Preheating and vaporization of hydrocarbon feedstock to an electrically powered cracking furnace

Abstract

Systems and methods for enhancing vaporization of a hydrocarbon feed supplied to an electrically powered steam cracker furnace can include a separation device disposed to receive a liquid hydrocarbon feed and dilution steam and capable of partially vaporizing the hydrocarbon feed to provide a gaseous hydrocarbon portion and a liquid hydrocarbon portion. The gaseous hydrocarbon portion can be heated and combined with the liquid hydrocarbon portion to form a substantially vaporized portion, which can be further heated to form a substantially vaporized furnace feed.

Description

Technical Field

[0001] This disclosure relates to systems and methods for preheating and vaporizing hydrocarbon feedstocks, and more specifically, to systems and methods for enhancing the preheating and vaporization of hydrocarbon feedstocks, particularly for use with electric cracking furnaces. Background Technology

[0002] Steam cracking of hydrocarbon feedstocks in a steam cracker is a common method for producing many desired petroleum derivatives. In many steam cracking methods, the hydrocarbon feedstock is supplied to the convection section of the steam cracker. In the convection section, the hydrocarbon feedstock is heated to a high intermediate temperature and then mixed with dilution steam, subsequently heated further to a temperature close enough to allow an endothermic reaction to crack the hydrocarbons. The preheated hydrocarbon feedstock and dilution steam mixture can be fed into the radiant section of the steam cracker, which may include radiant coils, where the mixture is further heated to a temperature sufficient to induce an endothermic reaction to crack the hydrocarbons in the mixture. In gas-fired steam crackers, the heat required for the convection section can be provided by the hot effluent from the radiant section. The cracked mixture can then be fed to a heat exchanger to rapidly quench the cracked mixture to minimize undesirable post-cracking reactions and, in some cases, recover heat from the process.

[0003] Heat in the radiant section can be provided by burning hydrocarbons and / or hydrogen, or by electric heating. If provided by electric heating, the heat effluent from the radiant section cannot be used in the convection section to evaporate and / or preheat the hydrocarbon feedstock. Therefore, in such a system, the heat for evaporating the hydrocarbon feedstock and preheating the hydrocarbon feedstock / dilution steam mixture can be provided by an electric heater. However, some hydrocarbon feedstocks contain mixtures of many hydrocarbon components, resulting in a wide boiling range. Furthermore, some hydrocarbon feedstocks can exhibit increased fouling potential due to the presence of reactive molecules and contaminants, as well as the amount of high-boiling-point substances that are more difficult to vaporize. Therefore, heating some hydrocarbon feedstocks to provide sufficient evaporation levels and / or sufficient temperature rise before being fed into the cracking furnace can lead to undesirable and significant equipment fouling. Consequently, for some hydrocarbon feedstocks, it may be difficult to adequately evaporate and / or preheat the feedstock without increasing the likelihood of fouling caused by one or more components of the hydrocarbon cracking mixture.

[0004] Compared to conventional convection sections, the electric heating and vaporization of hydrocarbon feedstocks present additional challenges. In the convection section of a conventional feed-flue gas heat exchanger, the maximum tube metal temperature (TMT) must never exceed the flue gas temperature. In contrast, electric heaters operate with a constant heat flux, therefore, the temperature at a specific point on the heating element will be strongly dependent on the state of the liquid hydrocarbon feedstock. The surface of the heating element in contact with the liquid has a much lower temperature than the surface in contact with the gas or bubbles. Therefore, bubble formation at the surface must be avoided, otherwise scaling can occur on the heating element, leading to heater failure.

[0005] International Publication No. WO 2009 / 088413 A1 (“'413 Publication”) of Equistar Chemicals, LP describes an attempt to provide a method for producing olefins using whole crude oil and / or natural gas condensate. Specifically, '413 Publication describes a method for thermally cracking a feedstock consisting of whole crude oil and / or natural gas condensate as feedstock for an olefin production unit that uses a combination of hydrocarbon thermal cracking in a pyrolysis furnace and a partitioned vaporization unit. '413 Publication describes the use of a separate vaporization facility that operates independently of and separate from the convection and radiant sections of the furnace. According to '413 Publication, the crude oil and / or condensate feedstock is preheated in the convection section of the furnace and transferred from the convection section and the furnace to the separate vaporization facility. The vaporized hydrocarbon products from the separate facility are then fed back into the furnace to enter the radiant section.

[0006] The applicant recognizes that the methods disclosed in '413 can still lead to a need for systems and methods for producing petroleum derivatives from hydrocarbon feedstocks, systems and methods that can be more precisely controlled or adjustable for different types of hydrocarbon feedstocks and are more efficient and / or more environmentally friendly. For example, while the methods described in '413 disclosure may provide gains in efficiency and the ability to crack whole crude oil, they may still fall short of desired efficiency, and furthermore, the methods described in '413 disclosure may result in undesirably high carbon dioxide emissions.

[0007] Therefore, the applicant has recognized a strong need for systems and methods that preheat and evaporate hydrocarbon feedstocks without causing undesirably high fouling in electric heaters; evaporate hydrocarbon feedstocks without causing heating element failure due to non-optimized evaporation behavior; and evaporate hydrocarbon feedstocks containing multiple hydrocarbons and / or having a wide boiling range. Furthermore, there is a need for systems and methods for evaporating hydrocarbon feedstocks in a more efficient and / or more environmentally friendly manner. This disclosure addresses one or more of the above-mentioned problems, as well as other potential issues. Summary of the Invention

[0008] In one embodiment, a vaporization assembly is provided to enhance the vaporization of a liquid hydrocarbon feed to an electric steam cracker. The vaporization assembly includes: a) a first heater configured to receive dilution steam and capable of heating the dilution steam to provide superheated dilution steam; b) a separation device configured to receive the liquid hydrocarbon feed and the superheated dilution steam and capable of evaporating at least a portion of the liquid hydrocarbon feed via energy associated with the superheated dilution steam to provide a gaseous hydrocarbon portion and a liquid hydrocarbon portion; c) a second electric heater configured to receive the gaseous hydrocarbon portion and capable of heating the gaseous hydrocarbon portion to provide a superheated gaseous hydrocarbon portion; d) a mixing unit capable of combining and mixing the superheated gaseous hydrocarbon portion and the liquid hydrocarbon portion, and allowing at least a portion of the liquid hydrocarbon portion to evaporate via energy associated with the superheated gaseous hydrocarbon portion to provide a substantially steam portion; and e) a third electric heater configured to receive the substantially steam portion and capable of heating the substantially steam portion to provide a substantially steam furnace.

[0009] In another embodiment, a method for enhancing the vaporization of a liquid hydrocarbon feed in an electric steam cracking furnace is provided. The method includes: a) supplying the liquid hydrocarbon feed and superheated dilution steam to a separation unit; b) evaporating at least a portion of the liquid hydrocarbon feed in the separation unit via energy associated with the superheated dilution steam to provide a gaseous hydrocarbon portion and a liquid hydrocarbon portion; c) separating the gaseous hydrocarbon portion from the liquid hydrocarbon portion; d) heating the gaseous hydrocarbon portion to provide a superheated gaseous hydrocarbon portion; e) combining the superheated gaseous hydrocarbon portion and the liquid hydrocarbon portion, and evaporating at least a portion of the liquid hydrocarbon portion via energy associated with the superheated gaseous hydrocarbon portion to form a substantially steam portion; and f) heating the substantially steam portion to provide a substantially steam furnace feed.

[0010] In yet another implementation, a system for cracking liquid hydrocarbon feedstock is provided. The system includes: a) a first heater configured to receive dilution steam and capable of heating the dilution steam to provide superheated dilution steam; b) a separation device configured to receive a liquid hydrocarbon feed and superheated dilution steam and capable of evaporating at least a portion of the liquid hydrocarbon feed via energy associated with the superheated dilution steam to provide a gaseous hydrocarbon portion and a liquid hydrocarbon portion; c) a second electric heater configured to receive the gaseous hydrocarbon portion and capable of heating the gaseous hydrocarbon portion to provide a superheated gaseous hydrocarbon portion; d) a mixing unit capable of combining and mixing the superheated gaseous hydrocarbon portion and the liquid hydrocarbon portion and allowing at least a portion of the liquid hydrocarbon portion to evaporate via energy associated with the superheated gaseous hydrocarbon portion to provide a substantially vapor portion; and e) a third electric heater configured to receive a substantially vaporized portion and capable of heating the substantially vaporized portion to provide a substantially vaporizer feed; and f) one or more electric furnaces configured to receive a substantially vaporizer feed and capable of allowing the substantially vaporizer feed to react endothermally to provide a cracked effluent.

[0011] These exemplary embodiments and other aspects and advantages of other embodiments are discussed in detail herein. Furthermore, it should be understood that both the foregoing information and the following detailed description provide only illustrative examples of various aspects and embodiments, and are intended to provide an overview or framework for understanding the characteristics and features of the claimed aspects and embodiments. Therefore, these and other purposes, together with the advantages and features of this disclosure, will become apparent by reference to the following description and accompanying drawings. Moreover, it should be understood that the features of the various embodiments described herein are not mutually exclusive and can exist in various combinations and arrangements. Attached Figure Description

[0012] The accompanying drawings, included to provide a further understanding of embodiments of this disclosure and forming part of this specification, illustrate embodiments of this disclosure and, together with the detailed description, serve to explain the principles of the embodiments discussed herein. No attempt is made to show the structural details of this disclosure in more detail than necessary for a basic understanding of the embodiments discussed herein and the various ways in which they can be practiced. By convention, the various features in the drawings discussed below are not necessarily drawn to scale. The dimensions of the various features and elements in the drawings may be enlarged or reduced to show the embodiments of this disclosure more clearly.

[0013] Figure 1 An exemplary vaporization component according to an embodiment of this disclosure is schematically shown.

[0014] Figures 2A-2D An exemplary vaporization component according to an embodiment of this disclosure is schematically shown.

[0015] Figure 3 Another exemplary vaporization component according to an embodiment of this disclosure is illustrated schematically. Detailed Implementation

[0016] The accompanying drawings may use similar numerals to indicate similar parts in several views. The following description is provided as a practical teaching of exemplary embodiments, and those skilled in the art will recognize that many changes can be made to the described embodiments. It will also be apparent that some desired benefits of the described embodiments can be obtained by selecting some features of the embodiments without utilizing others. Therefore, those skilled in the art will recognize that many modifications and changes to the described embodiments are possible, and in some cases even desirable. Thus, the following description is provided as an illustration of the principles of the embodiments, and not as a limitation thereof.

[0017] The wording and terminology used herein are for descriptive purposes and should not be considered restrictive. As used herein, the term "a plurality of" means two or more items or components. Unless otherwise stated, the terms "comprising," "including," "carrying," "having," "containing," and "involving" are open-ended terms, meaning "including but not limited to," whether in a written description or claims. Therefore, the use of such terms is intended to cover the items listed thereafter and their equivalents and additional items. The use of common terms such as "first," "second," "third," etc., to modify a claim element itself in a claim does not imply any priority, precedence, or order of one claim element relative to another claim element, or the chronological order of actions of a method, but merely serves as a label to distinguish one claim element having a certain name from another element having the same name (but for the purpose of using ordinal terms) to differentiate claim elements. The term "and / or" means both (inclusive) "and" (conjunction) and "or" (disjunction).

[0018] The terms "gas" or "gaseous state" are used interchangeably with "vapor" and refer to a substance or mixture of substances in a gaseous state, different from a liquid or solid state. Similarly, the term "liquid" refers to a substance or mixture of substances in a liquid state, different from a gaseous or solid state.

[0019] The term “substantially” means “substantially constitutes” and generally includes “consisting of”, and unless otherwise stated, these terms are interpreted in accordance with U.S. patent law. For example, a composition “substantially free of” a specified compound or material may be free of that compound or material, or may have a small amount of that compound or material present, such as by accidental contamination or incomplete purification. “Small amount” may be a trace amount, an unmeasurable amount, an amount that does not interfere with a value or property, or some other amount as provided in the context. A composition having a list of components provided “substantially only” may consist only of those components, or have a trace amount of some other components present, or have one or more additional components that do not substantially affect the properties of the composition. Additionally, the term “substantially” used in embodiments describing the present disclosure, such as the type or amount of an ingredient in a composition, property, measurable amount, method, value, or range, means a variation that does not affect the overall composition, property, amount, method, value, or range described herein in a manner that negates the intended composition, property, amount, method, value, or range. For example, essentially vaporized feed means that at least 80% or at least 85% by weight, or at least 90% by weight, or at least 95% by weight, or at least 99% by weight, or at least 99.5% by weight, or at least 99.9% by weight, or at least 99.99% by weight of the feed is in the vapor phase, or all of the feed is in the vapor phase.

[0020] As used herein, the term "separation device" refers to any container, vessel, or closure configured to receive at least one fluid having at least two component elements and configured to produce a gaseous stream from the top of the container and a liquid stream from the bottom of the container. In some embodiments, the separation device may be additionally configured to produce either a gaseous or liquid stream from a portion between the top and bottom of the container. The separation device may have any three-dimensional shape and may include: internal contact enhancement structures (e.g., packing elements, trays, weirs, and chimneys); internal heating elements; and additional inlets and outlets. Exemplary containers include, but are not limited to: bulk fractionators, steam strippers, phase separators, scrubbing towers, flash drums, co-current contact devices, countercurrent contact devices, etc.

[0021] The term "steam stripper" has its general meaning and refers to any unit suitable for vaporizing at least a portion of a liquid using steam, wherein the liquid and steam operate in countercurrent flow within the unit. The vaporized liquid portion is carried away by the steam at the top, while the unvaporized liquid portion is removed at the bottom of the unit. In some embodiments, the amount of vaporized portion may range from about 0.1% to about 95%.

[0022] As used herein, the term “heater” in its broadest sense refers to one or more devices that can be operated to jointly add heat to a feed stream, and unless otherwise stated, may include combinations of electrically operated heaters and heat exchangers using steam or other fluids (e.g., pyrolysis quench oil, boiler oil, fuel oil products, kerosene, diesel, other gas oils, hydrotreated or hydrocracking gas oils, naphthalene, tar, coking oil, lubricating oil, residual unvaporized components from hydrocarbon feed streams, heat transfer fluids, silicone oils, ionic liquids, molten metals, flowable slurries, particulate mixtures, molten salts, commercially synthesized heat transfer fluids, and combinations thereof) as the high-temperature feed stream.

[0023] In conventional naphtha cracking, naphtha is vaporized and preheated in the convection section of the cracking furnace in a very specific manner. First, the naphtha is substantially vaporized in a set of convection section tubes (typically, 85% or more of the naphtha is vaporized). Second, the substantially vaporized naphtha is mixed with superheated dilution steam outside the convection section to further vaporize the substantially vaporized naphtha. The substantially vaporized naphtha / steam mixture is then further heated in another set of convection section tubes before being fed into the radiant section of the cracking furnace.

[0024] Vaporization in the first convection section of the tube occurs in a plug flow manner. As naphtha travels along the tube, more and more fractions are vaporized. It is preferable to avoid crossing from a two-phase mixture to a fully vaporized mixture (or having a “dry point”) in the convection section of the tube, as small amounts of heavy material can deposit on the surface of the heat pipe, which can lead to significant fouling over time.

[0025] Low-carbon emission methods are those that minimize or essentially eliminate carbon dioxide emissions into the atmosphere. If a low-carbon emission steam cracker using an electric furnace is considered, there will be no flue gas, therefore no convection section, and new methods will be needed to vaporize naphtha and other hydrocarbon feedstocks, including but not limited to ethane, propane, C4 liquefied petroleum gas, gas condensate, coal oil, diesel, jet fuel, gas-to-liquid fuel, and biofuels.

[0026] For multi-component feedstocks, electrically heated vaporizers are not conventional. Electric heaters behave differently from conventional steam or flue gas combustion heaters. They operate with a constant heat flux on the heating element. Therefore, in the presence of two phases (i.e., gas and liquid), where the thermal diffusivity differs between the phases (e.g., gas has less thermal diffusivity than liquid), the uneven heat flux can lead to locally higher than desired heating element temperatures, potentially causing heating element burnout. Furthermore, and more specifically for steam cracking, the presence of solid heavy material deposits on the equipment near the point of complete vaporization can cause even more severe damage to the electric heater, as the resulting deposits locally increase thermal resistance, leading to higher heating element temperatures on the resistance wire and ultimately, heating element burnout. Commercial-scale heating load requirements for liquid feedstock vaporization services exceed those of currently available electric heating technologies in a single unit, thus necessitating consideration of the number, location, and control of heaters.

[0027] This article describes a design that addresses the technical challenges of using electric heaters and furnaces. In doing so, it may be necessary to manage the fluid (vapor / liquid) phase in contact with the electric heating element at all points in the design, while maintaining the process requirements and constraints already inherent in the cracking of liquid feedstocks.

[0028] Various specific process schemes and options exist that are consistent with this broader concept, and they are described in the accompanying drawings and in the claims.

[0029] Figure 1 An exemplary vaporization assembly 10 for enhancing the vaporization of hydrocarbon feed 12 according to an embodiment of this disclosure is schematically shown. The vaporization assembly 10 is capable of at least partially vaporizing the liquid hydrocarbon feed 12 and / or heating the liquid hydrocarbon feed 12 and / or diluting the vapor 14 to prepare for supplying the at least partially vaporized hydrocarbon feed to one or more furnaces 40, such as cracking furnaces, to produce petroleum derivatives, such as olefins. In some embodiments, heat is supplied to the vaporization assembly 10 independently of flue gas from the furnace 40, which may be heated without the combustion of fuel. Other uses of the at least partially vaporized hydrocarbon feed are considered. In some embodiments, the hydrocarbon feed 12 may include, for example, a variety of hydrocarbon components having very different boiling points, and in some embodiments, the hydrocarbon feed 12 may include one or more of, for example, ethane, propane, liquefied petroleum gas (e.g., C4-LPG), naphtha, gas condensate, coal gas oil, diesel, jet fuel, gas-to-liquid (GTL) fuel, pyrolysis oil, feedstock derived from recycled plastics, or bio-feedstock.

[0030] In some embodiments, the vaporization assembly 10 may include a first heater 15 configured to receive dilution vapor 14 and capable of heating the dilution vapor 14 to provide superheated dilution vapor 16. In some embodiments, the first heater 15 is an electric heater, a combination of an electric heater and a steam-heated heat exchanger, or an electric heater and a heat transfer fluid configured to heat the dilution vapor 14. In some embodiments, the heat transfer fluid may include, for example, pyrolysis quench oil, boiler oil, fuel oil products, kerosene, diesel oil, other gas oils, hydrotreated or hydrocracking gas oils, naphthalene, tar, coking oil, lubricating oil, residual unvaporized components from a hydrocarbon feed stream, heat transfer fluids, silicone oil, ionic liquids, molten metals, flowable slurries, particulate mixtures, molten salts, commercially synthesized heat transfer fluids, and combinations thereof. In some embodiments, the dilution vapor 14 may include one or more of, for example, hydrogen, water, methane, or nitrogen. In some embodiments, the dilution vapor 14 may include superheated dilution vapor or saturated vapor.

[0031] like Figure 1 As shown, in some embodiments, the vaporization assembly 10 may include a separation device 18 configured to receive hydrocarbon feed 12 and superheated dilution vapor 16, and capable of at least partially evaporating the hydrocarbon feed 12 to provide a gaseous hydrocarbon portion 20 and a liquid hydrocarbon portion 22.

[0032] According to one embodiment, the separation device 18 may be a steam stripper. In some embodiments, the steam stripper includes a stripping column capable of providing surface area for contact between the hydrocarbon feed 12 and the superheated dilution steam 16. According to some embodiments, the stripping column may be a packed column, a plate column, a foam column, or any other two-phase contact device that allows countercurrent vapor / liquid separation. Typically, the hydrocarbon feed 12 enters the steam stripper near its top, while the superheated dilution steam 16 enters the steam stripper near its bottom. As the hydrocarbon feed 12 moves generally downward through the stripping column, it comes into contact with the rising superheated dilution steam 16. The vapor generated from the evaporation of the liquid hydrocarbon feed 12 mixes with and is diluted by the rising superheated dilution steam 16, producing a gaseous hydrocarbon fraction 20, which is discharged near the top of the steam stripper. The unevaporated components of the hydrocarbon feed 12 are discharged near the bottom of the steam stripper as a liquid hydrocarbon fraction 22. Both 20 and 22 may additionally include molecular water.

[0033] According to some embodiments, the steam stripper can be designed based on the ratio of the amount of superheated dilution steam introduced into the steam stripper to the amount of liquid hydrocarbon feed introduced into the steam stripper. For example, in some embodiments, the mass ratio of the amount of superheated dilution steam introduced into the steam stripper to the amount of liquid hydrocarbon feed introduced into the steam stripper is at least 0.1, or at least 0.2, or at least 0.3, or at least 0.4, or at least 0.5. In some embodiments, the mass ratio of the amount of superheated dilution steam introduced into the steam stripper to the amount of liquid hydrocarbon feed introduced into the steam stripper is less than or equal to 1, or less than 0.9, or less than 0.8, or less than 0.7, or less than 0.6, or less than 0.5. In some embodiments, the mass ratio of the amount of superheated dilution steam introduced into the steam stripper to the amount of liquid hydrocarbon feed introduced into the steam stripper ranges from 0.1 to 1. If necessary, the steam stripper can operate at a pressure below the furnace supply pressure to help reduce the boiling temperature of the hydrocarbon feed 12 and minimize energy input requirements. This can be achieved using a vacuum blower. The vacuum blower is designed to provide the required vacuum at the designed steam flow rate. The liquid level in the steam stripper can be monitored via a level indicator. The steam stripper can operate under a wide range of conditions. In some embodiments, the temperature of the steam stripper can range from 150°C to 700°C. In some embodiments, the pressure in the steam stripper can be 0.1–15 bar absolute pressure.

[0034] like Figure 1 As shown, in some embodiments, the vaporization assembly 10 may additionally include a second heater 28 configured to receive the gaseous hydrocarbon portion 20 and be capable of heating the gaseous hydrocarbon portion 20 to provide a superheated gaseous hydrocarbon portion 30. In some embodiments, the second heater 28 is an electrically operated heater. In other embodiments, the second heater 28 may be a non-electric shell-and-tube heat exchanger, a non-electric shell-and-tube heat exchanger using saturated high-pressure steam generated in a transmission line exchanger (TLE) as a heat source, a heat exchanger supplied with hot effluent from a furnace (e.g., a radiant furnace), and / or a thermally integrated feed stream. In some embodiments, the second heater 28 is configured to receive the gaseous hydrocarbon portion 20 and be capable of heating the gaseous hydrocarbon portion 20 to a temperature in the range of 150°C to 450°C to provide a superheated gaseous hydrocarbon portion 30.

[0035] like Figure 1 As shown, in some embodiments, the vaporization assembly 10 may include a mixing unit 32 capable of combining and mixing the liquid hydrocarbon portion 22 and the superheated gaseous hydrocarbon portion 30, and allowing at least a portion of the liquid hydrocarbon portion 22 to evaporate, for example, via energy associated with the superheated gaseous hydrocarbon portion 30, to provide a substantially vaporized portion 34. In some embodiments, the mixing unit 32 may be a mixing drum, an in-line mixer, or a mixing point.

[0036] In some implementations, for example, Figure 1 As shown, the vaporization assembly 10 may further include a third heater 38 configured to receive the substantially vaporized portion 34 and be capable of heating the substantially vaporized portion 34 to form a substantially vaporized furnace feed 39. For example, the third heater 38 may be capable of heating the substantially vaporized portion 34 to a temperature of, for example, 500°C to 800°C (e.g., 550°C to 750°C). In some embodiments, the third heater 38 may be capable of heating the substantially vaporized portion 34 to a relatively low temperature (e.g., below 500°C) and relying on one or more furnaces 40 to add any additional heat to raise the temperature of the substantially vaporized portion 39 to the pyrolysis temperature. In one embodiment, the third heater 38 is an electrically powered heater. In other embodiments, the third heater 38 may be a heat exchanger supplied with a heat effluent from a furnace (e.g., a radiant furnace).

[0037] In some embodiments, furnace 40 may be an electrically heated furnace, such as one in which an electric heating element provides heat or thermal energy to a tube through which the substantially vaporized furnace feed 39 flows in a heating chamber. For example, furnace 40 may include a pyrolysis coil in a heating chamber, and electricity may be supplied to an electric heater in the heating chamber to heat the pyrolysis coil. The substantially vaporized furnace feed 39 may pass through the pyrolysis coil in the heating chamber and be heated and pyrolyzed in one or more endothermic reactions to provide pyrolysis effluent 41, as those skilled in the art will understand.

[0038] Therefore, in some embodiments, a system for cracking hydrocarbon feedstock is also provided, the system including the vaporization assembly of this disclosure and one or more furnaces 40. The one or more furnaces 40 are configured to receive substantially vaporizer feedstock 39 and are capable of allowing substantially vaporizer feedstock 39 to react endothermally to provide cracked effluent 41.

[0039] Although not in Figure 1 As shown, the pyrolyzed effluent 41 can then be supplied to a heat exchanger. The heat exchanger can be configured to receive the pyrolyzed effluent and be able to transfer heat from the pyrolyzed effluent 41, for example, to liquid water to generate steam, or to a third heater to heat the substantially vaporizing section 34 to provide substantially vaporizing furnace feed 39. In some embodiments, the heat exchanger can be a transfer line exchanger (TLE) capable of rapidly cooling the pyrolyzed effluent 41 received from furnace 40 and generating very high pressure (VHP) steam. In some embodiments, saturated VHP steam can be used for thermal integration, such as in elements of the vaporization assembly previously described. For example, VHP steam can be used as a heating medium for one or more heaters. In some embodiments, this may also include using at least a portion of the VHP steam to drive one or more turbines to perform work.

[0040] Figure 2A , 2B Figures 2C and 2D schematically illustrate example sub-components of the vaporization assembly 10 according to an embodiment of the present disclosure. Figure 2A , Figure 2B , Figure 2C and Figure 2D The implementation scheme shown is directed to Figure 1 Additional optional elements are added to the vaporization component 10 embodiment shown. First, as... Figure 2A As shown, the vaporization assembly 10A may include a heater 44 configured to receive dilution steam 14 and be capable of heating the dilution steam 14 to provide heated dilution steam 50. In some embodiments, the heater 44 may also be configured to receive common steam 52 (including, but not limited to, saturated or unsaturated steam) from, for example, a production facility, and the common steam 52 may heat the dilution steam 14 to provide heated dilution steam 50. In some embodiments, the heater 44 may be a shell-and-tube heat exchanger, a shell-and-tube heat exchanger using saturated high-pressure steam generated in a transmission line exchanger (TLE) as a heat source, and / or a heat source integrated with a production facility (e.g., an olefin production facility, such as a cracking furnace). In other embodiments, the heater 44 is configured to receive dilution steam 14 and common steam 52 and is capable of heating the dilution steam 14 to a temperature in the range of 180°C to 650°C to provide heated dilution steam 50. The heated dilution steam 50 is then supplied to a first heater 15 and heated to form superheated dilution steam 16.

[0041] exist Figure 2B In the embodiments shown, the vaporization assembly 10B may include a heater 45 configured to receive the hydrocarbon feed 12 and be capable of heating the hydrocarbon feed 12 to provide a heated hydrocarbon feed 51. In some embodiments, the heater 45 may also be configured to receive utilities 52 (including, but not limited to, saturated or unsaturated steam) from, for example, a production facility, and the utilities 52 may heat the hydrocarbon feed 12 to provide a heated hydrocarbon feed 51. Thus, in some embodiments, the heater 45 may be a shell-and-tube heat exchanger, a shell-and-tube heat exchanger using saturated high-pressure steam generated in a transfer line exchanger (TLE) as a heat source, and / or a heat source integrated with a production facility (e.g., an olefin production facility, such as a cracking furnace). In other embodiments, the heater 45 is configured to receive the hydrocarbon feed 12 and the utilities 52 and is capable of heating the hydrocarbon feed 12 to a temperature in the range of 50°C to 450°C to provide a heated hydrocarbon feed 12. In some embodiments, the vaporization assembly 10 may also include one or more filters 53 configured to receive the hydrocarbon feed 12 and remove unwanted components from the hydrocarbon feed 12 before the heater 45 and / or the separation device 18.

[0042] exist Figure 2C In the embodiments shown, the vaporization assembly 10C may include a heater 46 configured to receive the gaseous hydrocarbon portion 20 and be capable of heating the gaseous hydrocarbon portion 20 to provide a heated gaseous hydrocarbon portion 55. In some embodiments, the heater 46 may also be configured to receive utilities 52 (including, but not limited to, saturated VHP steam) from, for example, a production facility, and the utilities 52 may heat the gaseous hydrocarbon portion 20 to provide a heated gaseous hydrocarbon portion 55. Thus, in some embodiments, the heater 46 may be a shell-and-tube heat exchanger, a shell-and-tube heat exchanger using saturated high-pressure steam generated in a transmission line exchanger (TLE) as a heat source, and / or a heat source integrated with a production facility (e.g., an olefin production facility, such as a cracking furnace). In other embodiments, the heater 46 is configured to receive the gaseous hydrocarbon portion 20 and the utilities 52 and is capable of heating the gaseous hydrocarbon portion 20 to a temperature in the range of 50°C to 450°C to provide a heated gaseous hydrocarbon portion 55. The heated gaseous hydrocarbon portion 55 may then be supplied to a second heater 28.

[0043] exist Figure 2D In the embodiments shown, the vaporization assembly 10D may include a heater 47 configured to receive the liquid hydrocarbon portion 22 and be capable of heating the liquid hydrocarbon portion 22 to provide a heated liquid hydrocarbon portion 56. In some embodiments, the heater 47 may also be configured to receive steam 52 (including, but not limited to, saturated VHP steam) from, for example, a production facility, and the steam 52 may heat the liquid hydrocarbon portion 22 to provide a heated liquid hydrocarbon portion 56. Thus, in some embodiments, the heater 47 may be a shell-and-tube heat exchanger, a shell-and-tube heat exchanger using saturated high-pressure steam generated in a transfer line exchanger (TLE) as a heat source, and / or a heat source integrated with a production facility (e.g., an olefin production facility, such as a cracking furnace). In other embodiments, the heater 47 is configured to receive the liquid hydrocarbon portion 22 and the steam 52 and is capable of heating the liquid hydrocarbon portion 22 to a temperature in the range of 150°C to 450°C to provide a heated liquid hydrocarbon portion 56. The heated liquid hydrocarbon portion 56 can then be supplied to the mixing unit 32.

[0044] Figure 3 Another example of a vaporization component 100 according to an embodiment of the present disclosure is illustrated schematically. Figure 3The vaporization assembly 100 shown includes a partial feed evaporator 118. The partial feed evaporator 118 may have any three-dimensional shape and is configured to receive a hydrocarbon feed 112 and is capable of at least partially evaporating the hydrocarbon feed 112 to provide a gaseous hydrocarbon portion 120 and a liquid hydrocarbon portion 122. Therefore, the partial feed evaporator may be a container configured to receive the hydrocarbon feed 112 and is capable of sealing or containing a volume of the hydrocarbon feed 112. The partial feed evaporator 118 may be in direct contact with a heat source or thermal energy, or indirect contact with a heat source or thermal energy. Indirect contact may be provided through an interface, a medium, or other heat conduction methods (e.g., heat pipes).

[0045] A heat or thermal energy source may be in contact with the outer surface of the partially fed evaporator 118 or may be inside the partially fed evaporator 118. In one example, the heat or thermal energy source is inside the partially fed evaporator and is completely submerged in the liquid hydrocarbon feed. The partially fed evaporator may also include materials having high thermal conductivity, high corrosion resistance, or both. For example, the partially fed evaporator 118 may include materials with high thermal conductivity, such as metals (e.g., copper, aluminum, iron, steel, etc.), non-metallic conductors (e.g., graphite or silicon), heat transfer fluids, or any combination thereof.

[0046] In some embodiments, the partial feed evaporator 118 may include electrically heated coils, heated coils supplying steam, heated coils supplying hot effluent from a furnace (e.g., a radiant furnace), or a heat source integrated with a production facility (e.g., an olefin production facility, such as a cracking furnace). For example, the partial feed evaporator 118 may include submerged heating tubes, a thermosiphon, forced circulation, a double-shell system including a heat transfer medium, one or more of an electric shell-and-tube heat exchanger or a non-electric shell-and-tube heat exchanger, a non-electric shell-and-tube heat exchanger using saturated high-pressure steam generated in a transfer line exchanger (TLE) as a heat source, a heat exchanger supplying hot effluent from a furnace (e.g., a radiant furnace), and / or a thermally integrated feed stream. In some embodiments, the partial feed evaporator 118 may be operated such that the heated surfaces of the partial feed evaporator 118 have a surface temperature of 450°C or lower. This can reduce or prevent the possibility of scaling caused by the superheated hydrocarbon feed 112.

[0047] exist Figure 3In some embodiments of the evaporator assembly 100 shown, a substantially constant flow rate of hydrocarbon feed 112 may be supplied to a partial feed evaporator 118, and the hydrocarbon feed 112 may be in direct contact with the heating coils. In some embodiments, all heating coils may be completely submerged in the liquid portion of the hydrocarbon feed 112 during the heating / vaporization process. Upon contact with the heating coils, the liquid hydrocarbon feed 112 will be heated and at least partially vaporized to provide a gaseous hydrocarbon portion 120. The gaseous hydrocarbon portion 120 may exit the vaporization chamber of the partial feed evaporator 118 through a vapor flow outlet port (not shown), which may be located in the upper part of the partial feed evaporator 118. The gaseous hydrocarbon portion 120 may then be heated in two or more heaters to form a superheated vapor portion 142. In some embodiments, a substantially constant flow rate of liquid hydrocarbon portion 122 may be drawn through a liquid flow outlet port (not shown), which may be located in the lower part of the partial feed evaporator 118. Subsequently, at least a portion of the liquid hydrocarbon portion may be mixed with the superheated vapor portion 142 to form a substantially vaporized portion 146. The substantially vaporized portion 146 may be further heated to form a substantially vaporized furnace feed 152, which may be supplied to one or more furnaces 160.

[0048] In some embodiments, the vaporization assembly 100 may include a first mixing unit 128 capable of combining and mixing the gaseous hydrocarbon portion 120 and the dilution vapor 130 to provide a heated gaseous hydrocarbon portion 126. The first mixing unit 128 may be any means enabling the mixing of the gaseous hydrocarbon portion 126 and the dilution vapor 130 and providing a heated gaseous hydrocarbon portion 126. In some embodiments, the first mixing unit 128 may be a mixing drum, an in-line mixer, or a mixing point.

[0049] Additionally, in some embodiments, the vaporization assembly 100 may include a steam-based heat exchanger 132 configured to receive the heated gaseous hydrocarbon portion 126 and be capable of heating the heated gaseous hydrocarbon portion 126 to form a superheated gaseous hydrocarbon portion 134. In some embodiments, the steam-based heat exchanger 132 may be a shell-and-tube heat exchanger, a shell-and-tube heat exchanger using saturated high-pressure steam generated in a transmission line exchanger (TLE) as a heat source, and / or a heat source integrated with a production facility (e.g., an olefin production facility, such as a cracking furnace), and / or any other suitable heater type. In other embodiments, the steam-based heat exchanger 132 is configured to receive the heated gaseous hydrocarbon portion 134 and be capable of heating the heated gaseous hydrocarbon portion 134 to a temperature in the range of 150°C to 450°C to provide a superheated gaseous hydrocarbon portion 134.

[0050] Figure 3The illustrated embodiment also includes a heater 140 configured to receive the superheated gaseous hydrocarbon portion 134 and to heat the superheated gaseous hydrocarbon portion 132 to provide a superheated vapor portion 142. The heater 140 may be an electric heater, a combination of an electric heater and a steam-based heat exchanger, and / or an electric heater combined with a heater that receives a heat transfer fluid capable of heating the superheated gaseous hydrocarbon portion 134. In some embodiments, the heat transfer fluid may include, for example, pyrolysis quench oil, boiler oil, fuel oil products, kerosene, diesel oil, other gas oils, hydrotreated or hydrocracking gas oils, naphthalene, tar, coking oil, lubricating oil, residual unvaporized components from the hydrocarbon feed stream, heat transfer fluids, silicone oil, ionic liquids, molten metals, flowable slurries, particulate mixtures, molten salts, commercially synthesized heat transfer fluids, and combinations thereof. In other embodiments, the electric heater 140 is configured to receive the superheated gaseous hydrocarbon portion 134 and to heat the superheated gaseous hydrocarbon portion 134 to a temperature in the range of 150°C to 700°C to provide the superheated steam portion 142.

[0051] In some embodiments, the vaporization assembly 100 may include a second mixing unit 144 capable of combining and mixing the liquid hydrocarbon portion 122 and the superheated vapor portion 142, and allowing at least a portion of the liquid hydrocarbon portion 122 to evaporate, for example, via energy associated with the superheated vapor portion 142, to provide a substantially vaporized portion 146. The mixing unit 144 may be any means enabling the mixing of the superheated vapor portion 142 and the liquid hydrocarbon portion 122 and providing the substantially vaporized portion 146. In some embodiments, the second mixing unit 144 may be a mixing drum, an in-line mixer, or a mixing point. Although not shown, in some embodiments, the liquid hydrocarbon portion 122 may be supplied to a heater and heated to form a heated liquid hydrocarbon portion before being supplied to the second mixing unit 144. In such an implementation, the heater may be a steam-based heat exchanger, which may be a shell-and-tube heat exchanger, a non-electric shell-and-tube heat exchanger using saturated high-pressure steam generated in a transmission line exchanger (TLE) as a heat source, a heat exchanger supplying hot effluent from a furnace (e.g., a radiant furnace), and / or a heat source integrated with a production facility (e.g., an olefin production facility, such as a cracking furnace), and / or any other suitable heater type. Therefore, such a heater will be configured to receive the liquid hydrocarbon portion 122 and be capable of heating the liquid hydrocarbon portion 122 to a temperature in the range of 150°C to 450°C to provide a heated liquid hydrocarbon portion.

[0052] In yet another embodiment, the vaporization assembly 100 may include a second electric heater 148 configured to receive the substantially vaporized portion 146 and be capable of heating the substantially vaporized portion 146 to form a substantially vaporizer feed 152. The electric heater 148 may include an electric heater, a combination of an electric heater and a steam-based heat exchanger, and / or an electric heater and a heat transfer fluid configured and constructed to heat the substantially vaporized portion 146. In some embodiments, the heat transfer fluid may include, for example, pyrolysis quench oil, boiler oil, fuel oil products, kerosene, diesel oil, other gas oils, hydrotreated or hydrocracking gas oils, naphthalene, tar, coking oil, lubricating oil, residual unvaporized components from a hydrocarbon feed stream, heat transfer fluids, silicone oil, ionic liquids, molten metals, flowable slurries, particulate mixtures, molten salts, commercially synthesized heat transfer fluids, and combinations thereof. In other embodiments, the electric heater 148 is configured to receive the substantially vaporized portion 146 and to heat the substantially vaporized portion 146 to a temperature in the range of 150°C to 700°C to provide substantially vaporized furnace feed 152.

[0053] Furthermore, in some implementation schemes, such as Figure 3 As shown, this disclosure provides a system including a vaporization assembly 100 and one or more furnaces 160, such as cracking furnaces, for producing petroleum derivatives, such as olefins. In one embodiment, the cracking furnace 160 may be electrically powered, for example, a furnace in which electric heating elements provide heat or thermal energy to a tube through which the substantially vaporization feed 152 flows in a heating chamber. For example, the furnace 160 may include a cracking coil in the heating chamber, and electricity may be supplied to an electric heater in the heating chamber to heat the cracking coil. The substantially vaporization cracking feed 152 may pass through the cracking coil in the heating chamber and be heated and cracked in one or more endothermic reactions to provide, for example, a cracked effluent 180, as those skilled in the art will understand.

[0054] Although not in Figure 3 As shown, the pyrolysis effluent 180 can then be supplied to a heat exchanger. The heat exchanger may be able to transfer heat from the pyrolysis effluent 180, for example, to liquid water to generate steam. In some embodiments, the heat exchanger may be a transfer line exchanger (TLE) capable of rapidly cooling the pyrolysis effluent 180 received from the furnace 160.

[0055] In Figure 3In some embodiments of the vaporization assembly 100 shown, the heat exchanger includes a TLE (Transmission Electrode Regulator) which can be used to quench the cracked effluent 180, producing very high pressure (VHP) steam. In some embodiments, saturated VHP steam can be used for thermal integration within the assembly. For example, VHP steam can be used as a heating medium for one or more heaters of the vaporization assembly 100. In some embodiments, this can include using at least a portion of the VHP steam to drive one or more turbines to perform work.

[0056] and Figure 1-3 The vaporization units 10, 10A-D, and 100 shown are consistent, and one or more heaters can be operated and controlled independently of each other. This allows for improved operational control of the different processes occurring within units 10, 10A-D, and 100. In some embodiments, the ability to operate and control the heaters independently also allows for tailoring the operation of units 10, 10A-D, and 100 for cracking different types of hydrocarbon feedstocks. Additionally, one or more of the heaters described above may include multiple heaters and / or heat exchangers that can be arranged in series and / or in parallel.

[0057] In some embodiments, pressure changing devices, such as pumps, compressors, valves, orifices, etc., may be incorporated at any location into vaporization assemblies 10, 10A-D, and 100, for example, to maintain an indicated flow direction, as those skilled in the art will understand. The temperatures and / or pressures described herein may be adjusted, for example, according to the content of hydrocarbon feeds 12 and 112, to improve or optimize the operation of portions of vaporization assemblies 10, 10A-D, and 100.

[0058] Some illustrative embodiments of this disclosure have now been described. It will be apparent to those skilled in the art that the foregoing is merely illustrative and not restrictive, and is presented by way of example only. Many modifications and other embodiments are within the scope of those skilled in the art and are considered to fall within the scope of this disclosure. In particular, although many of the examples presented herein relate to specific combinations of method actions or system elements, it should be understood that those actions and those elements can be combined in other ways to achieve the same objective. Those skilled in the art will recognize that the parameters and configurations described herein are exemplary, and actual parameters and / or configurations will depend on the specific application of the system and techniques in which this disclosure is used. Those skilled in the art should also recognize or be able to determine equivalents of specific embodiments using no more than conventional experimentation. Therefore, it should be understood that the embodiments described herein are presented by way of example only, and that embodiments of this disclosure may be practiced differently than specifically described within the scope of any appended claims and their equivalents.

[0059] Furthermore, the scope of this disclosure should be interpreted as encompassing various modifications, combinations, additions, alterations, etc., of the above-described and above-described embodiments, which should be considered within the scope of this disclosure. Therefore, the various features and characteristics discussed herein are selectively interchangeable and applicable to other illustrated and unillustrated embodiments, and many further changes, modifications, and additions may be made thereto without departing from the spirit and scope of this disclosure as set forth in the appended claims.

Claims

1. A vaporization assembly for enhancing the vaporization of liquid hydrocarbon feed into an electric steam cracking furnace, the vaporization assembly comprising: a) A first heater, configured to receive dilution steam and capable of heating the dilution steam to provide superheated dilution steam; b) A separation device configured to receive the liquid hydrocarbon feed and the superheated dilution vapor, and capable of evaporating at least a portion of the liquid hydrocarbon feed via energy associated with the superheated dilution vapor to provide a gaseous hydrocarbon portion and a liquid hydrocarbon portion; c) A second electric heater, configured to receive the gaseous hydrocarbon portion and to heat the gaseous hydrocarbon portion to provide a superheated gaseous hydrocarbon portion; d) A mixing unit capable of combining and mixing the superheated gaseous hydrocarbon portion and the liquid hydrocarbon portion, and allowing at least a portion of the liquid hydrocarbon portion to evaporate via energy associated with the superheated gaseous hydrocarbon portion to provide a substantially vapor portion; and e) A third electric heater, which is configured to receive the substantially steam portion and be able to heat the substantially steam portion to provide substantially steam furnace feed.

2. The vaporization assembly according to claim 1, wherein the separation device comprises a steam stripper.

3. The vaporization assembly according to any one of claims 1 or 2, wherein the first heater configured to receive the dilution steam comprises an electric heater, a combination of an electric heater and a steam-based heat exchanger, and / or an electric heater and a heat transfer fluid configured to heat the dilution steam.

4. The vaporization assembly according to any one of the preceding claims, wherein the liquid hydrocarbon feed comprises one or more of ethane, propane, liquefied petroleum gas, naphtha, gas condensate, gas oil, diesel, jet fuel, gas-to-liquid fuel, pyrolysis oil, feedstock derived from recycled plastics, or bio-based feedstock.

5. The vaporization assembly according to any one of the preceding claims, the vaporization assembly further comprising a heater configured to directly receive the dilution vapor and capable of heating the dilution vapor to provide heated dilution vapor.

6. The vaporization assembly of claim 5, wherein the heater configured to directly receive the dilution steam is a steam-based heat exchanger.

7. The vaporization assembly according to any one of the preceding claims, the vaporization assembly further comprising a heater configured to receive the liquid hydrocarbon feed and to heat the liquid hydrocarbon feed to provide a heated liquid hydrocarbon feed.

8. The vaporization assembly of claim 7, wherein the heater configured to receive the liquid hydrocarbon feed is a steam-based heat exchanger, and / or wherein the steam-based heat exchanger is a shell-and-tube heat exchanger that uses saturated or unsaturated steam generated in a transmission line exchanger as a heat source.

9. The vaporization assembly according to any one of the preceding claims, the vaporization assembly further comprising a heater configured to receive the gaseous hydrocarbon portion and capable of heating the gaseous hydrocarbon portion to provide a heated gaseous hydrocarbon portion, wherein the heater configured to receive the gaseous hydrocarbon portion is a steam-based heat exchanger.

10. The vaporization assembly according to any one of the preceding claims, the vaporization assembly further comprising a heater configured to receive the liquid hydrocarbon portion and capable of heating the liquid hydrocarbon portion to provide a heated liquid hydrocarbon portion, wherein the heater configured to receive the liquid hydrocarbon portion is a steam-based heat exchanger.

11. A method for enhancing the vaporization of a liquid hydrocarbon feedstock in an electric steam cracking furnace, the method comprising: a) Supply the liquid hydrocarbon feed and superheated dilution steam to the separation unit; b) In the separation unit, at least a portion of the liquid hydrocarbon feed is evaporated via energy associated with the superheated dilution vapor to provide a gaseous hydrocarbon portion and a liquid hydrocarbon portion; c) Separating the gaseous hydrocarbon portion from the liquid hydrocarbon portion; d) Heating the gaseous hydrocarbon portion to provide a superheated gaseous hydrocarbon portion; e) Combining the superheated gaseous hydrocarbon portion and the liquid hydrocarbon portion, and evaporating at least a portion of the liquid hydrocarbon portion via energy associated with the superheated gaseous hydrocarbon portion to form a substantially vapor portion; and f) Heating the essentially steam section to provide essentially steam furnace feed.

12. The method of claim 11, wherein the superheated gaseous hydrocarbon portion in step d) and the substantially steam furnace feed in step f) are obtained by heating the gaseous hydrocarbon portion and the substantially steam portion in separate electric heaters, and / or wherein the superheated dilution steam is obtained by heating dilution steam in an electric heater.

13. A system for cracking liquid hydrocarbon feedstock, the system comprising: a) A first heater, which is configured to receive dilution steam and be able to heat the dilution steam to provide superheated dilution steam; b) A separation device configured to receive the liquid hydrocarbon feed and the superheated dilution vapor and to evaporate at least a portion of the liquid hydrocarbon feed via energy associated with the superheated dilution vapor to provide a gaseous hydrocarbon portion and a liquid hydrocarbon portion; c) A second electric heater, configured to receive the gaseous hydrocarbon portion and to heat the gaseous hydrocarbon portion to provide a superheated gaseous hydrocarbon portion; d) A mixing unit capable of combining and mixing the superheated gaseous hydrocarbon portion and the liquid hydrocarbon portion and allowing at least a portion of the liquid hydrocarbon portion to evaporate via energy associated with the superheated gaseous hydrocarbon portion to provide a substantially vapor portion; and e) A third electric heater, which is configured to receive the substantially vaporized portion and be able to heat the substantially steam portion to provide substantially vaporizer feed; and f) One or more electric heating furnaces configured to receive the substantially vaporizing furnace feed and to allow the substantially vaporizing furnace feed to react endothermally to provide pyrolysis effluent.

14. The system of claim 13, further comprising a transmission line exchange configured to receive the pyrolysis effluent and capable of rapidly cooling the pyrolysis effluent and / or wherein the separation device is a steam stripper.

15. The system according to claims 13-14, the system further comprising a steam-based heat exchanger configured to receive the liquid hydrocarbon portion and capable of heating the liquid hydrocarbon portion to provide a heated liquid hydrocarbon portion.

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