, wherein the multiple process stages utilize gas-liquid phase change; (b) Providing a vapor compression system, wherein the vapor compression system comprises at least a first vapor compressor and a second vapor compressor, wherein the first vapor compressor is a mechanical vapor compressor or a hot vapor compressor, and wherein the second vapor compressor is a mechanical vapor compressor or a hot vapor compressor; (c) The first vapor compressor and the second vapor compressor are arranged sequentially to increase the pressure and condensation temperature of the first vapor in the first process stage and the second vapor in the second process stage downstream of the first process stage, thereby providing compressed first vapor and compressed second vapor; (d) directing at least a portion of the compressed first vapor to (i) the second process stage, or (ii) a process stage downstream of the second process stage, or (iii) a process stage upstream of the first process stage, or (iv) a combination thereof; Furthermore, at least two of steps (e), (f), and (g) are performed. (e) directing at least a portion of the compressed second vapor to (i) the first process stage, or (ii) a process stage upstream of the first process stage, or (iii) a process stage downstream of the second process stage, or (iv) a combination thereof; (f) Guide at least a portion of the compressed first vapor back to the first process stage; as well as (g) At least a portion of the compressed second vapor is directed back to the second process stage.

2. The multi-stage energy integration process as described in claim 1, wherein, The raw materials include fossil hydrocarbons, renewable bio-based natural matrices, or combinations thereof.

3. The multi-stage energy integration process as described in claim 1, wherein, Perform all steps (e), (f), and (g).

4. The multi-stage energy integration process as described in claim 1, wherein, The multiple process stages refer to at least three process stages.

5. The multi-stage energy integration process as described in claim 1, wherein, At least one of the first process stage or the second process stage is selected from distillation, evaporation, stripping, molecular sieve treatment, chemical reaction, and combinations thereof.

6. The multi-stage energy integration process as described in claim 5, wherein, The chemical reaction is selected from the group consisting of: oxidation, reduction, hydrolysis, condensation, transesterification, polymerization, crystallization, isomerization, reforming, cracking, alkylation, hydrogenation, dehydrogenation, dehydration, cyclization, coking, catalyst regeneration, and combinations thereof.

7. The multi-stage energy integration process as described in claim 4, wherein, The vapor compression system further includes a third vapor compressor configured to compress a heat exchange medium that does not come into contact with the third vapor in the third process stage, and wherein the third vapor compressor is a mechanical vapor compressor or a thermal vapor compressor.

8. The multi-stage energy integration process as described in claim 1, wherein, The multi-stage energy integration process is carried out in biorefineries, oil refineries, petrochemical plants, biochemical plants, natural gas refineries, shale oil refineries, coal-derived product refineries, or syngas-derived product plants.

9. A multi-stage energy integration system, comprising: (a) A plurality of process subsystems configured to continuously or semi-continuously convert raw materials into one or more products, wherein the plurality of process subsystems are configured to utilize gas-liquid phase change; as well as (b) A vapor compression subsystem, wherein the vapor compression subsystem comprises at least a first vapor compressor and a second vapor compressor, wherein the first vapor compressor is a mechanical vapor compressor or a hot vapor compressor, and wherein the second vapor compressor is a mechanical vapor compressor or a hot vapor compressor. The first vapor compressor and the second vapor compressor are arranged and configured sequentially to increase the pressure and condensation temperature of the first vapor in the first process subsystem and the second vapor in the second process subsystem. The second process subsystem is physically separated from the first process subsystem but is in fluid communication with it. The first steam compressor is in fluid communication with the second or third process subsystem via a first compressed steam pipeline, wherein the first compressed steam pipeline is equipped with a first control valve; The second steam compressor is in fluid communication with the first process subsystem, the third process subsystem, or the fourth process subsystem via a second compressed steam pipeline, wherein the second compressed steam pipeline is equipped with a second control valve; The first steam compressor is in fluid communication with the first process subsystem; and The second steam compressor is in fluid communication with the second process subsystem.

10. The multi-stage energy integration system as described in claim 9, wherein, The first steam compressor is in fluid communication with the second process subsystem.

11. The multi-stage energy integration system as described in claim 9, wherein, The first steam compressor is in fluid communication with the third process subsystem.

12. The multi-stage energy integration system as described in claim 9, wherein, The second steam compressor is in fluid communication with the first process subsystem.

13. The multi-stage energy integration system as described in claim 9, wherein, The second vapor compressor is in fluid communication with the third process subsystem and / or the fourth process subsystem.

14. The multi-stage energy integration system as described in claim 9, wherein, The first steam compressor is in fluid communication with the first process subsystem, and / or the second steam compressor is in fluid communication with the second process subsystem.

15. The multi-stage energy integration system as described in claim 9, wherein, The plurality of process subsystems are at least three process subsystems.

16. The multi-stage energy integration system as described in claim 9, wherein, At least one of the first process subsystem or the second process subsystem is selected from a distillation unit, an evaporation unit, a stripping unit, a molecular sieve unit, a chemical reactor, and combinations thereof.

17. The multi-stage energy integration system as described in claim 9, wherein, The vapor compression subsystem further includes a third vapor compressor configured to compress a heat exchange medium that does not come into contact with a third vapor within the third process subsystem, and wherein the third vapor compressor is a mechanical vapor compressor or a thermal vapor compressor.

18. The multi-stage energy integration system as described in claim 9, wherein, The multi-stage energy integration system is part or all of a biorefinery, oil refinery, petrochemical plant, biochemical plant, natural gas refinery, shale oil refinery, coal derivatives refinery, or syngas derivatives plant.

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