Method and apparatus for continuous decomposition with integrated heating loop

Abstract

The present invention provides an apparatus for heating molten long-chain hydrocarbons in a continuous process, comprising: a heating fluid circuit having a heat source for heating a heating fluid and a heating fluid distribution line for circulating the heating fluid; a first heating section configured to heat the molten long-chain hydrocarbons to a first temperature; and a second heating section configured to heat the molten long-chain hydrocarbons to a second temperature, wherein the first heating section and the second heating section are configured to receive the heating fluid through the heating fluid distribution line, and the first heating section is configured to regulate the heating fluid circulation through the first heating section in a manner to regulate the first temperature.

Description

Detailed Description of the Invention

[0001] [Field of the Invention] FIELD OF THE INVENTION The present invention relates generally to equipment and methods for processing post-consumer plastics and polyolefins using decomposition, and more particularly to structures for heating plastics and polyolefins to decomposition temperatures.

[0002] [Background of the invention] While unprocessed post-consumer plastics have caused environmental problems, they also provide a resource to at least partially replace hydrocarbons typically recovered from crude oil and other fossil fuel sources. When using post-consumer plastics as a resource, known processes frequently produce relatively large amounts of heavy hydrocarbons and / or soot, which are solid carbon, that are not in high demand, while lighter hydrocarbons with shorter chain lengths are much more desirable in industry.

[0003] Thus, WO 2021 / 053139 discloses a method for breaking down long-chain hydrocarbons from plastic-containing waste and crude oil-based organic liquids, comprising the steps of providing a feedstock containing long-chain hydrocarbons, heating a specific volume of the feedstock containing long-chain hydrocarbons to a decomposition temperature at which the hydrocarbon chains in the feedstock begin to break down into shorter chains, and, for the specific volume having a temperature above the decomposition temperature, exposing the specific volume to heat not more than 50°C above the temperature of the specific volume. In the continuous heating process, the hydrocarbons are continuously transported from a first location at a first temperature to a second location at a higher second temperature, and to a third location at a third temperature higher than the second temperature.

[0004] German Utility Model No. 202015009755 describes an apparatus for processing plastic-containing waste and petroleum-based organic liquids, comprising a first heating device, a second heating device, a decomposition reactor, and a recycle line, designed to successively heat plastic recyclables in the first and second heaters and feed them to the decomposition reactor, and a recycle steam line runs from the lower part of the decomposition reactor through a separation system device into a feed line through which molten plastic recyclables run from the first heating device into the second heating device.

[0005] Furthermore, these processes have sometimes been found to produce more soot over the entire driving cycle than would be expected when considering portions of the driving cycle.

[0006] The object of the present invention is to improve known methods and systems.

[0007] [overview] While the invention is defined in the independent claims, further aspects of the invention are set out in the dependent claims, the drawings and the following description. [Brief explanation of the drawings]

[0008] The drawings are not to scale. Like numbers refer to like parts. [Figure 1] FIG. 1 shows an assembly for decomposing long chain hydrocarbons. [Figure 2] FIG. 1 illustrates an embodiment of a heating structure. [Figure 3] FIG. 1 illustrates an embodiment of a heating section for a heating structure. [Figure 4] FIG. 1 illustrates an embodiment of a heat transfer structure for a heating structure.

[0009] DESCRIPTION OF THE PREFERRED EMBODIMENTS Figure 1 shows an assembly for decomposing long chain hydrocarbons according to one embodiment of the present invention. Before further describing the details of the illustrated embodiment, general aspects of the invention are developed below.

[0010] According to one aspect, the present invention provides an apparatus for heating molten long-chain hydrocarbons in a continuous process, comprising: a heating fluid circuit having a heat source for heating a heating fluid and a heating fluid distribution line for circulating the heating fluid; a first heating section configured to heat the molten long-chain hydrocarbons to a first temperature; a second heating section configured to heat the molten long-chain hydrocarbons to a second temperature; Equipped with the first heating section and the second heating section are configured to receive a heating fluid through a heating fluid distribution line; the first heating section is configured to regulate a heated fluid circulation through the first heating section in a manner that regulates the first temperature; Regarding the device.

[0011] By having the first temperature adjusted by adjusting the heating fluid circulation through the heating zone, a heat source can be operated at a different temperature than the first heating zone and can be used for the heating zone configured to heat the molten long-chain hydrocarbons to a different temperature. In some embodiments, the heat source is configured to operate at an efficient condition.

[0012] In various embodiments, the second heating section is configured to regulate the circulation of a heated fluid through the second heating section in a manner that regulates the second temperature.

[0013] In various embodiments, the first heating section and the second heating section are configured to pass the molten long-chain hydrocarbons from the first heating section to the second heating section, i.e., the first heating section and the second heating section are disposed in series with respect to the flow of the molten long-chain hydrocarbons.

[0014] In various embodiments, the second temperature is configured to be greater than the first temperature.

[0015] In various embodiments, the second temperature and / or the first temperature are above the decomposition temperature of the molten long-chain hydrocarbons. In this regard, the decomposition temperature is the temperature at which at least a portion of the molten long-chain hydrocarbons begin to decompose into shorter-chain hydrocarbons under the conditions in the respective heating zones. Such conditions may be, for example, the pressure in the respective heating zones.

[0016] In various embodiments, the apparatus includes a third heating section configured to heat the molten long-chain hydrocarbons to a third temperature and to receive a heating fluid through a heating fluid distribution line, wherein the molten long-chain hydrocarbons are passed from the second heating section to the third heating section, and the third temperature is greater than the second temperature.

[0017] In various embodiments, at least one of the heating sections includes a heat transfer section and a heating fluid control member, the heat transfer section configured to transfer heat from the heating fluid to the molten long-chain hydrocarbons in at least one of the heating sections, and the heating fluid control member configured to mix the heating fluid from the heat transfer section and the heating fluid distribution line to adjust the temperature of the mixed heating fluid and to provide the mixed heating fluid to the heat transfer section. In this manner, any temperature between the temperature of the molten long-chain hydrocarbons and the temperature of the heating fluid in the heating fluid distribution line can be adjusted. That is, the molten long-chain hydrocarbons can be selectively not heated at all when only the heating fluid from the heat transfer section is recirculated, or can be heated to the temperature of the heating fluid in the heating fluid distribution line when only the heating fluid in the heating fluid distribution line is circulated to the heat transfer section. Also, any temperature in between can be adjusted by appropriate mixing.

[0018] In various embodiments, the heating fluid control member includes a fluid control pump for adjusting the heating fluid flow through the heat transfer section and / or a fluid control valve for adjusting the proportion of heating fluid from the heating fluid distribution line in the mixed heating fluid provided to the heat transfer section. When both a fluid control pump and a fluid control valve are used, the heating fluid flow can be adjusted separately from the proportion of heating fluid from the heating fluid distribution line, and thus the temperature from the heat transfer section.

[0019] In various embodiments, the apparatus includes a cooling structure including a heat sink for cooling a heating medium passing therethrough and a control valve configured to control a proportion of the heating medium that selectively bypasses the heat sink, the heating medium being a heating fluid or a cooling medium. Such a cooling structure can achieve faster setting reduction than would be possible without such a cooling structure, thus allowing for shorter downtime for maintenance. In various embodiments, the control valve is a split valve or a flow control valve.

[0020] According to one aspect, the present invention provides a method for heating molten long-chain hydrocarbons in a continuous process, comprising: heating a heating fluid; circulating a heating fluid; heating the molten long-chain hydrocarbons to a first temperature in a first heating zone; heating the molten long-chain hydrocarbons to a second temperature in a second heating zone; Including, the first heating section and the second heating section are configured to receive a heating fluid through a heating fluid distribution line; the first heating section regulating a heated fluid circulation through the first heating section in a manner that regulates the first temperature; Regarding the method.

[0021] In various embodiments, the second heating zone regulates the circulation of a heated fluid through the second heating zone in a manner that regulates a second temperature, and the molten long-chain hydrocarbons pass from the first heating zone to the second heating zone.

[0022] In various embodiments, the second temperature is configured to be greater than the first temperature, the second temperature being greater than the decomposition temperature of the molten long-chain hydrocarbons.

[0023] In various embodiments, the first temperature is above the decomposition temperature of the molten long-chain hydrocarbons.

[0024] In various embodiments, at least one of the heating sections includes a heat transfer section and a heating fluid control member, the heat transfer section providing heat transfer from the heating fluid to the molten long-chain hydrocarbons in at least one of the heating sections, and the heating fluid control member mixing heating fluids from the heat transfer section and from the heating fluid distribution line to adjust the temperature of the mixed heating fluid and provide the mixed heating fluid to the heat transfer section.

[0025] In various embodiments, the molten long-chain hydrocarbons are passed from the second heating section to a third heating section, which receives a heating fluid through a heating fluid distribution line and heats the molten long-chain hydrocarbons to a third temperature.

[0026] In various embodiments, the third temperature is greater than the second temperature.

[0027] In various embodiments, the cooling structure includes a heat sink that cools the heating medium passing through it, and a split valve that controls the proportion of the heating medium that selectively bypasses the heat sink. The heating medium is a heating fluid or a cooling medium.

[0028] In various embodiments, the heat transfer structure includes a primary heat sink that provides a flow path for the process fluid, a secondary heat sink that provides a flow path for a cooling fluid, and a cooling circuit that circulates a cooling medium through the primary and secondary heat sinks, thus transferring heat from the process fluid in the primary heat sink to the cooling fluid in the secondary heat sink.

[0029] In various embodiments, the cooling circuit includes a start-up heating supply that supplies heated cooling medium into the cooling circuit during start-up.

[0030] According to another aspect, alternative or additional to those enumerated above, the heat transfer structure includes a primary heat sink providing a flow path for a process fluid in a heating fluid distribution line, such as the heating fluid distribution line described above, a secondary heat sink providing a flow path for a cooling fluid, and a cooling circuit circulating a cooling medium through the primary and secondary heat sinks to transfer heat from the process fluid in the primary heat sink to the cooling fluid in the secondary heat sink.

[0031] In various embodiments, the cooling circuit includes a start-up heating supply configured to supply heated cooling medium into the cooling circuit. By having such a cooling circuit between the primary and secondary heat sinks, heated cooling medium can be supplied during start-up so that the process fluid is not cooled by the low temperature cooling medium in the cooling circuit.

[0032] In various embodiments, the heat transfer structure includes a cooling medium branch line and a cooling circuit valve. The cooling medium branch line and the cooling circuit valve are configured to control a proportion of the cooling medium that selectively bypasses the secondary heat sink. In various embodiments, the proportion of the cooling medium that bypasses the secondary heat sink is adjusted to adjust the temperature of the cooling medium and / or the process fluid. In particular, if the proportion of the cooling medium that bypasses the secondary heat sink is increased, a smaller amount of the cooling medium is cooled in the secondary heat sink, and the cooling medium is cooled less. As a result, the process fluid is cooled less. In particular, if the proportion of the cooling medium that bypasses the secondary heat sink is decreased, a larger amount of the cooling medium is cooled in the secondary heat sink, and the cooling medium is cooled more. As a result, the process fluid is cooled more. In various embodiments, the cooling circuit valve is a control valve in the cooling medium branch line and / or in a line before the secondary heat sink, and the control valve is configured to adjust the proportion of the cooling medium that selectively bypasses the secondary heat sink. In various embodiments, the cooling circuit valve is a split valve that divides the cooling medium to the secondary heat sink and the cooling medium branch line according to the percentage of the cooling medium that selectively bypasses the secondary heat sink.

[0033] Returning to the description of Figure 1, the assembly includes a heating structure 11 and an isolation structure 12. The heating structure 11 is in communication with the isolation structure 12 for delivering a fluid therethrough. In particular, the heating structure 11 delivers a fluid containing cracked hydrocarbons into the isolation structure 12.

[0034] In some embodiments, the feeding device 7 is configured to charge the feedstock containing long-chain hydrocarbons, such as waste plastic or crude oil, into the heating structure 11. In various embodiments, the feeding device includes components for storage and / or for pulverizing any solid feedstock exceeding a predetermined size. In some embodiments, the predetermined size is about 100 mm or about 50 mm. In further embodiments, the predetermined size is between 15 mm and 50 mm. In further embodiments, the predetermined size is between 2 mm and 15 mm. In some embodiments, the feeding device includes an effector 8 for heating and / or transporting the feedstock containing long-chain hydrocarbons. In some embodiments, the effector is an auger 8 configured to heat and / or transport the feedstock containing long-chain hydrocarbons. In some embodiments, the auger 8 moves the feedstock, and internal friction within the feedstock causes the feedstock to heat and melt. In further embodiments, the feeding device 7 includes a heating device, such as an electric heater or a heating device filled with a heating medium, such as thermal oil. In various embodiments, the heating causes water to evaporate. In various embodiments, the feed device 7 includes a pump, such as a liquid ring pump, for removing water and / or halogens by degassing. The feed device 7 delivers the feedstock containing long-chain hydrocarbons to the heating structure 11.

[0035] The heating structure 11 receives the feedstock containing long-chain hydrocarbons. In various embodiments, the heating structure includes at least one heating zone 1, 2, 3, 4. The heating zones 1, 2, 3, 4 are configured to expose the feedstock containing long-chain hydrocarbons to a limited temperature increase. In other words, the feedstock containing long-chain hydrocarbons is exposed to a temperature that exceeds the temperature of the feedstock by less than a predetermined temperature. It has been found that limiting the temperature increase increases the yield of usable feedstock containing hydrocarbons with the desired chain length resulting from operation of the assembly and limits the amount of resulting solid carbon. In various embodiments, the heating zones 1, 2, 3, 4 are configured to expose the feedstock containing long-chain hydrocarbons in each section of the heating zones 1, 2, 3, 4 to a predetermined temperature that exceeds the temperature of the feedstock containing long-chain hydrocarbons by no more than about 50°C.

[0036] Hereinafter, the temperature to which the feedstock containing long chain hydrocarbons is exposed will be referred to as the exposure temperature, which will have different values ​​depending on the location within the assembly and the corresponding temperature of the feedstock containing long chain hydrocarbons.

[0037] For example, for a feedstock containing long-chain hydrocarbons entering heating zones 1, 2, 3, and 4 having a temperature of approximately 200°C, heating zones 1, 2, 3, and 4 expose the feedstock containing long-chain hydrocarbons to an exposure temperature of 250°C or less at the entrance to heating zones 1, 2, 3, and 4. Once the feedstock containing long-chain hydrocarbons begins to heat up, heating zones 1, 2, 3, and 4 expose the feedstock to correspondingly increased exposure temperatures. For example, when the feedstock containing long-chain hydrocarbons is heated to a temperature of 250°C, heating zones 1, 2, 3, and 4 expose the feedstock to an exposure temperature of up to 300°C.

[0038] In various embodiments, heating zones 1, 2, 3, and 4 provide a flow path for the feedstock containing long-chain hydrocarbons. Heating zones 1, 2, 3, and 4 sequentially or gradually increase the exposure temperature along the flow path. In some embodiments, heating zones 1, 2, 3, and 4 provide at least one first tube for the feedstock containing long-chain hydrocarbons. The feedstock generally flows through the at least one first tube in a first direction. Heating zones 1, 2, 3, and 4 further provide at least one second tube in contact with the first tube along substantially the entire length of heating zones 1, 2, 3, and 4, such that heat can be transferred from the inside of the at least one second tube to the first tube. The second at least one tube provides a flow path for a heating medium.

[0039] In some of these embodiments, the heating medium is controlled to have a temperature when it enters the second at least one tube along heating zones 1, 2, 3, 4 that is not more than 50° C. above a predetermined final temperature, and to have a temperature when it enters heating zones 1, 2, 3, 4 that is not more than 50° C. above the temperature of the feedstock containing long chain hydrocarbons. In some embodiments, the temperature, velocity, and / or pressure of the heating medium in the second at least one tube and / or the feedstock containing long chain hydrocarbons in the first at least one tube are controlled. In some embodiments, the second at least one tube is sized so that the heating medium flowing therethrough at a predetermined velocity and having a predetermined start-up velocity has a predetermined temperature profile.

[0040] In some embodiments, heating zones 1, 2, 3, and 4 include multiple heating zones, each of which exposes the feedstock containing long-chain hydrocarbons to a predetermined temperature. The heating zones are configured so that the feedstock containing long-chain hydrocarbons flows through each of them sequentially. Each heating zone exposes the feedstock to a higher exposure temperature than the previous heating zone. The heating zones are configured so that the exposure temperature does not exceed the temperature of the feedstock containing long-chain hydrocarbons upon entering the respective heating zone by more than 50°C.

[0041] In the embodiment of FIG. 1 , heating zones 1, 2, 3, and 4 include four heating zones. For example, for a feedstock containing long-chain hydrocarbons entering the first heating zone and having a temperature of approximately 200°C, heating zone 1 exposes the feedstock containing long-chain hydrocarbons to a first exposure temperature of 250°C or less. As the feedstock containing long-chain hydrocarbons flows through first heating zone 1, the feedstock containing long-chain hydrocarbons heats up and the temperature of the feedstock approaches the first exposure temperature. In some embodiments, the first exposure temperature is between 200°C and 370°C. In some embodiments, the first exposure temperature is between 220°C and 320°C. In some embodiments, the first exposure temperature is approximately 250°C.

[0042] Whether decomposition occurs inside the first heated zone 1 depends, aside from temperature, on the long-chain hydrocarbons contained in the feedstock and other substances intentionally or accidentally contained in the feedstock, as well as the pressure of the feedstock. In some cases, when no additional parameters promote decomposition, substantially no decomposition occurs at low temperatures, such as between 200°C and 250°C. In such cases, the exposure temperature may exceed the temperature of the feedstock by more than 50°C. In some embodiments, the exposure temperature may exceed the minimum temperature at which substantial decomposition occurs by as much as 50°C.

[0043] Upon exiting the first heating zone 1, the feedstock proceeds to a second heating zone 2 downstream of the first heating zone 1. The second heating zone 2 exposes the feedstock containing long-chain hydrocarbons to a higher exposure temperature than the first heating zone 1, i.e., a second exposure temperature. The second exposure temperature does not exceed 50°C above the temperature of the feedstock containing long-chain hydrocarbons. In various embodiments, the second exposure temperature is between 250°C and 400°C. In some embodiments, the second exposure temperature is between 270°C and 370°C. In some embodiments, the second exposure temperature is approximately 300°C. The feedstock containing long-chain hydrocarbons flows through the second heating zone 2 and heats toward the second exposure temperature.

[0044] From the second heating zone 2, the feedstock containing long-chain hydrocarbons proceeds to a third heating zone 3 downstream of the second heating zone 2. The third heating zone 3 exposes the feedstock to a third exposure temperature. The third exposure temperature is higher than the second exposure temperature. The third exposure temperature does not exceed the temperature of the feedstock by 50°C. In various embodiments, the third exposure temperature is between 300°C and 400°C. In some embodiments, the third exposure temperature is between 320°C and 380°C. In some embodiments, the third exposure temperature is approximately 370°C. The feedstock containing long-chain hydrocarbons flows through the third heating zone 3 and heats toward the third exposure temperature.

[0045] From the third heating zone 3, the feedstock containing long-chain hydrocarbons proceeds to a fourth heating zone 4 downstream of the third heating zone 3. The fourth heating zone 4 exposes the feedstock to a fourth exposure temperature. The fourth exposure temperature does not exceed the temperature of the feedstock by 50°C. The fourth exposure temperature essentially determines the maximum temperature for cracking of the long-chain hydrocarbons. In some embodiments, the fourth exposure temperature is between 350°C and 450°C. In further embodiments, the fourth exposure temperature is between 380°C and 420°C. The feedstock containing long-chain hydrocarbons flows through the fourth heating zone 4 and heats toward the fourth exposure temperature.

[0046] As the feedstock containing long-chain hydrocarbons flows through the fourth heating zone 4, some of the long-chain hydrocarbons are cracked. In some embodiments, some of the long-chain hydrocarbons are cracked as the feedstock flows through the third heating zone 3. In some embodiments, some of the long-chain hydrocarbons are cracked as the feedstock flows through the second heating zone 2. In some embodiments, some of the long-chain hydrocarbons are cracked as the feedstock flows through the first heating zone 1. In principle, the higher the heating zone temperature, the more cracking occurs. Once a significant amount of the long-chain hydrocarbons has been cracked, the heating zone limits the exposure temperature to a maximum of 50°C above the temperature of the feedstock. Thus, the feedstock containing long-chain hydrocarbons also contains cracked hydrocarbons. That is, the proportion of hydrocarbons with shorter chain lengths is increased compared to the feedstock before entering the heating zone. The feedstock exiting the fourth heating zone 4 proceeds to the separation structure 12.

[0047] In various embodiments, the heating sections are of identical construction so that only one type of heating section can be used at each position in the series of heating sections. In various embodiments, the heating sections are designed to heat to a temperature of 450°C. In various embodiments, the heating sections are designed for an operating pressure between 0 bar and 80 bar. In various embodiments, the heating sections are supplied with thermal oil as a heating medium. In various embodiments, the thermal oil is selected to have a boiling point above the operating temperature of the heating section and / or a freezing temperature below 40°C.

[0048] In the case of heating structures with more or fewer heating sections, the above applies accordingly.

[0049] In some embodiments, backpressure control elements 5a, 5b are located downstream of heating zones 1, 2, 3, and 4. The backpressure control elements 5a, 5b are configured to adjust the pressure of the feedstock containing long-chain hydrocarbons within the heating zones. In various embodiments, the backpressure control elements control the throughput of the feedstock through the heating zones. The backpressure control elements are disposed between the heating zones and the separation structure 12. The feedstock containing long-chain hydrocarbons exiting the backpressure control elements 5a, 5b proceeds to the separation structure 12. In some embodiments, the backpressure control elements include an adjustable valve 5a and a pressure sensor 5b. The pressure sensor 5b is configured to detect the pressure of the feedstock within the heating zones. The adjustable valve 5a is configured to release the feedstock as long as the pressure sensor 5b detects a pressure within a specific range. In some embodiments, the specific range is between 10 bar and 40 bar. In some embodiments, the specific range is approximately 20 bar. If the feedstock within the heating zone has a pressure outside this range, the valve 5a controls the throughput of the feedstock. For example, if the pressure in the heated zone drops below the lower boundary of the pressure range, valve 5a reduces the throughput until the pressure in the heated zone increases. If the pressure in the heated zone exceeds the upper boundary, valve 5a allows the throughput to increase until the pressure drops. In some embodiments, valve 5a has a pressure relief valve structure, i.e., valve 5a is held closed by a pre-installed spring and opens to the subsequent isolation structure 12 when a predetermined pressure is exceeded, while closing when the pressure drops below the predetermined pressure. In further embodiments, valve 5a is a gate valve that opens and closes to regulate the throughput and thus the pressure detected by pressure sensor 5b. In some embodiments, valve 5a is configured to allow a small throughput at all times; in other words, valve 5a is configured not to close completely.

[0050] After the feed passes through the backpressure control element, the pressure of the feed drops, and hydrocarbons, particularly shorter chain hydrocarbons, resulting from cracking are vaporized into the gas phase, producing a hydrocarbon-containing gas.

[0051] The feedstock, along with the hydrocarbon-containing liquid and gas, proceeds to separation structure 12. In separation structure 12, the hydrocarbon-containing gas separates from the longer-chain hydrocarbon-containing liquid of the feedstock. The hydrocarbon-containing gas rises from the liquid. Separation structure 12 discharges hydrocarbon-containing gas with chain lengths equal to or less than a predetermined chain length. In some embodiments, separation structure 12 includes a gas discharge section at the top of separation structure 12. The gas discharge section is preferably equipped with a partial condenser 21.

[0052] In various embodiments, separation structure 12 comprises a partial condenser 21, a separation zone 25 containing the gas-liquid interface of the hydrocarbon feed, and a solidification zone 28 for accumulating heavy hydrocarbons and / or solid carbon. In some embodiments, separation structure 12 comprises a cylindrically shaped middle section 24 containing separation zone 25 and a funnel-shaped bottom section 27 containing solidification zone 28, with the funnel terminating in an outlet for heavy hydrocarbons and / or solid carbon.

[0053] The partial condenser 21 is configured to allow passage of gas having hydrocarbons with a maximum chain length. The partial condenser 21 cools the hydrocarbon-containing gas to a condensation temperature that condenses hydrocarbons above a certain chain length. The partial condenser circulates the condensed hydrocarbons back to a liquid. In some embodiments, the condensation temperature is between 270°C and 370°C. In a further embodiment, the condensation temperature is 320°C.

[0054] In some embodiments, the partial condenser 21 comprises a condenser vessel 22 that provides a flow path for the hydrocarbon-containing gas and cooling pipes 23 for a cooling medium, such as thermal oil, to cool the gas. In some embodiments, the cooling pipes 23 intersect the condenser vessel 22. In some embodiments, the cooling pipes extend serpentine, spiral, and / or helically inside the condenser vessel 22. In some embodiments, the condenser vessel 22 and the cooling pipes 23 are configured to allow the gas to flow both vertically and in one or more horizontal directions. In other words, the gas cannot pass through the partial condenser 21 in a straight line. In some embodiments, the cooling pipes 23 provide cooling ribs and / or baffles that increase the contact surface with the gas and direct and / or retard the gas flow, particularly inside the partial condenser 21. In some embodiments, the partial condenser 21 comprises a random arrangement of cooling ribs and / or baffles.

[0055] Thus, the dephlegmator 21 is configured to pass gas containing hydrocarbons having chain lengths up to and including a predetermined chain length. In some embodiments, the predetermined chain length is 30 carbon atoms. In further embodiments, the predetermined chain length is 25 carbon atoms. In further embodiments, the predetermined chain length is 22 or 20 carbon atoms. Hydrocarbons having chain lengths above the predetermined chain length are circulated back into the liquid within the separation structure 12.

[0056] In various embodiments, the separation structure 12 discharges liquids containing hydrocarbons with chain lengths greater than a predetermined chain length. The separation structure 12 removes heavy hydrocarbons and / or solid carbon resulting from cracking.

[0057] In some embodiments, heating structure 11 includes a reheat zone 6. Hydrocarbon-containing liquid is piped through reheat zone 6 from separation structure 12. Reheat zone 6 reheats the hydrocarbon-containing liquid to further crack long-chain hydrocarbons. In some embodiments, the reheat zone is configured to provide an exposure temperature that does not exceed the temperature of the hydrocarbon-containing liquid by more than 50°C. The limited exposure temperature can limit carbonization of hydrocarbons. In some embodiments, reheat zone 6 is configured to at least partially compensate for heat loss from the feedstock in separation structure 12 due to gas and carbon separation, as well as heat loss through the walls of separation structure 12 and any piping. In some embodiments, reheat zone 6 provides an exposure temperature between 380°C and 450°C. In further embodiments, reheat zone 6 provides an exposure temperature between 390°C and 440°C, preferably between 405°C and 430°C.

[0058] In some embodiments, the hydrocarbon-containing liquid is passed through a filter 9 to remove particles. In some embodiments, the hydrocarbon-containing liquid is pumped using a pump 10 configured to regulate the flow rate of the liquid.

[0059] The liquid exits reheat zone 6, vaporizing the gases of the cracked hydrocarbon chains. In some embodiments, the liquid in reheat zone 6 is not pressurized, so that some of the cracked hydrocarbons vaporize into the gases of the hydrocarbon chains already cracked in reheat zone 6. In some embodiments, the liquid and / or gas exiting reheat zone 6 is fed into separation structure 12 to release the vaporized gases. In some embodiments, the liquid and / or gas exiting reheat zone 6 is mixed with the feedstock exiting heating zones 1, 2, 3, and 4. In some embodiments, the liquid and / or gas exiting reheat zone 6 is mixed with the feedstock exiting backpressure control elements 5a and 5b. In some embodiments, the mixture ratio of the liquid and / or gas exiting reheat zone 6 to the feedstock exiting heating zones 1, 2, 3, and 4 is between 5:1 and 15:1 in flow rate, more preferably between 8:1 and 10:1 in flow rate. In some embodiments, the mixture ratio is adjusted by feed device 7, the heating zones, the backpressure control elements, and pump 10. In some embodiments, the reheat zone 6 is supplied with thermal oil, such as the thermal oil used in the first through fourth heating zones 1, 2, 3, 4. In some embodiments, the reheat zone 6 receives thermal oil at the same temperature as the fourth heating zone 4.

[0060] In some embodiments, the reheat zone 6 adjusts the temperature of the feedstock depending on the volume of the feedstock inside the separation structure 12. In some embodiments, the reheat zone adjusts the temperature of the feedstock to adjust the cracking rate of the feedstock. In some embodiments, the cracking rate is a measure of cracking events per time frame. In further embodiments, the cracking rate is a measure of cracking events per volume. Adjusting the cracking rate adjusts the amount of short-chain hydrocarbons in the feedstock, which adjusts the evaporation of the feedstock because cracked hydrocarbons generally have a lower evaporation temperature than the same hydrocarbons before cracking. Furthermore, heating the feedstock causes more of the feedstock to evaporate. Therefore, increasing the temperature of the feedstock promotes evaporation in the feedstock and reduces the volume of the liquid feedstock. In some embodiments, this is used to adjust the level of the liquid feedstock inside the separation structure 12.

[0061] In one exemplary embodiment, the heating sections 1, 2, 3, 4, the reheat zone 6 and the thermal oil used provide the following parameters:

[0062] [Table 1]

[0063] Here, "PM inlet temperature" designates the temperature of the feedstock containing long-chain hydrocarbons as it enters each heating zone, "PM outlet temperature" designates the temperature of the feedstock containing long-chain hydrocarbons as it exits each heating zone, "TO inlet temperature" designates the temperature of the thermal oil used as the heating medium in this exemplary embodiment as it is applied to each heating zone, and "TO outlet temperature" designates the temperature of the thermal oil after application in each heating zone. As can be seen in this table, the maximum difference between the TO inlet temperature and the PM outlet temperature, and between the TO outlet temperature and the PM inlet temperature, does not exceed 50°C. Because the thermal oil flows in the opposite direction to the flow direction of the feedstock through each heating zone, the exposure temperature does not exceed the temperature of the feedstock by more than 50°C.

[0064] In various embodiments, hydrocarbon-containing feedstock comes from heating structure 11 and enters separation structure 12 through inlet 26. Heavy hydrocarbons and / or solid carbon slow down and sink toward the bottom. In various embodiments, the heavy hydrocarbons and solid carbon accumulate in solidification zone 28. In some embodiments, funnel-shaped bottom portion 27 directs the heavy hydrocarbons and solid carbon to an outlet for the heavy hydrocarbons and / or solid carbon.

[0065] 2 shows one embodiment of the heating structure 11 in more detail. In the illustrated embodiment, the heating structure 11 is shown with first through fourth heating sections 1, 2, 3, and 4, a reheat zone 6, and a reboiler section 29. The reboiler section 29 is configured to adjust the temperature of a liquid condensed from the gas that has passed through the partial condenser 21. The heating structure 11 further includes a heating fluid circuit 30 having a heat source 31, a heating fluid distribution line 32, a distribution line pump 33 for circulating the heating fluid, and a choke valve 34. The heating fluid circuit 30 is configured to circulate a heating fluid as a heating medium through the heating fluid distribution line 32 to heat at least one of the first through fourth heating sections 1, 2, 3, and 4.

[0066] In various embodiments, the heating fluid distribution line 32 is configured to provide heating fluid from a single heat source 31 to at least two of the first through fourth heating sections 1, 2, 3, and 4, the reboiler section 29, and the reheat zone 6. In further embodiments, the heating fluid distribution line 32 is configured to provide heating fluid from a single heat source 31 to all of the first through fourth heating sections 1, 2, 3, and 4. In further embodiments, the heating fluid distribution line 32 is configured to provide heating fluid from a single heat source 32 to all of the first through fourth heating sections 1, 2, 3, and 4, the reheat zone 6, and the reboiler section 29. In various embodiments, the heating fluid circuit 30 comprises at least two heat sources.

[0067] In various embodiments, heat source 31 is a flame device 37 configured to burn a gas to heat the heating medium in heating fluid distribution line 32. In some embodiments, the gas for flame device 37 is non-condensable gas 37a produced in the cracking process. In some embodiments, the gas for flame device 37 is natural gas 37b. In some embodiments, flame device 37 includes oxygen source 37c. In further embodiments, heat source 31 is a heat pump. In further embodiments, the heat pump uses waste heat from the portion of the assembly for cracking long-chain hydrocarbons downstream of separation structure 12 to heat the heating medium. In further embodiments, the heat pump and flame device 37 are combined as heat sources in one heating fluid circuit 30. In such embodiments, the heat pump may use waste heat from the flue gas of flame device 37.

[0068] In various embodiments, the choke valve 34 is configured to regulate a differential pressure across a portion of the heating fluid distribution line 32 .

[0069] In various embodiments, the heating structure 11 further comprises an expansion vessel 38 that allows for expansion and contraction of the heating fluid.

[0070] In various embodiments, the heating structure 11 includes a cooling branch 35 configured to selectively cool the heating fluid. The cooling branch 35 includes a cooling branch split valve 351 and a heat sink portion 352. The cooling branch split valve 351 is configured to divert an adjustable amount of the heating fluid from the heating fluid distribution line 32 along the heat sink portion 352, thereby lowering the temperature of the heating fluid in the heating fluid distribution line 32 by an adjustable amount. In various embodiments, the heat sink portion 352 provides a flow path for the heating fluid and a flow path for the cooling fluid 353, which flow paths for the heating fluid and the cooling fluid 353 contact each other in a manner that promotes heat transfer from the heating fluid to the cooling fluid. In various embodiments, the cooling fluid is water or a fluid containing water. In further embodiments, the cooling fluid is selected to have a phase change from liquid to gas when heat is transferred from the heating fluid to the cooling fluid.

[0071] Each of the first to fourth heating sections 1, 2, 3, 4 includes first to fourth branch lines 310, 320, 330, 340, respectively, configured to pass heating fluid from the heating fluid distribution line 32 through the first to fourth heating sections 1, 2, 3, 4 and back to the heating fluid distribution line 32.

[0072] First heating zone 1 further comprises first heat transfer portion 312 and first heating fluid control members 311, 313. First branch line 310 is configured to advance heating fluid through first heat transfer portion 312. First heat transfer portion 312 is configured to provide heat transfer from the heating fluid to the molten long-chain hydrocarbons in first heating zone 1. First heating fluid control members 311, 313 are configured to adjust the flow rate of the heating fluid through first heat transfer portion 312. In various embodiments, first heating fluid control members 311, 313 are configured to adjust the flow rate of the heating fluid through first heat transfer portion 312 to adjust the temperature of the molten long-chain hydrocarbons in first heating zone 1. In various embodiments, first heating fluid control member comprises first fluid control pump 311 and / or first fluid control valve 313. In various embodiments, the first fluid control pump 311 is configured to regulate the throughput of the heating fluid through the first heating zone 1. In various embodiments, the first fluid control valve 313 is configured to regulate the throughput of the heating fluid through the first heating zone 1. In various embodiments, the first fluid control valve 313 is configured to split the flow of the heating fluid either through the first heating zone 1 or bypass the first heating zone 1. In further embodiments, the first fluid control valve 313 is configured to regulate the recirculation of the heating fluid after passing through the first heating zone 1 in such a way that at least a portion of the heating fluid passes through the first fluid control pump 311 and the first heating zone 1 without first passing through the heating fluid distribution line 32 and the heat source 31.

[0073] Because the temperature in the first heating section is adjusted by adjusting the ratio of the heating fluid from the heating fluid distribution line 32 and the recirculated heating fluid from the first heating section 1, the exposure temperature in the first heat transfer portion 312 is adjusted without requiring a specific heat source for this temperature.

[0074] The second heating zone 2 further comprises a second heat transfer portion 322 and second heating fluid control members 321, 323. The second branch line 320 is configured to advance the heating fluid through the second heat transfer portion 322. The second heat transfer portion 322 is configured to provide heat transfer from the heating fluid to the molten long-chain hydrocarbons in the second heating zone 2. The second heating fluid control members 321, 323 are configured to adjust the flow rate of the heating fluid through the second heat transfer portion 322. In various embodiments, the second heating fluid control members 321, 323 are configured to adjust the flow rate of the heating fluid through the second heat transfer portion 322 to adjust the temperature of the molten long-chain hydrocarbons in the second heating zone 2. In various embodiments, the second heating fluid control member comprises a second fluid control pump 321 and / or a second fluid control valve 323. In various embodiments, the second fluid control pump 321 is configured to regulate the throughput of the heating fluid through the second heating zone 2. In various embodiments, the second fluid control valve 323 is configured to regulate the throughput of the heating fluid through the second heating zone 2. In various embodiments, the second fluid control valve 323 is configured to split the flow of the heating fluid to either pass through the second heating zone 2 or bypass the second heating zone 2. In further embodiments, the second fluid control valve 323 is configured to regulate the recirculation of the heating fluid after passing through the second heating zone 2 in a manner such that at least a portion of the heating fluid passes through the second fluid control pump 321 and the second heating zone 2 without first passing through the heating fluid distribution line 32 and the heat source 31.

[0075] The third heating zone 3 further comprises a third heat transfer portion 332 and third heating fluid control members 331, 333. The third branch line 330 is configured to advance the heating fluid through the third heat transfer portion 332. The third heat transfer portion 332 is configured to provide heat transfer from the heating fluid to the molten long-chain hydrocarbons in the third heating zone 3. The third heating fluid control members 331, 333 are configured to adjust the flow rate of the heating fluid through the third heat transfer portion 332. In various embodiments, the third heating fluid control members 331, 333 are configured to adjust the flow rate of the heating fluid through the third heat transfer portion 332 to adjust the temperature of the molten long-chain hydrocarbons in the third heating zone 3. In various embodiments, the third heating fluid control member comprises a third fluid control pump 331 and / or a third fluid control valve 333. In various embodiments, the third fluid control pump 331 is configured to regulate the throughput of the heating fluid through the third heating zone 3. In various embodiments, the third fluid control valve 333 is configured to regulate the throughput of the heating fluid through the third heating zone 3. In various embodiments, the third fluid control valve 333 is configured to split the flow of the heating fluid to either pass through the third heating zone 3 or bypass the third heating zone 3. In further embodiments, the third fluid control valve 333 is configured to regulate the recirculation of the heating fluid after passing through the third heating zone 3 in a manner such that at least a portion of the heating fluid passes through the third fluid control pump 331 and the third heating zone 3 without first passing through the heating fluid distribution line 32 and the heat source 31.

[0076] The fourth heating zone 4 further comprises a fourth heat transfer portion 342 and fourth heating fluid control members 341, 343. The fourth branch line 340 is configured to advance the heating fluid through the fourth heat transfer portion 342. The fourth heat transfer portion 342 is configured to provide heat transfer from the heating fluid to the molten long-chain hydrocarbons in the fourth heating zone 4. The fourth heating fluid control members 341, 343 are configured to adjust the flow rate of the heating fluid through the fourth heat transfer portion 342. In various embodiments, the fourth heating fluid control members 341, 343 are configured to adjust the flow rate of the heating fluid through the fourth heat transfer portion 342 to adjust the temperature of the molten long-chain hydrocarbons in the fourth heating zone 4. In various embodiments, the fourth heating fluid control member comprises a fourth fluid control pump 341 and / or a fourth fluid control valve 343. In various embodiments, the fourth fluid control pump 341 is configured to regulate the throughput of the heating fluid through the fourth heating zone 4. In various embodiments, the fourth fluid control valve 343 is configured to regulate the throughput of the heating fluid through the fourth heating zone 4. In various embodiments, the fourth fluid control valve 343 is configured to split the flow of the heating fluid to either pass through the fourth heating zone 4 or bypass the fourth heating zone 4. In further embodiments, the fourth fluid control valve 343 is configured to regulate the recirculation of the heating fluid after passing through the fourth heating zone 4 in such a way that at least a portion of the heating fluid passes through the fourth fluid control pump 341 and the fourth heating zone 4 without first passing through the heating fluid distribution line 32 and the heat source 31.

[0077] In some embodiments, reheat zone 6 comprises a reheat branch line 360, a reheat heat transfer section 362, and a reheat fluid control element 363. Reheat branch line 360 ​​is configured to direct a heating fluid through reheat heat transfer section 362. Reheat heat transfer section 362 is configured to provide heat transfer from the heating fluid to the molten long-chain hydrocarbons in reheat zone 6, which is piped from separation structure 12. Reheat fluid control element 363 is configured to regulate the flow rate of the heating fluid through reheat heat transfer section 362. In various embodiments, reheat fluid control element 363 comprises a reheat fluid control valve 363. In various embodiments, reheat fluid control valve 363 is configured to regulate the throughput of the heating fluid through reheat zone 6. In various embodiments, the temperature of reheat heat transfer section 362 in reheat zone 6 corresponds to the temperature of the heating fluid regulated by heat source 31 and distributed to heating fluid distribution line 32.

[0078] In various embodiments, the reboiler section 29 further comprises a reboiler branch line 370, a reboiler heat transfer portion 372, and reboiler heating fluid control members 371, 373. The reboiler branch line 370 is configured to direct a heating fluid through the reboiler heat transfer portion 372. The reboiler heat transfer portion 372 is configured to provide heat transfer from the heating fluid to the gas coming from the partial condenser 21. The reboiler heating fluid control members 371, 373 are configured to adjust the flow rate of the heating fluid through the reboiler heat transfer portion 372. In various embodiments, the reboiler heating fluid control members 371, 373 are configured to adjust the flow rate of the heating fluid through the reboiler heat transfer portion 372 to adjust the temperature of the gas coming from the partial condenser 21. In various embodiments, the reboiler heating fluid control member comprises a reboil fluid control pump 371 and / or a reboil fluid control valve 373. In various embodiments, the reboiler fluid control pump 371 is configured to regulate the throughput of the heating fluid through the reboiler section 29. In various embodiments, the reboiler fluid control valve 373 is configured to regulate the throughput of the heating fluid through the reboiler section 29. In various embodiments, the reboiler fluid control valve 373 is configured to split the flow of the heating fluid to either pass through the reboiler section 29 or bypass the reboiler section 29. In further embodiments, the reboiler fluid control valve 373 is configured to regulate the recirculation of the heating fluid after passing through the reboiler section 29 in such a way that at least a portion of the heating fluid passes through the reboiler fluid control pump 371 and the reboiler section 29 without first passing through the heating fluid distribution line 32 and the heat source 31.

[0079] Thus, each of the first to fourth heating sections 1, 2, 3, 4 and the reboiler section 29 is equipped with both a first to fourth and reboiler fluid control pump 311, 321, 331, 341, 371 and a first to fourth and reboiler fluid control valve 313, 323, 333, 343, 371 to regulate the circulation of the heating fluid through the first to fourth heating sections 1, 2, 3, 4 and the reboiler section 29, respectively.

[0080] Because the temperatures in the first through fourth heating sections 1, 2, 3, 4 and the reboiler section 29 are adjusted by adjusting the respective proportions of heating fluid from the heating fluid distribution line 32 and recycled heating fluid from the first through fourth heating sections 1, 2, 3, 4 and the reboiler section 29, the respective exposure temperatures in the first through fourth and reboiler heat transfer sections 312, 322, 332, 342, 372 can be adjusted without requiring a specific heat source for each of these temperatures. Rather, multiple different temperatures can be adjusted while the heat source 31 operates at optimum conditions. Also, during start-up, the heat source 31 can operate at optimum conditions while the first through fourth heating sections 1, 2, 3, 4 are gradually heated. This increases the yield of usable feedstock containing hydrocarbons with the desired chain length resulting from the operation of the assembly during start-up, and limits the amount of resulting solid carbon. This also avoids buildup of solids in the respective heat transfer sections. The latter is particularly desirable since start-up is particularly following maintenance and thus cleaning of the heat transfer parts, and it is undesirable for recently cleaned heat transfer parts to be covered with solidified material immediately after start-up.

[0081] FIG. 3 shows the first heating section 1 and the first branch line 310 by way of example. In various embodiments, the example of FIG. 3 is equally applicable to the second through fourth and reboiler heating sections 1, 2, 3, 4, and 29 and their respective branch lines, with the parameters adapted accordingly. Thus, the first heating section 1 includes a first fluid control pump 311, and in the illustrated embodiment, a first fluid control valve 313 configured as a combination of an adjustable flow control valve 313a and a check valve 313b. Under normal conditions, the flow of the first fluid control pump 311 is regulated in such a way that the temperature of the heating fluid, and thus the exposure temperature, is limited as specified above. Generally, when the first fluid control pump 311 is not operating but blocks the passage of the heating fluid, the heating fluid will approach the temperature of the molten long-chain hydrocarbons entering the heating section 1. Similarly, when flow control valve 313 a is closed, the heating fluid will approach the temperature of the molten long chain hydrocarbons entering heating section 1 .

[0082] In various embodiments, first heating section 1 includes a flow control element 40, a media temperature sensor 42, and a feed temperature sensor 44. In various embodiments, first branch line 310 includes flow control line section 310a, a temperature regulated line section 310b, a return line section 310c, a bypass line section 310d, and a return line section 310e. Flow control line 310a includes flow control element 40 and a junction with bypass line section 310d leading to temperature regulated line section 310b. Temperature regulated line section 310b includes a first fluid control pump 311 and connects to first heat transfer section 312 so that any fluid passing through the temperature regulated line section passes through first heat transfer section 312. Return line section 310c leads from first heat transfer section 312 and splits into bypass line section 310d and return line section 310e. The bypass line section 310d includes a check valve 313b that prevents fluid from traveling from the flow control line 310a to the return line section 310e without passing through the first heat transfer portion 312.

[0083] The media temperature sensor 42 is disposed in the temperature regulated line section 310b and is configured to measure the temperature of a heating medium, such as a heating fluid, in the temperature regulated line section 310b and to send a signal representing the temperature of the heating medium to the flow control member 40. In some embodiments, the media temperature sensor 42 is configured to measure the temperature of the heating medium before the heating medium passes through the first heat transfer portion 312. In some embodiments, the media temperature sensor 42 is configured to measure the temperature of the heating medium after the heating medium passes through the first heat transfer portion 312. In various embodiments, the media temperature sensor 42 is configured to measure the temperature of the heating medium before and after the heating medium passes through the first heat transfer portion 312. In some of these embodiments, the media temperature sensor 42 determines the difference in temperature of the heating medium before passing through the heat exchanger 1 and after passing through the first heat transfer portion 312. In some of these embodiments, the medium temperature sensor 42 is configured to transmit a signal representative of the temperature of the heating medium before and after passing through the first heat transfer portion 312, and / or the temperature difference of the heating medium before and after passing through the first heat transfer portion 312.

[0084] The feedstock temperature sensor 44 is configured to measure the temperature of the feedstock containing long-chain hydrocarbons and to send a signal representing the temperature of the feedstock containing long-chain hydrocarbons to the flow control member 40. In various embodiments, the feedstock temperature sensor 44 is configured to measure the temperature of the feedstock containing long-chain hydrocarbons before the feedstock containing long-chain hydrocarbons passes through the first heat transfer section 312. In various embodiments, the feedstock temperature sensor 44 is configured to measure the temperature of the feedstock containing long-chain hydrocarbons after the feedstock containing long-chain hydrocarbons passes through the first heat transfer section 312. In various embodiments, the feedstock temperature sensor 44 is configured to measure the temperature of the feedstock containing long-chain hydrocarbons before and after the feedstock containing long-chain hydrocarbons passes through the first heat transfer section 312. In some of these embodiments, the feedstock temperature sensor 44 determines the difference in temperature of the feedstock containing long-chain hydrocarbons before and after passing through the first heat transfer section 312. In some of these embodiments, the feedstock temperature sensor 44 is configured to transmit a signal representative of the temperature of the feedstock containing long-chain hydrocarbons before and after passing through the first heat transfer section 312 and / or the temperature difference of the feedstock containing long-chain hydrocarbons before and after passing through the first heat transfer section 312.

[0085] The flow control member 40 is configured to operate the adjustable flow control valve 313a. In various embodiments, the flow control member 40 is configured to operate the adjustable flow control valve 313a in response to a signal representing the temperature of the feedstock containing long-chain hydrocarbons and / or a signal representing the temperature of the heating medium. In various embodiments, the flow control member 40 is configured to operate the adjustable flow control valve 313a in response to a signal representing the temperature difference of the feedstock containing long-chain hydrocarbons before and after passing through the first heat transfer portion 312 and / or a signal representing the temperature difference of the heating medium before and after passing through the first heat transfer portion 312.

[0086] In some embodiments, the temperature conditioned line section 310b includes a flow sensor 46 that detects the throughput of the heating medium through the temperature conditioned line section 310b and thus through the first heat transfer portion 312. In further embodiments, the temperature conditioned line section 310b includes a filter 48 for the heating medium.

[0087] In various embodiments, the flow sensor 46 is configured to send a signal representative of the throughput to the first fluid control pump 311. In various embodiments, the first flow control pump 311 and the flow sensor 46 are configured to provide a feedback control loop that regulates a constant throughput of the heating medium through the temperature-regulated line section 310b. As a result, the temperature of the heating medium in the temperature-regulated line section 310b is regulated by adjusting the adjustable flow control valve 313a. In the example of FIG. 3 , where the adjustment is kept constant unless otherwise specified, the temperature of the heating medium in the temperature-regulated line section 310b is primarily determined by the temperature of the heating medium in the flow control line section 310a coming from the heating fluid distribution line 32, the heating medium in the bypass line section 310d coming from the first heat transfer portion 312, and their mixture ratio as determined by the adjustable flow control valve 313a. The inventors have recognized that the flow control valve 313a does not significantly affect the pressure in the heating fluid distribution line 32 and, therefore, the distribution line pump 33.

[0088] When the throughput of the heating medium is increased, for example by adjusting the first fluid control pump 311, the heating medium spends less time in the first heat transfer section 312 and, as a result, cools less. Thus, the heating medium in the bypass line section 310d has a higher temperature. Therefore, the mixing ratio determined by the adjustable flow control valve 313 is adapted to maintain the temperature of the heating medium in the temperature-regulated line section 310b. In particular, the amount of heating medium in the flow control line section 310a, which comes from the heating fluid distribution line 32, is reduced. Correspondingly, when the throughput of the heating medium is decreased, for example by adjusting the first fluid control pump 311, the heating medium spends more time in the first heat transfer section 312 and, as a result, cools more, until it reaches the temperature of the long-chain hydrocarbon-containing feedstock at the inlet of the first heat transfer section 312, known as the "PM inlet temperature."

[0089] In various embodiments, the flow control member 40 is configured to adjust the adjustable flow control valve 313a and the first fluid control pump 311. Thus, the temperature of the heating medium can be adjusted in a range between the temperature of the heating medium in the heating fluid distribution line 32 provided by the heat source 31 and the temperature of the feedstock containing long-chain hydrocarbons. When the heating medium has the temperature of the feedstock containing long-chain hydrocarbons, no thermal energy is imparted from the heating medium to the feedstock containing long-chain hydrocarbons. In various embodiments, the flow control member 40 is configured to adjust the temperature of the heating medium in the temperature-regulated line section 310b to expose the feedstock containing long-chain hydrocarbons to a predetermined temperature that is approximately 50°C or less, preferably less than 40°C, more preferably less than 30°C, and more preferably less than 20°C, above the temperature of the feedstock containing long-chain hydrocarbons in each section of the first heat transfer portion 312.

[0090] From the above, it is clear that the temperature of the heating medium cannot be reduced below the temperature of the feedstock containing long-chain hydrocarbons unless the temperature of the heating medium in the first heat transfer section 312 is lower than the temperature of the feedstock containing long-chain hydrocarbons in the first heat transfer section 312.

[0091] FIG. 4 discloses one embodiment of a heat transfer structure 54 operable in particular in conjunction with the partial condenser 21. In the illustrated embodiment, the heat transfer structure 54 includes a primary heat sink 381 providing a flow path for the process fluid, particularly for the hydrocarbon-containing gas in the condenser vessel 22, a secondary heat sink 383 providing a flow path for a cooling fluid, and a cooling circuit 385 for circulating a cooling medium through the primary heat sink 381 and the secondary heat sink 383. In various embodiments, the primary heat sink 381 corresponds to the cooling pipes 23 of the partial condenser 21. In a further embodiment, the heat transfer structure is applied to a carbon discharge section from an outlet for the discharge process fluid of heavy hydrocarbons and / or solid carbon in the solidification zone 28. For the carbon discharge section, the heat transfer structure is configured to cool the carbon discharged from the solidification zone 28. In various embodiments, the partial condenser 21 and the carbon discharge section each include a heat transfer structure according to the heat transfer structure 54 of FIG. 4. In the following, the heat transfer structure 54 will be described primarily in terms of its operation with the partial condenser 21. The structure and function for cooling the heavy hydrocarbons and / or solid carbon exiting solidification zone 28 in the carbon discharge section is substantially the same.

[0092] In operation, the cooling circuit 385 circulates the cooling medium through the primary heat sink 381 where the hydrocarbon-containing gas in the condenser vessel 22 heats the cooling medium, the cooling circuit 385 then circulates the heated cooling medium through the secondary heat sink 383 where the cooling fluid cools the cooling medium, and the cooling circuit circulates the cooled cooling medium to the primary heat sink 381 where the cooling medium is heated by the hydrocarbon-containing gas.

[0093] In various embodiments, the heat transfer structure 54 includes a cooling medium branch line 387 and a cooling circuit split valve 389. The cooling medium branch line 387 and the cooling circuit split valve 389 are configured to selectively control the proportion of the cooling medium that bypasses the secondary heat sink 383. For example, the proportion of the cooling medium that bypasses the secondary heat sink 383 is adjusted to adjust the temperature of the cooling medium. In particular, if the proportion of the cooling medium that bypasses the secondary heat sink 383 increases, a smaller amount of the cooling medium is cooled within the secondary heat sink 383, and the cooling medium cools less. As a result, the hydrocarbon-containing gas is cooled less. In particular, if the proportion of the cooling medium that bypasses the secondary heat sink 383 decreases, a larger amount of the cooling medium is cooled within the secondary heat sink 383, and the cooling medium cools more. As a result, the hydrocarbon-containing gas is cooled more. In a further embodiment, a control valve in the coolant branch line 387 and / or in line before the secondary heat sink 383 adjusts the proportion of coolant that selectively bypasses the secondary heat sink 383 .

[0094] In various embodiments, cooling circuit 385 includes a coolant pump 391 configured to circulate a coolant within cooling circuit 385. In various embodiments, coolant pump 391 is configured to selectively adjust the coolant flow. In various embodiments, cooling circuit 385 includes a coolant flow control member 393, a coolant temperature sensor 395, a coolant flow sensor 397, and a hydrocarbon-containing gas temperature sensor 399. In carbon discharge applications, temperature sensor 399 senses the temperature of the heavy hydrocarbons and / or solid carbon exiting solidification zone 28.

[0095] In various embodiments, the coolant temperature sensor 395 measures the temperature of the coolant in the cooling circuit 385. In various embodiments, the coolant temperature sensor 395 measures the temperature of the coolant in the cooling circuit 385 after the coolant that has passed through the secondary heat sink 383 and the coolant that has passed through the coolant branch line 387 is combined.

[0096] In various embodiments, temperature sensor 399 is configured to measure the temperature of the hydrocarbon-containing gas near the outlet of primary heat sink 381. In principle, the temperature of the hydrocarbon-containing gas near the outlet of primary heat sink 381 is the temperature of the hydrocarbon-containing gas that has experienced negligible subsequent temperature fluctuations after the heating fluid has passed through primary heat sink 381. In various embodiments, cooling flow control member 393 adjusts the temperature of the hydrocarbon-containing gas at temperature sensor 399. In various embodiments, cooling flow control member 393 adjusts the temperature of the coolant at coolant temperature sensor 395. In various embodiments, cooling flow control member 393 adjusts the temperature of the coolant at coolant temperature sensor 395 and the temperature of the hydrocarbon-containing gas at temperature sensor 399 for the hydrocarbon-containing gas.

[0097] In various embodiments, the coolant flow sensor 397 is configured to measure the flow of coolant in the cooling circuit 385 before it enters the primary heat sink 381. In various embodiments, the coolant flow sensor 397 measures the coolant flow through the cooling circuit 385 in volumes per unit time. In various embodiments, the coolant flow sensor 397 measures the coolant flow through the cooling circuit 385 in liters per second. In various embodiments, the coolant pump 391 is configured to selectively adjust the specific coolant flow at the coolant flow sensor 397.

[0098] In various embodiments, the cooling circuit 385 includes a cooling medium filter 382 for removing contaminants from the cooling medium. Such contaminants may illustratively result from cooling medium degradation. In various embodiments, the heat transfer structure 54 includes a start-up heating supply 384 configured to supply heated cooling medium into the cooling circuit near the operating temperature of the partial condenser 21 at nominal conditions. This allows the operating temperature of the partial condenser 21 to be achieved more quickly, as otherwise the cooling medium at start-up would have a temperature lower than the operating temperature of the cooling medium, unnecessarily cooling the hydrocarbon-containing gas during start-up. In various embodiments, the start-up heating supply 384 is configured to provide heating fluid from the heating fluid distribution line 32 into the cooling circuit 385. In these embodiments, the heating fluid is selected to have an operating range extending from the operating temperature of the partial condenser 21 and / or the carbon discharge section to the operating temperature of all heating zones 1, 2, 3, 4, reheat zone 6, and / or reboiler section 29.

[0099] In various embodiments, the cooling circuit 385 includes a coolant check valve 386 that prevents backflow due to shutoff of the coolant pump 391 and / or due to the activation heating supply 384 providing the coolant. In various embodiments, the heat transfer structure 54 includes a vent line 388 in communication with the heating fluid distribution line 32 that allows for volumetric fluctuations of the coolant in the cooling circuit 385 due to, for example, temperature changes or the provision of bubbles if the coolant locally reaches or exceeds the boiling point of the coolant. The vent line 388 also allows for selective circulation of the heating fluid through the cooling circuit 385.

[0100] In various embodiments, the cooling fluid is or contains water. In various embodiments, the cooling medium has a boiling point above the boiling point of the cooling fluid. In various embodiments, the cooling medium is thermal oil.

[0101] In various embodiments, the process of operating the heating structure 11 and the heating fluid circuit 30 at nominal conditions is as follows.

[0102] In various embodiments, the heat source heats a heating fluid. In various embodiments, a flame device 37 burns gas to heat the heating fluid. The heating fluid distribution line 32 circulates the heated heating fluid to heating zones 1, 2, 3, 4, and 29. In various embodiments, the first branch line 310 of the first heating zone 1 selectively circulates a proportion of the heated heating fluid through the first heat transfer section 312. Specifically, the first heat transfer section 312 transfers heat from the heating fluid to the molten long-chain hydrocarbons within the first heating zone 1. The first heating fluid control members 311 and 313 adjust the flow rate of the heating fluid through the first heat transfer section 312 and accordingly adjust the proportion of the heating fluid passing through the first branch line 310 of the first heating zone 1. The flow rate of the heating fluid through the first heat transfer section 312 adjusts the temperature of the molten long-chain hydrocarbons in the first heating zone 1. In particular, the temperature of the heating fluid passing through the first heat transfer portion 312 determines the thermal energy imparted to the molten long-chain hydrocarbons in the first heating zone 1. In various embodiments, the first fluid control pump 311 of the first heating fluid control member regulates the throughput of the heating fluid through the first heating zone 1.

[0103] In various embodiments, the first fluid control valve 313 of the first heating fluid control member adjusts the throughput of the heating fluid through the first heating zone 1. In various embodiments, the first fluid control valve 313 adjusts the recirculation of the heating fluid after passing through the first heating zone 1 in a manner such that at least a portion of the heating fluid passes through the first fluid control pump 311 and the first heating zone 1 without first passing through the heating fluid distribution line 32 and the heat source 31. That is, the heating fluid coming from the heating fluid distribution line 32 mixes with the heating fluid coming from the first heating zone 1. Because the heating fluid coming from the first heating zone 1 has cooled due to exposure to the molten long-chain hydrocarbons, adjusting the mixing ratio of the heating fluid from the heating fluid distribution line 32 and from the first heating zone 1 adjusts the temperature of the heating fluid circulating in the first heat transfer portion 312 of the first heating zone 1. In this manner, the first fluid control valve 313 adjusts the temperature of the heating fluid in the first heat transfer portion 312, thereby providing the determined exposure temperature.

[0104] In embodiments where the temperature of the molten long-chain hydrocarbons is above the minimum decomposition temperature when entering the first heating section 1, the exposure temperature is determined to be no more than about 50°C above the temperature of the molten long-chain hydrocarbons in each section of the first heat transfer portion 312, preferably less than 40°C, more preferably less than 30°C, and more preferably less than 20°C above the temperature of the molten long-chain hydrocarbons.

[0105] In various embodiments where the temperature of the molten long-chain hydrocarbons is below the minimum decomposition temperature, the exposure temperature is determined to be close to or above the minimum decomposition temperature. For example, the exposure temperature is determined to be no more than about 50° C. above the minimum decomposition temperature, preferably less than 40° C., more preferably less than 30° C., and more preferably less than 20° C. above the minimum decomposition temperature. In further embodiments where the temperature of the molten long-chain hydrocarbons exiting the first heated zone is measured to be no more than about 50° C. above the minimum decomposition temperature, the first fluid control valve 313 adjusts the mixing ratio of the heating fluid from the heating fluid distribution line 32 and from the first heated zone 1 in such a way that essentially only the heating fluid from the heating fluid distribution line 32 passes through the first fluid control pump 311 and the first heated zone 1.

[0106] In various embodiments where the temperature of the molten long-chain hydrocarbons is above the minimum decomposition temperature, there is typically a temperature drop between the heating fluid entering the first heat transfer section 312 and the heating fluid exiting the first heat transfer section 312. If the flow rate of the heating fluid in the first heat transfer section 312 is significantly high, this temperature drop may be negligible relative to the above considerations. However, in various embodiments, the flow rate of the heating fluid in the first heat transfer section 312 is so low that this temperature drop may be taken into account in determining the temperature of the heating fluid in the first heat transfer section 312. In these cases, the temperature of the heating medium is determined so that the exposure temperature in any section of the first heating section 1 is determined within the above limits. That is, in various embodiments, because the heating fluid does not immediately come into contact with the molten long-chain hydrocarbons as it enters the first heating section 1, the temperature of the heating fluid before passing through the first heating section 1 is determined to be more than 50° C. above the temperature of the molten long-chain hydrocarbons before passing through the fourth heating section 4.

[0107] In various embodiments, the second branch line 320 of the second heating zone 2 selectively circulates a proportion of the heated heating fluid through the second heat transfer portion 322. Specifically, the second heat transfer portion 322 transfers heat from the heating fluid to the molten long-chain hydrocarbons within the second heating zone 2. The second heating fluid control members 321, 323 adjust the flow rate of the heating fluid through the second heat transfer portion 322 and accordingly adjust the proportion of the heating fluid through the second branch line 320 of the second heating zone 2. The flow rate of the heating fluid through the second heat transfer portion 322 adjusts the temperature of the molten long-chain hydrocarbons in the second heating zone 2. Specifically, the temperature of the heating fluid through the second heat transfer portion 322 determines the thermal energy imparted to the molten long-chain hydrocarbons in the second heating zone 2. In various embodiments, the second fluid control pump 321 of the second heating fluid control member adjusts the throughput of the heating fluid through the second heating zone 2.

[0108] In various embodiments, the second fluid control valve 323 of the second heating fluid control member adjusts the throughput of the heating fluid through the second heating zone 2. In various embodiments, the second fluid control valve 323 adjusts the recirculation of the heating fluid after passing through the second heating zone 2 in a manner such that at least a portion of the heating fluid passes through the second fluid control pump 321 and the second heating zone 2 without first passing through the heating fluid distribution line 32 and the heat source 31. That is, the heating fluid coming from the heating fluid distribution line 32 mixes with the heating fluid coming from the second heating zone 2. Because the heating fluid coming from the second heating zone 2 has cooled due to exposure to the molten long-chain hydrocarbons, adjusting the mixing ratio of the heating fluid from the heating fluid distribution line 32 and from the second heating zone 2 adjusts the temperature of the heating fluid circulating in the second heat transfer portion 322 of the second heating zone 2. In this manner, the second fluid control valve 323 adjusts the temperature of the heating fluid in the second heat transfer portion 322, thereby providing the determined exposure temperature.

[0109] In embodiments where the temperature of the molten long-chain hydrocarbons is above the minimum decomposition temperature when entering the second heating section 2, the exposure temperature is determined to be no more than about 50°C above the temperature of the molten long-chain hydrocarbons in each section of the second heat transfer portion 322, preferably less than 40°C, more preferably less than 30°C, and more preferably less than 20°C above the temperature of the molten long-chain hydrocarbons.

[0110] For example, if the temperature of the molten long-chain hydrocarbons entering the second heating section 2 is 300°C, the exposure temperature is between 310°C and 350°C. The second fluid control valve 323 appropriately adjusts the mixing ratio of the heating fluid from the heating fluid distribution line 32 and the second heating section 2. Typically, there is a temperature drop between the heating fluid entering the second heat transfer section 322 and the heating fluid exiting the second heat transfer section 322. If the flow rate of the heating fluid in the second heat transfer section 322 is significantly high, this temperature drop can be ignored relative to the above considerations. However, in various embodiments, the flow rate of the heating fluid in the second heat transfer section 322 is so low that this temperature drop may be taken into account in determining the temperature of the heating fluid in the second heat transfer section 322. In these cases, the temperature of the heating medium is determined so that the exposure temperature in any section of the second heating section 2 is determined within the above limits. That is, in various embodiments, the temperature of the heating fluid before passing through the second heating zone 2 is determined to be more than 50°C above the temperature of the molten long-chain hydrocarbons before passing through the second heating zone 2.

[0111] In various embodiments, the third branch line 330 of the third heating zone 3 selectively circulates a proportion of the heated heating fluid through the third heat transfer portion 332. In particular, the third heat transfer portion 332 transfers heat from the heating fluid to the molten long-chain hydrocarbons within the third heating zone 3. The third heating fluid control members 331, 333 adjust the flow rate of the heating fluid through the third heat transfer portion 332 and accordingly adjust the proportion of the heating fluid through the third branch line 330 of the third heating zone 3. The flow rate of the heating fluid through the third heat transfer portion 332 adjusts the temperature of the molten long-chain hydrocarbons in the third heating zone 3. In particular, the temperature of the heating fluid through the third heat transfer portion 332 determines the thermal energy imparted to the molten long-chain hydrocarbons in the third heating zone 3. In various embodiments, the third fluid control pump 331 of the third heating fluid control member adjusts the throughput of the heating fluid through the third heating zone 3.

[0112] In various embodiments, the third fluid control valve 333 of the third heating fluid control member adjusts the throughput of the heating fluid through the third heating zone 3. In various embodiments, the third fluid control valve 333 adjusts the recirculation of the heating fluid after passing through the third heating zone 3 in a manner such that at least a portion of the heating fluid passes through the third fluid control pump 331 and the third heating zone 3 without first passing through the heating fluid distribution line 32 and the heat source 31. That is, the heating fluid coming from the heating fluid distribution line 32 mixes with the heating fluid coming from the third heating zone 3. Because the heating fluid coming from the third heating zone 3 has cooled due to exposure to molten long-chain hydrocarbons, adjusting the mixing ratio of the heating fluid from the heating fluid distribution line 32 and from the third heating zone 3 adjusts the temperature of the heating fluid circulating in the third heat transfer portion 332 of the third heating zone 3. In this manner, the third fluid control valve 333 adjusts the temperature of the heating fluid in the third heat transfer portion 332, thereby providing the determined exposure temperature.

[0113] The temperature of the molten long-chain hydrocarbons is typically above their minimum decomposition temperature when they enter the third heating section 3. In various embodiments, the exposure temperature is determined to be no more than about 50° C. above the temperature of the molten long-chain hydrocarbons in each section of the third heat transfer portion 332, preferably less than 40° C., more preferably less than 30° C., and more preferably less than 20° C. above the temperature of the molten long-chain hydrocarbons.

[0114] For example, if the temperature of the molten long-chain hydrocarbons entering the third heating section 3 is 330°C, the exposure temperature is between 340°C and 380°C. The third fluid control valve 333 appropriately adjusts the mixing ratio of the heating fluid from the heating fluid distribution line 32 and the third heating section 3. Typically, there is a temperature drop between the heating fluid entering the third heat transfer section 332 and the heating fluid exiting the third heat transfer section 332. If the flow rate of the heating fluid in the third heat transfer section 332 is significantly high, this temperature drop can be ignored relative to the above considerations. However, in various embodiments, the flow rate of the heating fluid in the third heat transfer section 332 is so low that this temperature drop may be taken into account in determining the temperature of the heating fluid in the third heat transfer section 332. In these cases, the temperature of the heating medium is determined so that the exposure temperature in any section of the third heating section 3 is determined within the above limits. That is, in various embodiments, the temperature of the heating fluid before passing through the third heating zone 3 is determined to be more than 50°C above the temperature of the molten long-chain hydrocarbons before passing through the third heating zone 3.

[0115] In various embodiments, the fourth branch line 340 of the fourth heating zone 4 selectively circulates a proportion of the heated heating fluid through the fourth heat transfer portion 342. Specifically, the fourth heat transfer portion 342 transfers heat from the heating fluid to the molten long-chain hydrocarbons within the fourth heating zone 4. The fourth heating fluid control members 341, 343 adjust the flow rate of the heating fluid through the fourth heat transfer portion 342 and accordingly adjust the proportion of the heating fluid through the fourth branch line 340 of the fourth heating zone 4. The flow rate of the heating fluid through the fourth heat transfer portion 342 adjusts the temperature of the molten long-chain hydrocarbons in the fourth heating zone 4. Specifically, the temperature of the heating fluid through the fourth heat transfer portion 342 determines the thermal energy imparted to the molten long-chain hydrocarbons in the fourth heating zone 4. In various embodiments, the fourth fluid control pump 341 of the fourth heating fluid control member adjusts the throughput of the heating fluid through the fourth heating zone 4.

[0116] In various embodiments, the fourth fluid control valve 343 of the fourth heating fluid control member adjusts the throughput of the heating fluid through the fourth heating zone 4. In various embodiments, the fourth fluid control valve 343 adjusts the recirculation of the heating fluid after passing through the fourth heating zone 4 in a manner such that at least a portion of the heating fluid passes through the fourth fluid control pump 341 and the fourth heating zone 4 without first passing through the heating fluid distribution line 32 and the heat source 31. That is, the heating fluid coming from the heating fluid distribution line 32 mixes with the heating fluid coming from the fourth heating zone 4. Because the heating fluid coming from the fourth heating zone 4 has cooled due to exposure to the molten long-chain hydrocarbons, adjusting the mixing ratio of the heating fluid from the heating fluid distribution line 32 and the fourth heating zone 4 adjusts the temperature of the heating fluid circulating in the fourth heat transfer portion 342 of the fourth heating zone 4. In this manner, the fourth fluid control valve 343 adjusts the temperature of the heating fluid in the fourth heat transfer portion 342, thereby providing the determined exposure temperature.

[0117] The temperature of the molten long-chain hydrocarbons is typically above their minimum decomposition temperature when they enter the fourth heating section 4. In various embodiments, the exposure temperature is determined to be no more than about 50° C. above the temperature of the molten long-chain hydrocarbons in each section of the fourth heat transfer portion 342, preferably less than 40° C., more preferably less than 30° C., and more preferably less than 20° C. above the temperature of the molten long-chain hydrocarbons.

[0118] For example, if the temperature of the molten long-chain hydrocarbons entering the fourth heating section 4 is 370°C, the exposure temperature is between 390°C and 420°C. The fourth fluid control valve 343 appropriately adjusts the mixing ratio of the heating fluid from the heating fluid distribution line 32 and the fourth heating section 4. Typically, there is a temperature drop between the heating fluid entering the fourth heat transfer section 342 and the heating fluid exiting the fourth heat transfer section 342. If the flow rate of the heating fluid in the fourth heat transfer section 342 is significantly high, this temperature drop can be ignored relative to the above considerations. However, in various embodiments, the flow rate of the heating fluid in the fourth heat transfer section 342 is so low that this temperature drop may be taken into account in determining the temperature of the heating fluid in the fourth heat transfer section 342. In these cases, the temperature of the heating medium is determined so that the exposure temperature in any section of the fourth heating section 4 is determined within the above limits. That is, in various embodiments, the temperature of the heating fluid before passing through the fourth heating zone 4 is determined to be more than 50°C above the temperature of the molten long-chain hydrocarbons before passing through the fourth heating zone 4.

[0119] In various embodiments, the reboiler branch line 370 of the reboiler section 29 selectively circulates a percentage of the heated heating fluid through the reboiler heat transfer portion 372. Specifically, the reboiler heat transfer portion 372 transfers heat from the heating fluid to the liquid coming from the partial condenser 21, which is the liquid condensed from the gas in the partial condenser 21. The reboiler heating fluid control members 371, 373 adjust the flow rate of the heating fluid through the reboiler heat transfer portion 372 and accordingly adjust the percentage of the heating fluid passing through the reboiler branch line 370 of the reboiler section 29. The flow rate of the heating fluid through the reboiler heat transfer portion 372 adjusts the temperature of the liquid coming from the partial condenser 21. Specifically, the temperature of the heating fluid passing through the reboiler heat transfer portion 372 determines the thermal energy imparted to the gas coming from the partial condenser 21. In various embodiments, the reboiler fluid control pump 371 of the reboiler heating fluid control member adjusts the throughput of the heating fluid through the reboiler section 29.

[0120] In various embodiments, the reboiler fluid control valve 373 of the reboiler heating fluid control member adjusts the throughput of the heating fluid through the reboiler section 29. In various embodiments, the reboiler fluid control valve 373 adjusts the recirculation of the heating fluid after passing through the reboiler section 29 in a manner such that at least a portion of the heating fluid passes through the reboiler fluid control pump 371 and the reboiler section 29 without first passing through the heating fluid distribution line 32 and the heat source 31. That is, the heating fluid coming from the heating fluid distribution line 32 mixes with the heating fluid coming from the reboiler section 29. Because the heating fluid coming from the reboiler section 29 has been cooled by exposure to the liquid coming from the partial condenser 21, adjusting the mixing ratio of the heating fluids from the heating fluid distribution line 32 and the reboiler section 29 adjusts the temperature of the heating fluid circulating in the reboiler heat transfer portion 372 of the reboiler section 29. In this manner, the reboiler fluid control valve 373 adjusts the temperature of the heating fluid in the reboiler heat transfer section 372, thus providing the determined exposure temperature.

[0121] The hydrocarbons in the gas coming from the partial condenser 21 are usually fully cracked when they enter the reboiler section 29. The reboiler section 29 adjusts the temperature of the gas to allow for further separation in the fractionation column.

[0122] The reboiler fluid control valve 373 adjusts the mix ratio of the heating fluid from the heating fluid distribution line 32 and from the reboiler section 29 accordingly. Typically, there is a temperature drop between the heating fluid entering the reboiler heat transfer section 372 and the heating fluid exiting the reboiler heat transfer section 372. If the flow rate of the heating fluid in the reboiler heat transfer section 372 is significantly high, this temperature drop may be negligible relative to the above considerations. However, in various embodiments, the flow rate of the heating fluid in the reboiler heat transfer section 372 is so low that this temperature drop may be taken into account in determining the temperature of the heating fluid in the reboiler heat transfer section 372.

[0123] Reheat branch line 360 ​​in reheat zone 6 routes heating fluid through reheat heat transfer section 362. Reheat heat transfer section 362 provides heat transfer from the heating fluid to the molten long-chain hydrocarbons in reheat zone 6, which are piped from separation structure 12. Reheat fluid control member 363 regulates the flow rate of heating fluid through reheat heat transfer section 362. In various embodiments, reheat fluid control valve 363 regulates the throughput of heating fluid through reheat zone 6. In various embodiments, the temperature of reheat heat transfer section 362 is regulated by heat source 31.

[0124] During the startup process, each of the first through fourth heating fluid control members 311, 313, 321, 323, 331, 333, 341, 343 regulates the flow of heating fluid through the first through fourth heat transfer portions 312, 322, 332, 342 so that the exposure temperature is no more than about 50° C. above the temperature of the molten long-chain hydrocarbons in each of the first through fourth heat transfer portions 312, 322, 332, 342, and preferably less than 40° C., more preferably less than 30° C., and more preferably less than 20° C. above the temperature of the molten long-chain hydrocarbons in each of the first through fourth heat transfer portions 312, 322, 332, 342. In various embodiments, during startup, the startup heating supply 384 supplies heated cooling medium into the cooling circuit that is close to the operating temperature of the heating fluid at nominal conditions. In this way, the heat source can be operated at nominal conditions from the start, while the first through fourth heating fluid control members ensure that the exposure temperature remains within a desired range.

[0125] In the turndown process, the cooling circuit passes the heated fluid or cooling medium along the heat sink so that the heated fluid cools quickly and the time for cooling is reduced. In this manner, downtime for maintenance or general shutdown is also reduced. In a further embodiment, the cooling loop also allows for cooling in a controlled, staged manner. For some fluids, such as hot charcoal, this avoids blockages and solidification.

Claims

1. 1. An apparatus for heating molten long-chain hydrocarbons in a continuous process, comprising: a heating fluid circuit having a heat source for heating a heating fluid and a heating fluid distribution line for circulating said heating fluid; a first heating section configured to heat the molten long-chain hydrocarbons to a first temperature; a second heating section configured to heat the molten long-chain hydrocarbons to a second temperature; Equipped with the first heating section and the second heating section are configured to receive a heating fluid through the heating fluid distribution line; The apparatus, wherein the first heating section is configured to regulate a heated fluid circulation through the first heating section in a manner that regulates the first temperature.

2. The apparatus of claim 1 , wherein the second heating section is configured to regulate a heated fluid circulation through the second heating section in a manner that regulates the second temperature.

3. 3. The apparatus of claim 1 or 2, wherein the first heating section and the second heating section are configured to pass molten long-chain hydrocarbons from the first heating section to the second heating section.

4. the second temperature is configured to be greater than the first temperature; and / or 4. The apparatus of claim 1, wherein the second temperature and / or the first temperature is above the decomposition temperature of the molten long-chain hydrocarbons.

5. 5. The apparatus of claim 1, further comprising a third heating section configured to heat molten long-chain hydrocarbons to a third temperature and to receive a heating fluid through the heating fluid distribution line, wherein the molten long-chain hydrocarbons are passed from the second heating section to the third heating section, and wherein the third temperature is greater than the second temperature.

6. 6. The apparatus of claim 1, wherein at least one of the heating sections includes a heat transfer section and a heating fluid control member, the heat transfer section configured to effect heat transfer from the heating fluid to the molten long-chain hydrocarbons in the at least one of the heating sections, and the heating fluid control member configured to mix heating fluids from the heat transfer section and from the heating fluid distribution line to adjust the temperature of the mixed heating fluid, and to provide the mixed heating fluid to the heat transfer section.

7. 7. The apparatus of claim 6, wherein the heating fluid control member includes a fluid control pump for adjusting the heating fluid flow through the heat transfer section, and / or a fluid control valve for adjusting the proportion of heating fluid from the heating fluid distribution line in the mixed heating fluid provided to the heat transfer section.

8. 8. The apparatus of claim 1, further comprising a cooling structure, the cooling structure including a heat sink for cooling a heating medium passing therethrough, and a split valve configured to control a proportion of the heating medium that selectively bypasses the heat sink, the heating medium being the heating fluid or the cooling medium.

9. 9. Apparatus according to any one of claims 1 to 8, comprising a heat transfer structure comprising a primary heat sink providing a flow path for a process fluid, a secondary heat sink providing a flow path for a cooling fluid, and a cooling circuit for circulating a cooling medium through the primary heat sink and the secondary heat sink to transfer heat from the process fluid in the primary heat sink to the cooling fluid in the secondary heat sink, the cooling circuit preferably including an active heating supply configured to supply the heating fluid into the cooling circuit as a cooling medium.

10. 10. The apparatus of claim 9, wherein the heat transfer structure includes a cooling medium branch line and a cooling circuit valve configured to control a proportion of the cooling medium that selectively bypasses the secondary heat sink, the proportion of the cooling medium that bypasses the secondary heat sink preferably being adjusted to adjust a temperature of the cooling medium and / or the process fluid.

11. 1. A method for heating molten long chain hydrocarbons in a continuous process, comprising: heating a heating fluid; circulating the heating fluid; heating the molten long-chain hydrocarbons to a first temperature in a first heating zone; heating the molten long-chain hydrocarbons to a second temperature in a second heating zone; Including, the first heating section and the second heating section are configured to receive a heating fluid through the heating fluid distribution line; The method wherein the first heating section regulates the heating fluid circulation through the first heating section in a manner that regulates the first temperature.

12. 12. The method of claim 11, wherein the second heating zone regulates the heating fluid circulation through the second heating zone in a manner that regulates the second temperature, and the molten long-chain hydrocarbons pass from the first heating zone to the second heating zone.

13. 13. The method of claim 11 or 12, wherein the second temperature is configured to be greater than the first temperature, and the second temperature, and preferably the first temperature, is greater than the decomposition temperature of the molten long-chain hydrocarbons.

14. 14. The method according to any one of claims 11 to 13, wherein at least one of the heating sections includes a heat transfer section and a heating fluid control member, the heat transfer section configured to effect heat transfer from the heating fluid to the molten long-chain hydrocarbons in the at least one of the heating sections, and the heating fluid control member mixes heating fluids from the heat transfer section and from the heating fluid distribution line to adjust the temperature of the mixed heating fluid and provide the mixed heating fluid to the heat transfer section.

15. 15. The method of any one of claims 11 to 14, wherein the molten long-chain hydrocarbons are passed from the second heating section to a third heating section, the third heating section receiving a heating fluid through the heating fluid distribution line and heating the molten long-chain hydrocarbons to a third temperature, the third temperature being greater than the second temperature.

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