Systems and processes for improved hydrocarbon upgrading - Patents.com

Abstract

1. A system and process for upgrading a hydrocarbonaceous composition, comprising: introducing a hydrocarbonaceous composition into a reaction zone heated by electricity, concentrated solar radiant heat, nuclear reactor heat, geothermal heat, molten salt, molten metal, or combinations thereof; heating the hydrocarbonaceous composition in the reaction zone to produce a product stream; and cooling the product stream to create a cooled product stream, wherein the reaction zone does not produce flue gas.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of and priority to U.S. patent application Ser. No. 63 / 290,692, entitled "SYSTEMS AND PROCESSES FOR IMPROVING HYDROCARBON UPGRADING," filed on December 17, 2021, the entire contents of which are incorporated by reference into this disclosure.

[0002] This disclosure relates generally to systems and processes for converting hydrocarbonaceous compositions to desired products while minimizing carbon dioxide (CO2) emissions through the use of electrical heating. In particular, this disclosure relates to systems and processes that use an electrically heated reaction zone. [Background technology]

[0003] Feedstocks of ethane, propane, butane, naphtha, and other hydrocarbons must be upgraded before they can be used to produce commercially valuable products such as hydrogen, olefins, and aromatic hydrocarbons. This upgrading process traditionally employs reactor systems that use combustion, such as the combustion of methane, to heat the hydrocarbonaceous composition and convert it into a product stream containing the desired products. Additionally, the combustion furnaces of conventional reactor systems generate additional CO2 emissions.

[0004] Therefore, there is a need for systems and processes for converting hydrocarbonaceous compositions to desirable products while reducing CO2 emissions. Summary of the Invention

[0005] According to one embodiment of the present disclosure, a system for upgrading a hydrocarbonaceous composition includes a reaction vessel including a heating column, a heat recovery exchanger including a molten salt, a molten metal, an organic fluid as a heat transfer medium, or no intermediate fluid heat transfer, or a combination thereof, and an electric heater, the heating column thermally connected to the electric heater, and the heating column thermally connected to the heat recovery exchanger.

[0006] According to another embodiment of the present disclosure, a process for upgrading a hydrocarbonaceous composition includes introducing a hydrocarbonaceous composition to a reaction zone heated by electricity, concentrated solar radiant heat, nuclear reactor heat, geothermal heat, molten salt, molten metal, or combinations thereof, heating the hydrocarbonaceous composition in the reaction zone to produce a product stream, and cooling the product stream to create a cooled product stream, wherein the reaction zone does not produce flue gas.

[0007] Additional features and advantages will be described in the following Detailed Description of the Invention and will be readily apparent to those skilled in the art from that description or will be learned in part by practicing the embodiments described herein, including the following Detailed Description of the Invention, the claims, and the accompanying drawings.

[0008] It should be understood that both the foregoing general description and the following detailed description are intended to provide an overview or framework for understanding the nature and features of the claimed subject matter, describing various embodiments. The accompanying drawings are included to provide a further understanding of the various embodiments, and are incorporated in and constitute a part of this specification. The drawings illustrate various embodiments described herein, and together with the description, serve to explain the principles and operation of the claimed subject matter. [Brief description of the drawings]

[0009] [Figure 1] 1 illustrates generally a system and process for upgrading a hydrocarbon-based composition into desired products according to embodiments disclosed and described herein. [Diagram 2] 1 illustrates generally a system and process for upgrading a hydrocarbon-based composition into desired products according to embodiments disclosed and described herein. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Reference will now be made in detail to embodiments of systems and processes for upgrading hydrocarbon-based compositions into desired products, such as, for example, at least one of hydrogen, olefins, or aromatic hydrocarbons, which embodiments are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

[0011] In one embodiment, a system for upgrading a hydrocarbonaceous composition includes a reaction vessel containing a heating column, a heat recovery exchanger containing molten salt, molten metal, organic fluid as a heat transfer medium, or no intermediate fluid heat transfer, or a combination thereof, and an electric heater, the heating column thermally connected to the electric heater, and the heating column fluidly connected to the heat recovery exchanger. One or more of these systems may be replaced by another type of heat exchanger.

[0012] In another embodiment, a process for upgrading a hydrocarbonaceous composition includes introducing a hydrocarbonaceous composition into a reaction zone, heating the hydrocarbonaceous composition in the reaction zone to produce a product stream, and cooling the product stream to produce a cooled product stream, wherein the reaction zone is electrically heated.

[0013] Referring now to FIG. 1, an embodiment of a system for converting a hydrocarbonaceous composition into a desired product is provided. It should be understood that the embodiment depicted in FIG. 1 is exemplary and does not limit the scope of the present disclosure. As shown in the embodiment depicted in FIG. 1, a system 100 for converting a hydrocarbonaceous composition 240 into a product stream 310 comprising a desired product comprises, in series and / or parallel, a feed preheat unit 110, a first hydrocarbon heating unit 120, a dilution steam heating unit 130, a second hydrocarbon heating unit 140, an electric heater 150, and a reaction zone 160. It should be understood that according to various embodiments, the system 100 can include various combinations of the above-listed components of the system 100. Additionally, the system 100 can comprise one or more heat exchangers that can be thermally coupled to each other in series and / or parallel.

[0014] As shown in FIG. 1, in an embodiment, the reaction zone 160 may be part of the heating column 104 capable of creating the reaction conditions defined herein. However, in an embodiment, the reaction zone 160 may be outside the heating column 104 and may be fluidly connected to the heating column 104, as shown in FIG. 2. The reaction zone 160 may operate at a temperature in the range of 600° C. to 1200° C., e.g., 800° C. to 1000° C., 850° C. to 950° C., or 825° C. to 900° C., and at a pressure above 0 bar gauge (0 kPa gauge), e.g., at least 0.5 bar (50 kPa) or at least 1 bar (100 kPa). The lower the operating pressure, the better the selectivity. The operating pressure is limited by downstream pressure drop and the typical desire to run downstream processes at pressures above atmospheric pressure. In an embodiment, the operating pressure in the reaction zone may be any value above 0 bar gauge (0 kPa gauge). In some embodiments, reaction zone 160 may operate at a gauge pressure of 0.5-3 bar (50-300 kPa), 1-3 bar (100-300 kPa), 2-3 bar (200-300 kPa), 0.5-2 bar (50-200 kPa), 1-2 bar (100-200 kPa), or 0.5-1 bar (50-100 kPa).

[0015] In some embodiments, the duty (or power) required for the reaction in reaction zone 160 may range from 20 gigacalories per hour (Gcal / hr) to 50 Gcal / hr, 20 Gcal / hr to 40 Gcal / hr, 20 Gcal / hr to 35 Gcal / hr, 20 Gcal / hr to 32 Gcal / hr, 25 Gcal / hr to 50 Gcal / hr, 25 Gcal / hr to 40 Gcal / hr, 25 Gcal / hr to 35 Gcal / hr, 25 Gcal / hr to 32 Gcal / hr, 30 Gcal / hr to 50 Gcal / hr, 30 Gcal / hr to 40 Gcal / hr, 30 Gcal / hr to 35 Gcal / hr, or 30 Gcal / hr to 32 Gcal / hr. It is understood that the duty required for the reaction may be proportional to the throughput, according to an embodiment.

[0016] The systems and processes disclosed herein for converting a hydrocarbonaceous composition to a desired product address the need to reduce CO2 emissions, the need to heat at least one reaction zone 160 by electrical heating, or the need for direct or indirect heat input by convection, conduction, or thermal radiation. Some examples include concentrated solar radiation, nuclear reactor heat, geothermal heat, or heat storage in molten salts or molten metals. In an embodiment, the electric heater 150 heats the hydrocarbonaceous composition 240 to a desired reaction zone 160 inlet temperature of approximately 600°C. Conventional combustion reactors generate flue gas (which generally has a temperature higher than 600°C) as a by-product from combustion. In conventional upgrading systems and processes, the flue gas constitutes approximately 60% of the heat and energy input of the combustion reaction, thereby creating significant inefficiencies. Because the flue gas is a natural result of the combustion reaction and has approximately 60% of the energy of the reaction, heat from the flue gas is conventionally utilized upstream of the conversion reaction zone to heat the hydrocarbonaceous composition prior to reaction and to heat a dilution steam stream. Because no flue gas is produced from the reaction zone disclosed herein, the disclosed systems and processes incorporate new process designs for heating the hydrocarbonaceous composition prior to reaction and for heating the dilution vapor stream.

[0017] In some embodiments, the reactor system 100 is connected to a current source that provides current to the reactor system 100 through electrical leads. In embodiments, the heating column 104 may include at least one trim temperature controller 180. In embodiments, the trim temperature controller 180 may be a trim heater or a trim cooler configured to heat or cool. In embodiments, the trim heater 180 may be a single unit for either heating or cooling, and in other embodiments, heating and cooling may be provided by separate units. In embodiments, the trim heater may be electrically driven. Current may be provided to the electric heater 150, the trim heater, or a combination thereof. The electrical leads convey the current from the current source to the electric heater 150, the at least one trim temperature controller 180, or both, via an electrical connection between the current source and the electric heater 150, the at least one trim temperature controller 180, or both. In various embodiments, the current source may be a renewable energy source that does not emit CO2. The source of current may be, in embodiments, nuclear, steam energy, natural gas, coal, etc. The source of current may be, in embodiments, a renewable source, such as batteries, solar power, wind energy, hydroelectric power, etc. The current may be decreased or increased external to the system 100. In some embodiments, the current may be actively controlled, turned on and off, decreased or increased to control the heat generated in the electric heater 150, the at least one trim temperature controller 180, or both.

[0018] In some embodiments, the heating column 104 of the reactor system 100 comprises one reaction zone 160 (as shown). In some embodiments, the heating column 104 comprises at least two reaction zones 160 (additional reaction zones not shown). The at least two reaction zones 160 may be configured in parallel or in series. Each of these at least two reaction zones 160 may independently receive an electric current. The voltage of the electric current that may be converted to heat indicates the heat of the reaction zone 160 with a particular ampere of current. Specifically, the temperature of the reaction zone 160 during the process of converting the hydrocarbonaceous composition 240 may be determined from the resistivity value of the electric heater that heats the reaction zone 160 and the ampere of electric current that is converted to heat in the electric heater 150. Joule's first law states that the power (P) of heat generated by an electric conductor is proportional to the product of its resistance (R) and the square of the current (I), as shown by Equation 1. P ∝ I 2 R (1)

[0019] According to an embodiment, one or more additional components may be included in the reactor system 100. In an embodiment as shown in FIG. 1, the heating column 104 may further comprise a feed preheat unit 110, a first hydrocarbon heating unit 120, a dilution steam heating unit 130, and a second hydrocarbon heating unit 140. The first hydrocarbon heating unit 120 may be fluidly connected to the feed preheat unit 110, the dilution steam heating unit 130, and the second hydrocarbon heating unit 140. The second hydrocarbon heating unit 140 may be fluidly connected to the dilution steam heating unit 130, the first hydrocarbon heating unit 120, and the reaction zone 160. The feed preheat unit 110, the first hydrocarbon heating unit 120, the dilution steam heating unit 130, and the second hydrocarbon heating unit 140 may function as heat exchangers. There may be one or more heat exchangers in the system 100, which may be in parallel and / or in series. The heat exchangers may minimize the electrical energy consumption of the system. As mentioned above, the heating column 104 may further include at least one trim temperature controller 180. The trim temperature controller 180 may be thermally connected to at least one of the feed preheating unit 110, the first hydrocarbon heating unit 120, the dilution steam heating unit 130, or the second hydrocarbon heating unit 140. Although FIG. 1 shows the trim temperature controller 180 thermally connected only to the dilution steam heating unit 130, this should be understood as merely an exemplary embodiment. As shown in FIG. 2, there may be a trim temperature controller 180 connected to each of the feed preheating unit 110, the first hydrocarbon heating unit 120, the dilution steam heating unit 130, or the second hydrocarbon heating unit 140. Thus, it should be understood that the trim temperature controller 180 may or may not be connected to any of the feed preheating unit 110, the first hydrocarbon heating unit 120, the dilution steam heating unit 130, or the second hydrocarbon heating unit 140, as needed.In an embodiment, the trim temperature controller 180 may be a trim heater or trim cooler configured to heat or cool at least one of the feed preheat unit 110, the first hydrocarbon heating unit 120, the dilution steam heating unit 130, or the second hydrocarbon heating unit 140, as appropriate. In an embodiment, the trim temperature controller 180 may be electrically heated and cooled by other means. The trim temperature controller 180 operates to heat or cool either the feed preheat unit 110, the first hydrocarbon heating unit 120, the dilution steam heating unit 130, or the second hydrocarbon heating unit 140 to optimize heating and cooling efficiency in the system.

[0020] According to one or more embodiments, a process for converting a hydrocarbonaceous composition 240 into a desired product, such as a product stream 310 comprising at least one of hydrogen, olefins, or aromatic hydrocarbons, using the system 100 shown in the embodiment of FIG. 1 will now be described. The hydrocarbonaceous composition 240 is introduced into the reaction zone 160. It should be understood that the hydrocarbonaceous composition 240 may comprise naphtha or a heavier hydrocarbon mixture, methane, ethane, propane, butane, pentane, water, and low levels of at least one of CO2, CO, N2, and H2, according to various embodiments. In an embodiment, the naphtha may comprise, by way of non-limiting example, atmospheric gas oil, vacuum gas oil, or both. In an embodiment, the butane may comprise, by way of non-limiting example, n-butane, i-butane, or both. In some embodiments, the hydrocarbonaceous composition 240 comprises C1-C5 hydrocarbons. In other embodiments, the hydrocarbonaceous composition 240 may comprise, by way of non-limiting example, C1-C5 hydrocarbons. 20 In yet another embodiment, the hydrocarbon-based composition 240 comprises a C1-C 50 Contains hydrocarbons.

[0021] The temperature at which reaction zone 160 operates is not particularly limited, so long as it is capable of driving reactions to convert the hydrocarbonaceous composition 240 to desired products, such as, for example, hydrogen, olefins, aromatic hydrocarbons, or combinations thereof. In embodiments, reaction zone 160 is capable of converting the hydrocarbonaceous composition 240, which comprises at least C2 hydrocarbons, to a product stream 310, which comprises at least C2 olefins. In one or more embodiments, reaction zone 160 operates at a temperature between 600 degrees Celsius (°C) and 850°C, such as between 825°C and 845°C, or about 840°C. Similarly, the pressure at which reaction zone 160 operates is not particularly limited so long as it is capable of driving the above reactions, and in one or more embodiments, reaction zone 160 operates at a pressure of 0.3-3 bar(g) (30-300 kPa), 1-3 bar(g) (100-300 kPa), 2-3 bar(g) (200-300 kPa), 0.5-2 bar(g) (50-200 kPa), 1-2 bar(g) (100-200 kPa), or 0.5-1 bar(g) (50-100 kPa).

[0022] Finally, the process includes converting the hydrocarbonaceous composition 240 to a product stream 310 in the reaction zone 160 and removing the product stream 310 from the reaction zone 160. Converting the hydrocarbonaceous composition 240 to the product stream 310 may include increasing the temperature of the hydrocarbonaceous composition 240, thereby causing a chemical reaction to produce the product stream 310. The hydrocarbonaceous composition 240 may be heated by an electric heater 150 under reactive conditions sufficient to form the product stream 310. The reaction conditions may include a temperature between 600 degrees Celsius (°C) and 850°C, for example, between 825°C and 845°C, or about 840°C, and a pressure between 0.3 and 3 bar (30 and 300 kPa), 1 and 3 bar (100 and 300 kPa), 2 and 3 bar (200 and 300 kPa), 0.5 and 2 bar (50 and 200 kPa), 1 and 2 bar (100 and 200 kPa), or 0.5 and 1 bar (50 and 100 kPa). In some embodiments, the electric heater 150 is heated to a temperature greater than 500°C, greater than 600°C, greater than 700°C, greater than 750°C, greater than 800°C, greater than 850°C, greater than 900°C, greater than 950°C, or greater than 1000°C. The reaction occurring in the reaction zone 160 produces a product stream 310. In some embodiments, the reaction that occurs further produces by-products including one or more of CO, CO2, H2, H2O, CH4, C2H6, C2H2, C3H6, C3H8, and C3H4. The temperature of the product stream 310 leaving the reaction zone 160 may be between 750°C-900°C, 780°C-900°C, 800°C-900°C, 850°C-900°C, 860°C-900°C, 870°C-900°C, 880°C-900°C, 890°C-900°C, 750°C-890°C, 780°C-890°C, 800°C-890°C, 850°C-890°C, 860°C-89 ...890°C, 880°C-890°C, 890°C-890°C, 890°C-890°C, 890°C-890°C, 890°C-890°C, 890°C-890°C, 890°C-890°C, 890°C-890°C, 890°C-890°C, 890°C-890°C, 890°C-890°C, 90°C, 870°C to 890°C, 880°C to 890°C, 750°C to 880°C, 780°C to 880°C, 800°C to 880°C, 850°C to 880°C, 860°C to 880°C, 870°C to 880°C, 750°C to 870°C, 780°C to 870°C, 800°C to 870°C, 850°C to 870°C, 860°C to 870°C, or approximately 860°C.

[0023] The product stream 310 includes at least one of hydrogen, olefins, and aromatic hydrocarbons. In one or more embodiments, the product stream 310 consists essentially of, or consists of, at least one of hydrogen, olefins, and aromatic hydrocarbons. In embodiments, the olefins include C2-C5 olefins, such as, for example, ethylene (C2H4), propylene (C3H6), butylenes (C4H8), butadiene (C4H6), or combinations thereof. In embodiments, the butylenes may include, by way of non-limiting examples, 1-butylene, 2-butylene, i-butylene, or combinations thereof. In other embodiments, the olefins include, for example, C2-C5 olefins, such as, for example, ethylene (C2H4), propylene (C3H6), butylenes (C4H8), butadiene (C4H6), or combinations thereof. In other embodiments, the olefins include, for example, 1-butylene, 2-butylene, i-butylene, or combinations thereof. 10 Olefins include C2 to C 20 In yet another embodiment, the olefin may comprise a C2-C 50 The aromatic hydrocarbons may include olefins. The aromatic hydrocarbons may include benzene and its derivatives, such as toluene, ethylbenzene, o-xylene, p-xylene, m-xylene, mesitylene, durene, 2-phenylhexane, and biphenyl. The product stream 310 is collected and separated or purified in various other processes to produce desired intermediates and final products.

[0024] The process may further include preheating the hydrocarbonaceous composition 240 prior to introducing the hydrocarbonaceous composition 240 into the reaction zone 160. As previously discussed, flue gas produced from a conventional combustion reaction is traditionally used to heat the hydrocarbonaceous composition prior to reaction. However, because the systems and processes disclosed herein do not use a conventional combustion reaction to heat the reaction zone 160, there is no flue gas in the systems and processes disclosed herein. Thus, the absence of flue gas opens the door to new process designs for heating the hydrocarbonaceous composition prior to reaction. There may be one or more heat exchangers, such as a feed preheat unit 110, a first hydrocarbon heating unit 120, a dilution steam heating unit 130, and a second hydrocarbon heating unit 140, through which the product stream 310 (having a higher temperature than the hydrocarbonaceous composition 240 before it enters the reaction zone 160) may pass (described in more detail below) to heat the hydrocarbonaceous composition 240, any stream precursors of the hydrocarbonaceous composition, the dilution steam stream 410, or a combination thereof. By using the heat of the product stream 310 to heat other streams in the heating column 104, the overall efficiency of the process is increased by recycling the energy of the reaction. In embodiments, the disclosed systems and processes may require less than 99%, 95%, 90%, 85%, 80%, 75%, 70%, 65%, or 62% of the power of conventional hydrocarbon upgrading systems and processes using conventional gas combustion reactions. By using heat in this manner, stack losses from conventional gas-fired furnaces can be eliminated, resulting in approximately 10% energy savings. Elimination of high pressure steam production can result in up to 40% savings in furnace energy input. When high pressure steam production is required, downstream process compressors may be switched from steam turbine driven to electric motor driven.In embodiments, the systems and processes of the present disclosure may require only 50%-99%, 50%-95%, 50%-90%, 50%-85%, 50%-80%, 50%-75%, 50%-70%, 50%-65%, 50%-62%, 55%-99%, 55%-95%, 55%-90%, 55%-85%, 55%-80%, 55%-75%, 55%-70%, 55%-65%, 55%-62%, 60%-99%, 60%-95%, 60%-90%, 60%-85%, 60%-80%, 60%-75%, 60%-70%, 60%-65%, or 60%-62% of the power of conventional hydrocarbon upgrading systems and processes using conventional gas combustion reactions.

[0025] In an embodiment, the process includes passing the feed stream 210 through a feed preheat unit 110 to produce a preheated hydrocarbonaceous composition 220. The temperature of the feed stream 210 prior to being introduced into the feed preheat unit 110 may be between 50°C and 110°C, between 60°C and 110°C, between 70°C and 110°C, between 80°C and 110°C, between 90°C and 110°C, between 100°C and 110°C, between 50°C and 100°C, between 60°C and 100°C, between 70°C and 100°C, between 80°C and 100°C, between 90°C and 100°C, between 50°C and 90°C, between 60°C and 90°C, between 70°C and 90°C, between 80°C and 90°C, between 50°C and 80°C, between 60°C and 80°C, between 70°C and 80°C, between 50°C and 70°C, between 60°C and 70°C, or between 50°C and 60°C. The outlet temperature of the preheated hydrocarbonaceous composition 220 from the feed preheat unit 110 may be less than the operating temperature of the reaction zone 160. The outlet temperature of the preheated hydrocarbonaceous composition 220 from the feed preheat unit 110 may be 150°C to 300°C, 150°C to 275°C, 150°C to 250°C, 150°C to 225°C, 150°C to 220°C, 150°C to 200°C, 150°C to 175°C, 175°C to 300°C, 175°C to 275°C, 175°C to 250°C, 175°C to 225°C, 175°C to 220°C, 175°C to The reaction temperature may be 200°C, 200°C-300°C, 200°C-275°C, 200°C-250°C, 200°C-225°C, 200°C-220°C, 220°C-300°C, 220°C-275°C, 220°C-250°C, 220°C-225°C, 225°C-300°C, 225°C-275°C, 225°C-250°C, 250°C-300°C, 250°C-275°C, or 275°C-300°C. The feed preheat unit 110 may be used to remove heat from the product stream 310, and the heat removed from the product stream 310 may be used to preheat the hydrocarbonaceous composition 240. The feed preheat unit 110 may cool the product stream 310 below the reaction temperature. Cooling the product stream 310 below the reaction temperature prevents further reaction or conversion of the product stream 310.The feed preheat unit 110 preheats the product stream 310 at temperatures between 300°C and 500°C, 300°C and 450°C, 300°C and 425°C, 300°C and 405°C, 300°C and 400°C, 300°C and 375°C, 300°C and 350°C, 350°C and 500°C, 350°C and 450°C, 350°C and 425°C, 350°C and 405°C, 350°C and 400°C, The hydrocarbonaceous composition 240 may be cooled to 350° C.-375° C., 375° C.-500° C., 375° C.-450° C., 375° C.-425° C., 375° C.-405° C., 375° C.-400° C., 400° C.-500° C., 400° C.-450° C., 400° C.-425° C., 400° C.-405° C., 425° C.-500° C., 425° C.-450° C., or 450° C.-500° C. If the hydrocarbonaceous composition 240 is a vapor stream, it is not necessary to preheat the hydrocarbonaceous composition 240 before introducing the hydrocarbonaceous composition 240 into the electric heater 150 or reaction zone 160, and therefore this may be an optional component in the systems and processes disclosed herein.

[0026] In an embodiment, the process may further include mixing the heated dilution steam 410 from the dilution steam heating unit 130 with the preheated composition 220 from the feed preheater 110 to obtain a mixed hydrocarbonaceous composition 225, and subsequently heating the mixed hydrocarbonaceous composition 225 by introducing the mixed hydrocarbonaceous composition 225 to the first hydrocarbon heating unit 120 to produce a heated hydrocarbonaceous composition 230. In an embodiment in which the heated dilution steam 410 is not mixed with the preheated composition 220, the process may include heating the preheated composition 220 by introducing the preheated composition 220 to the first hydrocarbon heating unit 120 to produce a heated hydrocarbonaceous composition 230. The outlet temperature of the heated hydrocarbonaceous composition 230 from the first hydrocarbon heating unit 120 may be less than the operating temperature of the reaction zone 160. The outlet temperature of the heated hydrocarbon composition 230 from the first hydrocarbon heating unit 120 is 300°C to 500°C, 300°C to 450°C, 300°C to 425°C, 300°C to 400°C, 300°C to 375°C, 300°C to 350°C, 300°C to 325°C, 325°C to 500°C, 325°C to 450°C, 325°C to 425°C, 325°C to 400°C, 325°C to 37 ... The reaction temperature may be between 300°C and 350°C, between 300°C and 500°C, between 300°C and 450°C, between 300°C and 425°C, between 300°C and 400°C, between 300°C and 45 ... Cooling the product stream 310 below the reaction temperature prevents further reaction or conversion of the product stream 310.The first hydrocarbon heating unit 120 may cool the product stream 310 to between 450°C and 600°C, between 450°C and 575°C, between 450°C and 550°C, between 450°C and 525°C, between 450°C and 500°C, between 450°C and 475°C, between 475°C and 600°C, between 475°C and 575°C, between 475°C and 550°C, between 475°C and 525°C, between 475°C and 500°C, between 500°C and 600°C, between 500°C and 575°C, between 500°C and 550°C, between 500°C and 525°C, between 525°C and 600°C, between 525°C and 575°C, between 525°C and 550°C, between 550°C and 600°C, between 550°C and 575°C, or between 575°C and 600°C. This may likewise be an optional component in the systems and processes disclosed herein.

[0027] The process may further include heating the heated hydrocarbonaceous composition 230 by introducing the pre-heated hydrocarbonaceous composition 220 into a second hydrocarbon heating unit 140 to produce a hydrocarbonaceous composition 240. The outlet temperature of the hydrocarbonaceous composition 240 from the second hydrocarbon heating unit 140 may be less than the operating temperature of the reaction zone 160. The outlet temperature of the hydrocarbon composition 240 from the second hydrocarbon heating unit 140 may be 450°C to 600°C, 450°C to 575°C, 450°C to 550°C, 450°C to 525°C, 450°C to 500°C, 450°C to 475°C, 475°C to 600°C, 475°C to 575°C, 475°C to 550°C, 475°C to 525°C, 475°C to 500°C, 500°C to 600°C, 500°C to 575°C, 500°C to 550°C, 500°C to 525°C, 525°C to 600°C, 525°C to 575°C, 525°C to 550°C, 550°C to 600°C, 550°C to 575°C, or 575°C to 600°C. The second hydrocarbon heating unit 140 can be used to remove heat from the product stream 310, and the heat removed from the product stream 310 can be used to heat the heated hydrocarbon-based composition 240. The second hydrocarbon heating unit 140 can rapidly cool the product stream 310 below the reaction temperature. By cooling the product stream 310 below the reaction temperature, further reaction or conversion of the product stream 310 is prevented. The second hydrocarbon heating unit 140 can rapidly cool the product stream 310 below the reaction temperature to 600°C to 800°C, 600°C to 750°C, 600°C to 725°C, 600°C to 700°C, 600°C to 675°C, 600°C to 650°C, 600°C to 625°C, 625°C to 800°C, 625°C to 750°C, 625°C to 725°C, 625°C to 700°C, 625°C to 675°C, 625°C to 650°C, 650 ... ℃~800℃, 650℃~750℃, 650℃~725℃, 650℃~700℃, 650℃~675℃, 675℃~800℃, 675℃~750℃, 675℃~725℃, 675℃~700℃, 700℃~800℃, 700℃~750℃, 700℃~725℃, 725℃~800℃, 725℃~750℃, or 750℃~800℃.In some embodiments, the second hydrocarbon heating unit 140 cools the product stream 310 to less than 800° C., less than 700° C., less than 600° C., or less than 500° C. within 1000 ms, 500 ms, 200 ms, 100 ms, or 50 ms, which may also be an optional component in the systems and processes disclosed herein.

[0028] In some embodiments, the process further includes removing heat from the product stream 310 after it is removed from the reaction zone 160 by passing the product stream 310 through a dilution steam heating unit 130. The dilution steam heating unit 130 can cool the product stream 310 below the reaction temperature. By rapidly cooling the product stream 310 below the reaction temperature, further reaction or conversion of the product stream 310 is prevented. In some embodiments, the dilution steam heating unit 130 cools the product stream 310 to below 600° C. or below 500° C. The process may further include passing the dilution steam stream 410 through the dilution steam heating unit 130. The temperature of the dilution steam stream 410 prior to being introduced into the dilution steam heating unit 130 may be between 150° C. and 200° C., between 160° C. and 200° C., between 170° C. and 200° C., between 180° C. and 200° C., between 190° C. and 200° C., between 150° C. and 190° C., between 160° C. and 190° C., between 170° C. and 190° C., between 180° C. and 190° C., between 150° C. and 180° C., between 160° C. and 180° C., between 170° C. and 180° C., between 150° C. and 170° C., between 160° C. and 170° C., between 150° C. and 160° C., or about 175° C. The process may include cooling the product stream 310 in the dilution steam heating unit 130 with the dilution steam stream 410. In an embodiment, the process may further include passing the dilution steam stream 410 from the dilution steam heating unit 130 to mix with the pre-heated hydrocarbonaceous composition 220, thereby transferring heat from the dilution steam stream 410 to the pre-heated hydrocarbonaceous composition 220. Passing the dilution steam stream 410 may increase the energy efficiency of the system 100. Additionally, it is contemplated that mixing the dilution steam stream 410 with the pre-heated hydrocarbonaceous composition 220 prior to introducing the pre-heated hydrocarbonaceous composition 220 to the first hydrocarbon heating unit 120 may prevent condensation. The product stream 310 may be cooled according to other methods known in the art, and therefore these are optional components of the systems and processes disclosed herein.

[0029] In an embodiment, the process may further include cooling the product stream 310 in a heat recovery exchanger 170. The heat recovery exchanger 170 may include a heat exchanger having molten salt, molten metal, organic fluid, or water as the heat transfer medium, a spray nozzle, a quench column, direct heat transfer, or a combination thereof. In an embodiment, the product stream 310 may be cooled below the reaction temperature before being introduced into the heat recovery exchanger 170. In an embodiment, the product stream 310 may not be cooled below the reaction temperature before being introduced into the heat recovery exchanger 170, which may function as a quenching step. Quenching the product stream 310 below the reaction temperature prevents further reaction or conversion of the product stream 310 and rapidly stops such reaction and conversion in the product stream. It should be understood that the term "cooling" is used throughout this disclosure to describe various steps in which a stream is cooled as described herein and may encompass steps in which a stream is quenched. The term "cooling" is not meant to be limiting, but instead is meant to encompass embodiments in which a stream is quenched to stop reaction or conversion within the stream. If the cooling step involves direct heat transfer, the process may further include passing a low temperature coolant stream (not shown) through a coolant drum (not shown) and then moving to the heat recovery exchanger 170. The process may include cooling the product stream 310 in the heat recovery exchanger 170 with the low temperature coolant stream.

[0030] Additionally, in some embodiments, the systems and processes claimed herein do not produce CO2 emissions from the heating process. Specifically, the systems and processes herein utilize electrical heating systems and processes, which results in no direct CO2 production from the heating systems and processes, as compared to traditional systems that utilize combustion reactions to generate heat. These combustion reaction systems and processes traditionally burn methane or other gases, which results in CO2 emissions. Although the product stream 310 may include CO2, the systems and processes claimed herein do not produce CO2 emissions from the heating process. EXAMPLES

[0031] The following examples illustrate one or more of the embodiments of the present disclosure discussed above. Additionally, comparative examples were performed.

[0032] Comparative example A A conventional upgrading process was determined in which the feedstock was introduced into a 90°C preheater and heated to 149°C. A dilution steam stream was introduced into a dilution steam heating unit where the dilution steam stream was heated from an initial 175°C to 465°C. The dilution steam stream was then mixed with the feedstock before the feedstock was sent to a first hydrocarbon heating unit where the feedstock was heated to 205°C. The feedstock was then introduced into a first hydrocarbon heating unit where it was heated to 385°C. The feedstock was then sent to a second hydrocarbon heating unit where it was heated to 597°C and sent to a reaction zone where it was heated and converted to form a product stream with a propylene / ethylene ratio of 0.51, resulting in an exit temperature of 861°C. The product stream was then sent to two transfer line exchangers in series where it was cooled from 855°C to 469°C in the first transfer line exchanger and then cooled from 469°C to 353°C in the second transfer line exchanger. High pressure steam having a temperature of 310°C was generated in the transfer line exchanger. The product stream was then sent to a heat recovery exchanger. Flue gas from a conventional combustion reaction zone was used to superheat steam from 311°C to 433°C and 391°C to 490°C in steam superheater units 1 and 2. Boiler feed water sent to the steam drum is preheated from 120°C to 202°C in an economizer. The flue gas in this simulation is cooled from 1187°C to 136°C. The results of this simulation are summarized in Tables 1 and 2 below.

[0033] [Table 1]

[0034] [Table 2]

[0035] Example 1 An upgrading process according to the present disclosure was determined. A similar procedure to Comparative Example A was followed, but an electrically heated reaction zone (as opposed to a conventional combustion reaction zone in Comparative Example A) was used, so there was no flue gas in Example 1, and instead, an electric heater was used to heat steam, since no flue gas was produced in Example 1. The feedstock was introduced into a 90°C preheater and heated to 149°C. A dilution steam stream was introduced into a dilution steam heating unit, where the dilution steam stream was heated from an initial 175°C to 465°C. The dilution steam stream was then mixed with the feedstock, after which the feedstock was sent to a first hydrocarbon heating unit, where the feedstock was heated to 205°C. The feedstock was then introduced into a first hydrocarbon heating unit, where it was heated to 385°C. The feedstock was then sent to a second hydrocarbon heating unit, where it was heated to 597°C, and sent to a reaction zone, where it was heated to 861°C to form a product stream. The product stream was then sent to two transfer line exchangers in series, cooled from 855°C to 469°C in the first transfer line exchanger, and then cooled from 469°C to 353°C in the second transfer line exchanger. High pressure steam having a temperature of 310°C was used in the transfer line exchangers. The product stream was then sent to a heat recovery exchanger. The results of this simulation are summarized in Table 3 below.

[0036] [Table 3]

[0037] Example 2 An upgrade process according to the present disclosure was determined. The reaction zone was electrically heated as in Example 1, but in Example 2, the product stream was further utilized to heat the feed stream to maximize process efficiency. As a result of this change, the intermediate temperatures of the feed stream and the product stream were further optimized. In Example 2, in contrast to Comparative Example A and Example 1, no high pressure steam was generated. For comparison purposes only, the equivalent shaft power per ton of high pressure steam generated was calculated for 90 bar to the condensing steam turbine. Using the calculated steam production from Example 1, the equivalent power requirement for the electric motor was calculated and included in the form of power as "high pressure steam credit for turbine", as shown in Table 4. The feed stream 210 was introduced into the preheater 110 at 90°C and heated to 224°C to form the preheated hydrocarbonaceous composition 220. The dilution steam stream 410 was introduced into the dilution steam heating unit 130, where the dilution steam stream 410 was heated from an initial 175°C to 465°C. The dilution vapor stream 410 was then mixed with the preheated hydrocarbonaceous composition 220 before the mixed hydrocarbonaceous composition 225 was sent to the first hydrocarbon unit 120. The mixed hydrocarbonaceous composition 225 was then introduced into the first hydrocarbon heating unit 120 and heated to 385°C to produce a heated hydrocarbonaceous composition 230. The heated hydrocarbonaceous composition 230 was then sent to the second hydrocarbon heating unit 140 and heated to 550°C to form a hydrocarbonaceous composition 240, which was sent to the electric heater 150 and heated to 597°C. The hydrocarbonaceous composition 240 was then sent to the reaction zone 160 where it was heated to 861°C to form a product stream 310. The product stream 310 was then passed to the second hydrocarbon heating unit 140 where it heated the heated hydrocarbonaceous composition 230 as previously described, thereby cooling from 855°C to 692°C. The product stream 310 was then passed to the dilution steam heating unit 130 where it heated the dilution steam stream 410, as previously described, and was thereby cooled to 615° C. The product stream 310 was then sent to the first hydrocarbon heating unit 120 where it heated the preheated hydrocarbon-based composition 220, as previously described, and was thereby cooled to 528° C.The product stream 310 was then transferred to the preheater 110 where it heated the feed stream 210 as previously described, thereby cooling it to 401° C. The results of this simulation are summarized in Tables 4 and 5 below.

[0038] [Table 4]

[0039] [Table 5]

[0040] Pinch analysis is a methodology for minimizing the energy consumption of a chemical process by calculating a thermodynamically feasible energy target (or minimum energy consumption) and achieving it by optimizing the heat recovery system, energy supply method, and process operating conditions. The pinch temperature is the minimum temperature difference (ΔT) between the feed and product streams. The salt temperature is the temperature of the salt bath (which is equal to the feed outlet temperature plus an offset). The offset is the difference between the temperature of the salt bath and the inlet feed temperature. This energy balance is based on the worst case assumption of an isothermal temperature for the heat transfer fluid (salt bath); in other embodiments, a temperature profile of the heat transfer fluid can be achieved that results in a larger minimum temperature difference (ΔT) between the feed and product streams.

[0041] The energy consumption for each of Comparative Example A, Example 1, and Example 2 is shown in Table 6 below.

[0042] [Table 6]

[0043] Comparative Example A utilized a conventional combustion reaction zone and required a combustion duty (power) of 77.42 Gcal / hr to operate the reaction. In Comparative Example A, high pressure steam was generated by recovering residual heat from a conventional combustion furnace. As previously mentioned, Example 1, in which all heating was done electrically, required 71.77 Gcal / hr of power, which was slightly less than Comparative Example A due to the elimination of stack losses. In Example 1, high pressure steam was generated by recovering residual heat from electrical heating. Example 2 did not include a high pressure steam stream since there was no residual heat by using the product stream to heat the feed stream. Example 2 showed a 61% reduction in power usage compared to Example 1, which indicates that the power required to operate the system was reduced from 71.77 Gcal / hr to 43.8 Gcal / hr using the product stream to heat the feed stream (in other words, Example 2 required only 61% of the power required by Comparative Example A and Example 1, reducing power consumption by 39% compared to Comparative Example A and Example 1).

[0044] It will be apparent to those skilled in the art that various modifications and variations can be made to the embodiments described herein without departing from the spirit and scope of the claimed subject matter. Accordingly, it is intended that the present specification cover modifications and variations of the various embodiments described herein, provided such modifications and variations come within the scope of the appended claims and their equivalents.

Claims

1. 1. A process for upgrading a hydrocarbon-based composition, comprising: introducing the hydrocarbonaceous composition into a reaction zone heated by electricity, concentrated solar radiation, nuclear reactor heat, geothermal heat, molten salt, molten metal, or a combination thereof; heating the hydrocarbonaceous composition in the reaction zone to produce a product stream; cooling the product stream to produce a cooled product stream; Including, The process wherein the reaction zone does not produce flue gas.

2. 10. The method of claim 1, further comprising preheating the hydrocarbonaceous composition prior to heating the hydrocarbonaceous composition in the reaction zone, wherein preheating the hydrocarbonaceous composition comprises transferring heat from the product stream to the hydrocarbonaceous composition, thereby cooling the product stream.

3. cooling the product stream transferring heat from said product stream to a dilution vapor stream; transferring heat from the product stream to the hydrocarbonaceous composition; or The method of claim 1 including both.

4. introducing the feed stream into a feed preheating unit; introducing the product stream into the feed preheat unit; preheating the feed stream in the feed preheat unit to produce a preheated hydrocarbonaceous composition, and cooling the product stream in the feed preheat unit by transferring heat from the product stream to the feed stream; The method of claim 1 further comprising:

5. introducing the preheated hydrocarbon-based composition into a first hydrocarbon heating unit; introducing the product stream into the first hydrocarbon heating unit; heating the preheated hydrocarbon-based composition in the first hydrocarbon heating unit to produce a heated hydrocarbon-based composition; and cooling the product stream in the first hydrocarbon heating unit, comprising transferring heat from the product stream to the preheated hydrocarbon-based composition; The method of claim 4 further comprising:

6. introducing the heated hydrocarbon-based composition into a second hydrocarbon heating unit; introducing the product stream into the second hydrocarbon heating unit; heating the heated hydrocarbon-based composition in the second hydrocarbon heating unit to produce a hydrocarbon-based composition; and cooling the product stream in the second hydrocarbon heating unit, comprising transferring heat from the product stream to the heated hydrocarbon-based composition. The method of claim 5 further comprising:

7. introducing a dilution steam stream into a steam unit; introducing the product stream into the steam unit; cooling the product stream in the dilution steam heating unit by transferring heat from the product stream to the dilution steam stream; The method of claim 5 further comprising:

8. 10. The method of claim 1, wherein heating the hydrocarbonaceous composition in the reaction zone to produce a product stream comprises heating the hydrocarbonaceous composition to a reaction temperature in the range of 700°C to 950°C, thereby cracking the hydrocarbonaceous composition to produce the product stream.

9. 10. The method of claim 1, further comprising further cooling the cooled product stream with a fluid comprising a molten salt, a molten metal, an organic fluid, an inorganic fluid, or a combination thereof.

10. 10. The method of any of claims 1 to 9, wherein the hydrocarbonaceous composition comprises naphtha, ethane, propane, butane, pentane, atmospheric gas oil (AGO), vacuum gas oil (VGO), or a combination thereof, and the product stream comprises hydrogen, olefins, and aromatic hydrocarbons.

11. 1. A system for improving the quality of a hydrocarbon-based composition, comprising: a reaction vessel containing a heating column; a heat recovery exchanger containing a molten salt, a molten metal, an organic fluid, an inorganic fluid, or a combination thereof; An electric heater and Equipped with the heating column is thermally connected to the electric heater; The heating column is thermally connected to the heat recovery exchanger.

12. a reaction zone, wherein the heating column comprises a preheat unit, a first hydrocarbon unit, a dilution unit, a second hydrocarbon unit, and a trim heater, a trim cooler, or both; the first hydrocarbon unit is fluidly connected to the preheat unit, the dilution unit, and the second hydrocarbon unit; 12. The system of claim 11, wherein the second hydrocarbon unit is fluidly connected to the dilution unit, the first hydrocarbon unit, and the reaction zone.

13. 13. The system of claim 11 or 12, wherein the heating column is heated solely by the electric heater.

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