Device and method for electrothermal catalytic cracking and gasification of crude oil

Abstract

The invention discloses a device and a method for electrothermal catalytic cracking and gasification of crude oil, and relates to the technical field of petrochemical industry. A crude oil inlet and a high-temperature particle inlet are respectively formed in the lower part of the side wall of the cracking reactor, and a pre-lifting gas inlet is formed in the bottom; the upper part of the side wall of the gasification reactor is communicated with the top of the cracking reactor through an outlet pipeline, the bottom is provided with a water vapor inlet, and the top is provided with a cyclone separator; particles are accommodated in the gasification reactor to form bed layer particles; the internal component is arranged in the gasification reactor and comprises a plurality of layers of breathable partition plates and a plurality of flow guide descending pipes; the multiple layers of breathable partition plates are arranged at intervals in the height direction of the gasification reactor; the plurality of flow guide descending pipes respectively penetrate through the corresponding breathable partition plates; and the electromagnetic induction heating assembly sleeves the outer wall of the gasification reactor. According to the device, an oxygen-free induction heating technology is adopted to replace combustion gasification, so that the risk of flash explosion possibly caused by the existence of oxygen is fundamentally eliminated, and the running safety of the device is improved.

Description

Technical Field

[0001] This application relates to the technical field of petrochemical engineering, and particularly to a device and method for electrothermal catalytic cracking and gasification of crude oil. Background Art

[0002] The refining industry is accelerating its transformation towards low-carbonization. In existing technical paths, short-process processing (such as direct steam cracking and catalytic cracking of crude oil) reduces energy consumption by reducing process units, and heat supply electrification (such as electric heating cracking furnaces) reduces direct carbon emissions by replacing fossil fuels for heat supply. The technology of gasifying petroleum coke to produce hydrogen is regarded as the key path for the synergy of resource utilization of refining by-products and clean hydrogen supply.

[0003] Currently, the technology of gasifying coke to produce hydrogen mainly adopts the combustion gasification method or the partial oxidation method. Its typical process flow is as follows: Petroleum coke generated during the refining process and oxygen / enriched air are jointly introduced into the gasifier, and syngas (H2, CO, etc.) is generated through an oxidation reaction under high temperature and high pressure conditions. However, this process requires continuous introduction of high-purity oxygen to maintain the gasification reaction, and flash explosion accidents are likely to occur due to out-of-control oxygen concentration in links such as the feed end of the gasifier and the gas mixing area, posing significant safety hazards. At the same time, the intense exothermic reaction between oxygen and high-temperature coke easily causes local overheating, accelerating the deterioration of the lining material of the reactor. Summary of the Invention

[0004] The embodiments of this application solve the problems raised in the background art by providing a device and method for electrothermal catalytic cracking and gasification of crude oil.

[0005] In a first aspect, the embodiments of this application provide a device for electrothermal catalytic cracking and gasification of crude oil, including:

[0006] A cracking reactor, with a crude oil inlet and a high-temperature particle inlet respectively provided at the lower part of its side wall, and a pre-lift gas inlet provided at the bottom. The crude oil inlet is connected to a crude oil and catalyst mixing device, the high-temperature particle inlet is communicated with the lower part of the side wall of the gasification reactor through an inclined pipeline, and a slide valve is provided on the inclined pipeline;

[0007] A gasification reactor, whose upper part of the side wall is communicated with the top of the cracking reactor through an outlet pipeline, has a steam inlet provided at the bottom, and a cyclone separator is provided at the top for separating cracked oil and gas from particles; the interior of the gasification reactor contains particles to form a bed of particles, and the particles are inert carrier particles;

[0008] The internal structure components are arranged inside the gasification reactor and include multiple layers of breathable partition plates and multiple downward flow guiding pipes; the multiple layers of breathable partition plates are arranged at intervals along the height direction of the gasification reactor for controlling the gradient fluidization of the bed particles; the multiple downward flow guiding pipes respectively penetrate through the corresponding breathable partition plates for guiding the particles to flow downward; wherein, both the internal structure components and the gasification reactor are made of metal materials;

[0009] The electromagnetic induction heating component is sleeved on the outer wall of the gasification reactor for inductively heating the gasification reactor and the internal structure components, and further heating the particles in the gasification reactor;

[0010] The cooling and separation device has its input end connected to the output end of the cyclone separator, its first output end connected to the light cracking product storage area, and its second output end connected to the heavy recycle stream storage area.

[0011] Combined with the first aspect, in a possible implementation manner, the heavy recycle stream storage area is connected to the side wall of the cracking reactor through an output pipeline, and the outlet of the output pipeline is located below the crude oil inlet.

[0012] Combined with the first aspect, in a possible implementation manner, the downward flow guiding pipe includes a circumferential distribution group and a central distribution group;

[0013] The circumferential distribution group is arranged in an equally spaced circular arrangement along the outer edge of the breathable partition plate;

[0014] The central distribution group is located in the central area of the breathable partition plate and is radially distributed;

[0015] The circumferential distribution group and the central distribution group are staggeredly distributed on adjacent breathable partition plates to form a particle radial flow channel.

[0016] Combined with the first aspect, in a possible implementation manner, the downward flow guiding pipe includes a left distribution group and a right distribution group;

[0017] The left distribution group and the right distribution group are symmetrically distributed along the transverse central axis of the breathable partition plate;

[0018] The left distribution group and the right distribution group are staggeredly distributed on adjacent breathable partition plates to form a particle transverse flow channel.

[0019] Combined with the first aspect, in a possible implementation manner, the device for electrothermal catalytic cracking and gasification of crude oil further includes multiple atomizing nozzles; the multiple atomizing nozzles are respectively arranged at the outlet of the output pipeline and the crude oil inlet.

[0020] In combination with the first aspect, in a possible implementation, the catalyst includes at least one of clay, kaolin, red mud, pyrite, calcium hydroxide, calcium oxide, sodium hydroxide, potassium hydroxide, biomass ash, biomass carbon, potassium acetate, sodium acetate, potassium carbonate, sodium carbonate, potassium fatty acid, sodium fatty acid, iron tetroxide, and iron oxide.

[0021] In combination with the first aspect, in a possible implementation, the electromagnetic induction heating assembly includes an upper coil, a middle coil, and a lower coil that are sequentially sleeved on the outer wall of the gasification reactor from top to bottom and are independently temperature-controlled; the temperature ranges of the upper coil, the middle coil, and the lower coil are 700 - 800 °C, 800 - 1000 °C, and 700 - 800 °C, respectively;

[0022] The upper coil, the middle coil, and the lower coil respectively correspond to the upper region, the middle region, and the lower region of the internal structure assembly in the gasification reactor.

[0023] In combination with the first aspect, in a possible implementation, the breathable partition is 3 - 15 layers.

[0024] In a second aspect, an embodiment of the present application provides a method for electrothermal catalytic cracking and gasification of crude oil, including the device for electrothermal catalytic cracking and gasification of crude oil according to the first aspect or any one of the first aspect, and the method further includes:

[0025] S1: Add inert carrier particles into the gasification reactor to form a bed of particles, turn on the electromagnetic induction heating assembly to heat the bed of particles to a preset temperature to obtain high-temperature particles, and transport the high-temperature particles to the high-temperature particle inlet of the cracking reactor through an inclined pipeline, and a slide valve controls the flow rate of the high-temperature particles;

[0026] S2: Mix and atomize the crude oil and the catalyst in a crude oil and catalyst mixing device, and then transport them to the bottom of the cracking reactor through the crude oil inlet, while introducing pre-lift gas from the pre-lift gas inlet; the crude oil contacts the high-temperature particles to undergo a catalytic cracking reaction, generating cracked oil gas and particles with coke attached to the surface, and the cracked oil gas and the particles with coke attached enter the gasification reactor through the outlet pipeline;

[0027] S3: The cyclone separator at the top of the gasification reactor separates the cracked oil gas and the particles with coke attached, and the cracked oil gas is fractionated into light cracked products and heavy recycle streams through a cooling and separation device, and is respectively transported to a light cracked product storage area and a heavy recycle stream storage area;

[0028] S4: The particles with coke attached settle to the bottom of the gasification reactor through a diversion downcomer, introduce steam from the steam inlet, and heat it to catalytic gasification of coke through the electromagnetic induction heating assembly to generate high-temperature particles that are recycled to the cracking reactor.

[0029] In combination with the second aspect, in a possible implementation manner, in step S4:

[0030] The upper coil, middle coil, and lower coil of the electromagnetic induction heating assembly are independently temperature-controlled, corresponding to the upper region, middle region, and lower region of the internal structure assembly in the gasification reactor respectively;

[0031] The following functions are achieved through temperature gradient control:

[0032] Upper region: 700 - 800 °C, the hydrocarbon volatiles remaining on the coke surface are desorbed to avoid cracking and carbon deposition;

[0033] Middle region: 800 - 1000 °C, steam reacts with the catalyst-containing coke through a catalytic gasification reaction to generate H2 and CO, eliminating most of the coke;

[0034] Lower region: 700 - 800 °C, the residual coke is eliminated through a low-temperature gasification reaction, while maintaining the cracking reaction activity to improve product selectivity, and this temperature range is beneficial to ensuring the long-term stable operation of the slide valve and reducing the adhesion of particles.

[0035] One or more technical solutions provided in the embodiments of the present application have at least the following technical effects:

[0036] The device for electrothermal catalytic cracking and gasification of crude oil provided in the embodiments of the present application includes a cracking reactor, a gasification reactor, an internal structure assembly, an electromagnetic induction heating assembly, and a cooling and separation device. The device for electrothermal catalytic cracking and gasification of crude oil provided in the embodiments of the present application successfully realizes the closed-loop operation of the process flow through the ingenious coupling design of the cracking reactor and the gasification reactor. During operation, after the crude oil is fully mixed with the catalyst, it enters from the bottom of the cracking reactor. In the cracking reactor, the crude oil is in direct contact with the circulating high-temperature particles, and a catalytic cracking reaction occurs under the combined action of high temperature and the catalyst. This reaction generates oil and gas as well as particles with coke attached to the surface.

[0037] Subsequently, the oil and gas and these particles with coke attached enter the gasification reactor together. At the top of the gasification reactor, a cyclone separator is provided, whose function is to effectively separate the oil and gas from the particles. The separated oil and gas are subjected to cooling and fractionation treatment to further separate light cracking products and heavy recycle streams. Among them, the light cracking products can be used as valuable chemical raw materials or fuels.

[0038] The particles with coke attached in the gasification reactor form a gradient fluidized state through the synergistic action of multiple layers of breathable baffles and the diversion downcomer. The main function of the diversion downcomer is to guide the particles with coke attached to flow downward. By reasonably controlling the flow rate of the particles in the diversion downcomer, the height of the particle bed above the breathable baffle can be adjusted to ensure uniform particle distribution and stable reaction conditions in the gasification reactor.

[0039] Multiple downward diversion pipes have a large surface area, which provides a sufficient heating contact surface for the electromagnetic induction heating component. Under the induction heating effect of the electromagnetic induction heating component, the particles can be heated quickly and evenly, significantly improving the heating efficiency of the particles. The heated particles and water vapor undergo a catalytic gasification reaction in the gasification reactor to generate synthesis gas such as hydrogen and carbon monoxide. These synthesis gases can be used as clean energy or chemical raw materials and have broad application prospects.

[0040] After the gasification reaction, the coke on the particle surface is consumed, and the particles are regenerated and become high-temperature particles again. These regenerated high-temperature particles then return to the cracking reactor, continuously providing the heat required for the cracking reaction, forming an efficient energy cycle system.

[0041] Compared with the traditional combustion gasification method, this device uses anaerobic induction heating technology to replace combustion gasification, fundamentally eliminating the flash explosion risk that may be caused by the presence of oxygen and improving the safety of the device operation. At the same time, the anaerobic environment avoids the emission of greenhouse gases such as carbon dioxide during the combustion process, effectively reducing carbon emissions and conforming to the current development concept of green and low-carbon. In addition, the directional diversion design of the internal structure components of this device further optimizes the flow paths of the particles and oil gas, improving the reaction efficiency and product quality. Brief Description of the Drawings

[0042] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the following will briefly introduce the drawings required to be used in the description of the embodiments of the present application. Obviously, the drawings in the following description are some embodiments of the present application. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on these drawings.

[0043] Figure 1 Structural schematic of the device for electrothermal catalytic cracking and gasification of crude oil provided by the embodiment of the present application Figure 1 ;

[0044] Figure 2 Structural schematic of the device for electrothermal catalytic cracking and gasification of crude oil provided by the embodiment of the present application Figure 2 ;

[0045] Figure 3 Structural schematic diagram of the internal structure component provided by the embodiment of the present application.

[0046] Icon: 1 - cracking reactor; 11 - crude oil inlet; 12 - high - temperature particle inlet; 13 - pre - lifting gas inlet; 2 - gasification reactor; 21 - steam inlet; 3 - internal structure component; 31 - breathable partition; 32 - diversion down - pipe; 321 - circumferential distribution group; 322 - middle distribution group; 323 - left - hand distribution group; 324 - right - hand distribution group; 4 - electromagnetic induction heating component; 41 - upper coil; 42 - middle coil; 43 - lower coil; 5 - crude oil and catalyst mixing device; 6 - inclined pipe; 7 - outlet pipe; 8 - cyclone separator; 9 - cooling and separation device; 91 - light cracking product storage area; 10 - slide valve; 101 - output pipe. Detailed implementation manners

[0047] The following will clearly and completely describe the technical solutions in the embodiments of the present application with reference to the accompanying drawings in the embodiments of the present application. Obviously, the described embodiments are some, but not all, of the embodiments of the present application. All other embodiments obtained by those of ordinary skill in the art based on the embodiments in the present application without creative efforts shall fall within the protection scope of the present application.

[0048] In the description of the embodiments of the present application, it should be noted that the orientation or positional relationship indicated by the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc. is based on the orientation or positional relationship shown in the accompanying drawings. It is only for the convenience of describing the embodiments of the present application and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, it should not be construed as a limitation to the present application. The terms "first", "second", "third" are only used for descriptive purposes and cannot be construed as indicating or implying relative importance. In addition, the terms "installation", "connection", "connected" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium, and it can be the internal communication of two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the embodiments of the present application can be understood according to specific circumstances.

[0049] The embodiments of the present application provide a device for electro - thermal catalytic cracking and gasification of crude oil, as Figures 1 to 3 shown. The device for electro - thermal catalytic cracking and gasification of crude oil includes a cracking reactor 1, a gasification reactor 2, an internal structure component 3, an electromagnetic induction heating component 4, and a cooling and separation device 9.

[0050] The cracking reactor 1 is provided with a crude oil inlet 11 and a high-temperature particle inlet 12 at the lower part of its side wall respectively, and a pre-lift gas inlet 13 at the bottom. The crude oil inlet 11 is connected to the crude oil and catalyst mixing device 5, and the high-temperature particle inlet 12 is communicated with the lower part of the side wall of the gasification reactor 2 through an inclined pipeline 6, and a slide valve 10 is arranged on the inclined pipeline 6.

[0051] The gasification reactor 2 is communicated with the top of the cracking reactor 1 through an outlet pipeline 7 at the upper part of its side wall, and is provided with a steam inlet 21 at the bottom and a cyclone separator 8 at the top for separating cracking oil gas and particles. The inside of the gasification reactor 2 contains particles to form a bed of particles, and the particles are inert carrier particles. Specifically, multiple groups of cyclone separators 8 can be arranged in the present application. The multiple groups of cyclone separators 8 adopt a series or parallel layout. The primary cyclone separator 8 realizes efficient capture of large-particle-size particles, and the secondary cyclone separator 8 conducts in-depth purification of fine particles, gradually reducing the particle entrainment in the oil gas and ensuring the purity of the cracking products.

[0052] The internal structure component 3 is arranged inside the gasification reactor 2 and includes multiple layers of breathable partition plates 31 and multiple diversion downcomers 32. The multiple layers of breathable partition plates 31 are arranged at intervals along the height direction of the gasification reactor 2 for controlling the gradient fluidization of the bed of particles. The multiple diversion downcomers 32 respectively penetrate through the corresponding breathable partition plates 31 for guiding the particles to flow downward. Among them, both the internal structure component 3 and the gasification reactor 2 are made of metal materials. The breathable partition plates 31 are provided with multiple tiny air holes that can allow gas to pass through. The electromagnetic induction heating component 4 is sleeved on the outer wall of the gasification reactor 2 for performing induction heating on the gasification reactor 2 and the internal structure component 3, and then heating the particles inside the gasification reactor 2;

[0053] The cooling and separation device 9 has its input end connected to the output end of the cyclone separator 8, its first output end connected to the light cracking product storage area 91, and its second output end connected to the heavy recycle stream storage area.

[0054] It should be noted that for the crude oil electrothermal catalytic cracking and gasification device provided by the embodiments of the present application, through the ingenious coupling design of the cracking reactor 1 and the gasification reactor 2, the closed-loop operation of the process flow is realized. During the operation process, after the crude oil and the catalyst are fully mixed and atomized in the crude oil and catalyst mixing device 5, they are transported to the bottom of the cracking reactor 1 through the crude oil inlet 11. At the same time, pre-lift gas is introduced through the pre-lift gas inlet 13 to make the materials more evenly distributed in the reactor. Inside the cracking reactor 1, the crude oil is in direct contact with the circulating high-temperature particles, and under the combined action of high temperature and the catalyst, a catalytic cracking reaction occurs, generating oil gas and particles with coke attached to the surface.

[0055] Subsequently, the oil and gas enter the gasification reactor 2 together with the particles attached with coke. At the top of the gasification reactor 2, the cyclone separator 8 effectively separates the oil and gas from the particles. The separated oil and gas enter the cooling and separation device 9, and through fractional distillation treatment, light cracking products and heavy recycle streams are further separated. The light cracking products can be utilized as valuable chemical raw materials or fuels.

[0056] After the particles attached with coke enter the gasification reactor 2, through the synergistic effect of the multi-layer permeable baffle 31 and the diversion downcomer 32, a gradient fluidization state is formed. The main function of the diversion downcomer 32 is to guide the particles attached with coke to flow downward. By reasonably controlling the flow rate of the particles in the diversion downcomer 32, the height of the particle bed above the permeable baffle 31 can be regulated, ensuring uniform particle distribution and stable reaction conditions in the gasification reactor 2.

[0057] The multiple diversion downcomers 32 have a large surface area, providing a sufficient heating contact surface for the electromagnetic induction heating component 4. Under the induction heating of the electromagnetic induction heating component 4, the particles can be heated quickly and uniformly, significantly improving the heating efficiency of the particles. The heated particles react with water vapor in the gasification reactor 2 to generate syngas such as hydrogen and carbon monoxide. These syngas have low carbon emissions and high hydrogen concentration, and can be used as clean energy or chemical raw materials, with broad application prospects.

[0058] After the gasification reaction, the coke on the particle surface is consumed, and the particles are regenerated and become high-temperature particles again. These regenerated high-temperature particles return to the cracking reactor 1 through the inclined pipe 6, continuously providing the heat required for the cracking reaction, forming an efficient energy cycle system.

[0059] Compared with the traditional combustion gasification method, this device uses the anaerobic induction heating technology to replace combustion gasification, fundamentally eliminating the flash explosion risk that may be caused by the presence of oxygen, and improving the safety of the device operation. At the same time, the anaerobic environment avoids the emission of greenhouse gases such as carbon dioxide during the combustion process, effectively reducing carbon emissions, which is in line with the current development concept of green and low-carbon. In addition, the directional diversion design of the internal structure component 3 of this device further optimizes the flow paths of the particles and the oil and gas, improving the reaction efficiency and product quality.

[0060] Furthermore, in this application, the traditional settler is changed to the gasification reactor 2, eliminating the need for a separate regenerator or gasifier. The particle flow path is short, the overall height of the equipment is low, the process is simpler, and the operation is convenient. At the same time, the cracking reaction time can be shortened from 2 - 3 seconds to less than 1 second, reducing excessive secondary cracking reactions.

[0061] In the embodiment of the present application, the heavy recycle stream storage area is connected to the side wall of the cracking reactor 1 through the output pipeline 101, and the outlet of the output pipeline 101 is located below the crude oil inlet 11.

[0062] It should be noted that the heavy recycle stream is the part that is not fully converted during the crude oil cracking process, and still contains a large amount of crackable hydrocarbon substances. Returning it to the cracking reactor 1 allows these substances to undergo secondary or even multiple cracking under suitable temperature, pressure, and catalyst conditions. By recycling the heavy recycle stream, the distribution of cracking products can be adjusted. The yield of light cracking products (such as gasoline, diesel, etc.) can be increased, and the residue of heavy oil products can be reduced. This helps to improve the added value and market competitiveness of the products and meet the market demand for light oil products.

[0063] In the embodiment of the present application, the diversion downcomer 32 includes a circumferential distribution group 321 and a central distribution group 322.

[0064] The circumferential distribution group 321 is arranged in an equally spaced circular pattern along the outer edge of the air-permeable partition 31.

[0065] The central distribution group 322 is located in the central area of the air-permeable partition 31 and is radially distributed.

[0066] The circumferential distribution group 321 and the central distribution group 322 are staggeredly distributed on adjacent air-permeable partitions 31 to form a particle radial flow channel.

[0067] It should be noted that when the scale of the gasification reactor 2 is large, the combination of arranging the circumferential distribution group 321 (arranged in an equally spaced circular pattern along the outer edge of the air-permeable partition 31) and the central distribution group 322 (radially distributed in the central area) in the diversion downcomer 32, and the two are staggeredly distributed on adjacent air-permeable partitions 31 to form a particle radial flow channel can promote the efficient and uniform radial flow and full mixing of particles in the reactor, enhance the contact between particles and the reaction medium, improve the uniformity and efficiency of the catalytic gasification reaction, avoid excessive or insufficient local reactions, and ensure the stable and efficient operation of the reactor at a large size.

[0068] In the embodiment of the present application, the diversion downcomer 32 includes a left distribution group 323 and a right distribution group 324.

[0069] The left distribution group 323 and the right distribution group 324 are symmetrically distributed along the transverse central axis of the air-permeable partition 31.

[0070] The left distribution group 323 and the right distribution group 324 are staggeredly distributed on adjacent air-permeable partitions 31 to form a particle transverse flow channel.

[0071] It should be noted that the diversion downcomer 32 is provided with left and right distribution groups 324 on the left and right, and is symmetrically distributed along the horizontal central axis of the breathable partition 31. The two are staggered in adjacent breathable partitions 31 to form a particle horizontal flow channel. This design can promote the orderly and uniform horizontal flow of particles in the reactor, enhance the full contact and exchange between particles and the reaction medium or heat, avoid local particle accumulation or reaction dead zones, improve the reaction efficiency and product uniformity, and ensure the stable and efficient operation of the reactor.

[0072] In the embodiment of the present application, the device for electrothermal catalytic cracking and gasification of crude oil further includes a plurality of atomizing nozzles. The plurality of atomizing nozzles are respectively arranged at the outlet of the output pipeline 101 and the crude oil inlet 11. By arranging the atomizing nozzles here, efficient atomization and dispersion of the heavy recycle stream and crude oil can be achieved, enabling them to enter the cracking reactor 1 uniformly in the form of tiny droplets, increasing the contact area with the catalyst and high-temperature particles, significantly enhancing the reaction rate and conversion rate, promoting full mixing of the materials at the same time, optimizing the reaction conditions, reducing local overheating or uneven reaction phenomena, and ensuring the stable and efficient operation of the device.

[0073] In the embodiment of the present application, the catalyst includes at least one of clay, kaolin, red mud, pyrite, calcium hydroxide, calcium oxide, sodium hydroxide, potassium hydroxide, biomass ash, biomass carbon, potassium acetate, sodium acetate, potassium carbonate, sodium carbonate, potassium fatty acid, sodium fatty acid, iron tetroxide, and iron oxide.

[0074] It should be noted that by using these substances as catalysts, their unique physical and chemical properties, such as rich pore structures, diverse active sites, and suitable acid-base properties, can promote the cracking and gasification reactions of crude oil from different action mechanisms, improve the reaction rate and product selectivity. At the same time, the catalyst formulation can be flexibly adjusted according to the properties of crude oil and target products, enhancing the adaptability of the device to different raw materials and operating conditions, and improving the overall process efficiency and economic benefits.

[0075] In the embodiment of the present application, the electromagnetic induction heating assembly 4 includes an upper coil 41, a middle coil 42, and a lower coil 43 that are sleeved on the outer wall of the gasification reactor 2 from top to bottom and are independently temperature-controlled. The temperature ranges of the upper coil 41, the middle coil 42, and the lower coil 43 are 700 - 800 °C, 800 - 1000 °C, and 700 - 800 °C respectively.

[0076] The upper coil 41, the middle coil 42, and the lower coil 43 respectively correspond to the upper region, the middle region, and the lower region of the internal structure assembly 3 in the gasification reactor 2.

[0077] In this application, the electromagnetic induction heating component 4 adopts a design of independent temperature control for different zones (upper zone: 700 - 800 °C, middle zone: 800 - 1000 °C, lower zone: 700 - 800 °C), precisely matching the functional requirements of different zones in the gasification reactor 2: the low temperature in the upper zone inhibits the secondary cracking of oil and gas and reduces the formation of carbon deposits; the high temperature in the middle zone enhances the catalytic gasification reaction of coke and steam, improving the yields of hydrogen and carbon monoxide; the low temperature in the lower zone maintains the fluidity of particles and ensures the operating stability of the slide valve 10. Combining the characteristics of efficient heat transfer of electromagnetic induction heating, this gradient temperature control mechanism realizes the directional conversion of coke and the recycling of thermal energy in an oxygen-free environment. In an oxygen-free environment, the combustion reaction of coke is avoided, enabling it to undergo a catalytic gasification reaction with steam in a directional manner to produce useful gases such as hydrogen and carbon monoxide. At the same time, by optimizing the heat distribution, the recycling of thermal energy is achieved, significantly improving the energy efficiency, reducing energy consumption and carbon emissions, and meeting the current environmental protection requirements of energy conservation and emission reduction.

[0078] In addition, this layered structure combined with the design of segmented temperature regulation precisely adapts to the thermodynamic requirements of different reaction stages. During the reaction process, the reaction rates and required heat in different stages are different. Through zone temperature control, the waste of energy consumption caused by local overheating is avoided, and at the same time, it is ensured that the gasification reaction continues within the optimal temperature range, improving the reaction efficiency. By dynamically balancing the heat distribution and the particle residence time, this design significantly enhances the carbon conversion rate and hydrogen selectivity, making the reaction process more efficient and precise.

[0079] More importantly, this design reduces the system operation volatility. Under oxygen-free conditions, by precisely controlling the temperature, the risk of peroxide flash explosion that may be caused by the presence of oxygen in the traditional process is avoided, ensuring the safety of the production process. At the same time, safe, efficient, and stable low-carbon hydrogen production and heat energy recycling are achieved, providing strong support for the efficient utilization of energy and sustainable development.

[0080] In the embodiment of this application, the breathable partition 31 has 3 - 15 layers. Every 1 - 5 layers control the reaction temperature through the corresponding upper coil 41, middle coil 42, and lower coil 43.

[0081] The embodiment of this application provides a method for electrothermal catalytic cracking and gasification of crude oil, including the above-mentioned device for electrothermal catalytic cracking and gasification of crude oil. The method further includes:

[0082] S1: Add inert carrier particles into the gasification reactor 2 to form a bed of particles, turn on the electromagnetic induction heating component 4 to heat the bed of particles to a preset temperature to obtain high-temperature particles, and transport the high-temperature particles to the high-temperature particle inlet 12 of the cracking reactor 1 through the inclined pipe 6. The slide valve 10 controls the flow rate of the high-temperature particles.

[0083] S2: After mixing and atomizing crude oil and a catalyst in the crude oil and catalyst mixing device 5, they are transported to the bottom of the cracking reactor 1 through the crude oil inlet 11. Meanwhile, pre-lift gas is introduced through the pre-lift gas inlet 13. The crude oil contacts with high-temperature particles to undergo a catalytic cracking reaction, generating cracked oil gas and particles with coke attached to the surface. The cracked oil gas and the particles with coke attached enter the gasification reactor 2 through the outlet pipe 7.

[0084] S3: The cyclone separator 8 at the top of the gasification reactor 2 separates the cracked oil gas and the particles with coke attached. The cracked oil gas is fractionated into light cracked products and heavy recycle streams through the cooling and separation device 9, and is respectively transported to the light cracked product storage area 91 and the heavy recycle stream storage area.

[0085] S4: The particles with coke attached settle to the bottom of the gasification reactor 2 through the diversion downcomer 32. Steam is introduced through the steam inlet 21 and heated to coke catalytic gasification through the electromagnetic induction heating component 4 to generate high-temperature particles, which are recycled to the cracking reactor 1.

[0086] In the embodiment of the present application, in step S4:

[0087] The upper coil 41, the middle coil 42, and the lower coil 43 of the electromagnetic induction heating component 4 are independently temperature-controlled, corresponding to the upper region, the middle region, and the lower region of the internal structure component 3 in the gasification reactor 2 respectively.

[0088] The following functions are achieved through temperature gradient control:

[0089] Upper region: 700 - 800 °C, the hydrocarbon volatiles remaining on the coke surface are desorbed to avoid cracking and carbon deposition;

[0090] Middle region: 800 - 1000 °C, steam and coke containing a catalyst undergo a catalytic gasification reaction to generate H2 and CO, eliminating most of the coke;

[0091] Lower region: 700 - 800 °C, the residual coke is eliminated through a low-temperature gasification reaction. Meanwhile, the cracking reaction activity is maintained to improve the product selectivity, and this temperature range is beneficial to ensuring the long-term stable operation of the slide valve 10 and reducing the particle adhesion.

[0092] It should be noted that the method provided by the embodiments of the present application realizes the efficient conversion of crude oil and the recycling of resources through the process closed-loop design of cracking-vaporization-circulation. The inert particles are heated by electromagnetic induction to form a stable heat carrier. In the catalytic cracking section, the high-temperature particles are in full contact with the crude oil, generating high-value-added oil and gas and coke deposits; the light products and the recyclable heavy components are accurately separated by cyclone separation and cooling fractionation; the coke particles are gasified through gradient fluidization diversion and zone temperature control, and are directionally converted into hydrogen-rich syngas with water vapor in an oxygen-free environment, while the regenerated particles recycle heat. This process replaces traditional oxygen-rich gasification with electromagnetic heating, eliminates the risk of flash explosion and reduces carbon emissions. Combining coke directional conversion, heat energy closed-loop recovery and heavy oil recycling, while improving the product selectivity and energy efficiency, realizes the safe and low-carbon deep conversion of crude oil in the whole process.

[0093] The various embodiments in this specification are described in a progressive manner. For the same or similar parts between the various embodiments, reference can be made to each other. Each embodiment focuses on the differences from other embodiments.

[0094] The above embodiments are only used to illustrate the technical solutions of the present application, rather than limiting the present application; although the present application has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that they can still modify the technical solutions recorded in the foregoing embodiments, or perform equivalent replacements on some or all of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the scope of the technical solutions of the present application.

Claims

1. An apparatus for electrothermal catalytic cracking and gasification of crude oil, characterized in that, Comprising: A cracking reactor, with a crude oil inlet and a high-temperature particle inlet respectively arranged at the lower part of its side wall, and a pre-lift gas inlet arranged at the bottom. The crude oil inlet is connected to a crude oil and catalyst mixing device. The high-temperature particle inlet is communicated with the lower part of the side wall of the gasification reactor through an inclined pipeline, and a slide valve is arranged on the inclined pipeline; A gasification reactor, whose upper part of the side wall is communicated with the top of the cracking reactor through an outlet pipeline, with a steam inlet arranged at the bottom and a cyclone separator arranged at the top for separating cracked oil gas and particles. Inside the gasification reactor, particles are accommodated to form a bed of particles, and the particles are inert carrier particles; An internal structure component, arranged inside the gasification reactor, including multiple layers of breathable partitions and a plurality of diversion downcomers. The multiple layers of breathable partitions are arranged at intervals along the height direction of the gasification reactor for controlling the gradient fluidization of the bed of particles. The plurality of diversion downcomers respectively penetrate through the corresponding breathable partitions for guiding the particles to flow downward. Among them, both the internal structure component and the gasification reactor are made of metal materials; An electromagnetic induction heating component, sleeved on the outer wall of the gasification reactor, for performing induction heating on the gasification reactor and the internal structure component, and then heating the particles inside the gasification reactor; A cooling and separation device, whose input end is connected to the output end of the cyclone separator, with a first output end connected to a light cracked product storage area and a second output end connected to a heavy recycle stream storage area.

2. The device for electrothermal catalytic cracking and gasification of crude oil according to claim 1, characterized in that, The heavy recycle stream storage area is connected to the side wall of the cracking reactor through an output pipeline, and the outlet of the output pipeline is located below the crude oil inlet.

3. The device for electrothermal catalytic cracking and gasification of crude oil according to claim 1, characterized in that The diversion downcomer includes a circumferential distribution group and a central distribution group; The circumferential distribution group is arranged in an equidistant circular arrangement along the outer edge of the breathable partition; The central distribution group is located in the central area of the breathable partition and is radially distributed; The circumferential distribution group and the central distribution group are staggeredly distributed on adjacent breathable partitions to form a particle radial flow channel.

4. The device for electrothermal catalytic cracking and gasification of crude oil according to claim 1, characterized in that The diversion downcomer includes a left distribution group and a right distribution group; The left distribution group and the right distribution group are symmetrically distributed along the transverse central axis of the breathable partition; The left distribution group and the right distribution group are staggeredly distributed on adjacent breathable partitions to form a particle transverse flow channel.

5. The device for electrothermal catalytic cracking and gasification of crude oil according to claim 2, characterized in that, It further includes a plurality of atomizing nozzles; The plurality of atomizing nozzles are respectively arranged at the outlet of the output pipeline and the crude oil inlet.

6. The device for electrothermal catalytic cracking and gasification of crude oil according to claim 1, wherein The catalyst includes at least one of clay, kaolin, red mud, pyrite, calcium hydroxide, calcium oxide, sodium hydroxide, potassium hydroxide, biomass ash, biomass carbon, potassium acetate, sodium acetate, potassium carbonate, sodium carbonate, potassium fatty acid, sodium fatty acid, iron tetroxide, and iron oxide.

7. The device for electrothermal catalytic cracking and gasification of crude oil according to claim 1, characterized in that, The electromagnetic induction heating assembly includes an upper coil, a middle coil, and a lower coil that are sequentially sleeved on the outer wall of the gasification reactor from top to bottom and are independently temperature-controlled; the temperature ranges of the upper coil, the middle coil, and the lower coil are 700-800 °C, 800-1000 °C, and 700-800 °C, respectively; The upper coil, the middle coil, and the lower coil respectively correspond to the upper region, the middle region, and the lower region of the internal structure assembly in the gasification reactor.

8. The device for electrothermal catalytic cracking and gasification of crude oil according to claim 1, wherein, The breathable partition plate is 3-15 layers.

9. A method for electrothermal catalytic cracking and gasification of crude oil, characterized in that, Including the device for electrothermal catalytic cracking and gasification of crude oil according to any one of claims 1-8, the method further includes: S1: Add inert carrier particles into the gasification reactor to form a bed of particles, start the electromagnetic induction heating assembly to heat the bed of particles to a preset temperature to obtain high-temperature particles, and transport the high-temperature particles to the high-temperature particle inlet of the cracking reactor through an inclined pipe, and a slide valve controls the flow rate of the high-temperature particles; S2: After mixing and atomizing the crude oil and the catalyst in the crude oil and catalyst mixing device, transport them to the bottom of the cracking reactor through the crude oil inlet, and at the same time introduce pre-lift gas from the pre-lift gas inlet; the crude oil contacts the high-temperature particles to undergo a catalytic cracking reaction to generate cracked oil gas and particles with coke attached to the surface, and the cracked oil gas and the particles with coke attached enter the gasification reactor through the outlet pipe; S3: The cyclone separator at the top of the gasification reactor separates the cracked oil gas and the particles with coke attached, and the cracked oil gas is fractionated into light cracked products and heavy recycle streams through a cooling and separation device and is respectively transported to the light cracked product storage area and the heavy recycle stream storage area; S4: The particles with coke attached settle to the bottom of the gasification reactor through the diversion downcomer, introduce steam from the steam inlet, and heat it to coke catalytic gasification through the electromagnetic induction heating assembly to generate high-temperature particles and recycle them to the cracking reactor.

10. The method for electrothermal catalytic cracking and gasification of crude oil according to claim 9, wherein In step S4: The upper coil, the middle coil, and the lower coil of the electromagnetic induction heating assembly are independently temperature-controlled and respectively correspond to the upper region, the middle region, and the lower region of the internal structure assembly in the gasification reactor; The following functions are achieved through temperature gradient control: Upper region: 700-800 °C, the hydrocarbon volatiles remaining on the coke surface are desorbed to avoid cracking and carbon deposition; Middle region: 800-1000 °C, steam undergoes a catalytic gasification reaction with the coke containing the catalyst to generate H2 and CO, eliminating most of the coke; Lower region: 700-800 °C, the residual coke is eliminated through a low-temperature gasification reaction, while maintaining the cracking reaction activity to improve the product selectivity, and this temperature range is beneficial to ensuring the long-term stable operation of the slide valve and reducing the adhesion of particles.

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